No description available.

No description available.

Irregularities in pavement profiles that exceed standard thresholds are usually rectified using a Diamond Grinding Process. Diamond Grinding is a method of Concrete Pavement Rehabilitation that involves the use of grinding wheels mounted on a machine that scraps off the top surface of the pavement to smooth irregularities. Profile Analysis Software like ProVAL© offers simulation modules that allow users to investigate various grinding strategies and prepare a corrective action plan for the pavement. The major drawback with the current Smoothness Assurance Module© (SAM) in ProVAL© is that it provides numerous grind locations which are both redundant and not feasible in the field. This problem can be overcome by providing a constrained grinding model in which a cost function is minimized; the resulting grinding strategy satisfies requirements at the least possible cost. Another drawback with SAM exists in the built-in grinder models that do not factor in the effect of speed and depth of cut on the grinding head. High speeds or deep cuts will result in the grinding head riding out the cut and likely worsening the roughness. A constrained grinding strategy algorithm with grinder models that factor in speed and depth of cut that results in cost effective grinding with better prediction of post grind surfaces through simulation is developed in this work. The outcome of the developed algorithm is compared to ProVAL's© SAM results. / Master of Science

In this work, measurements and simulations were used to investigate the effects of grinding wheel topography on the geometric aspects of the grinding process. Since existing methods for measuring the grinding wheels were either not accurate enough or could only measure a small portion of a grinding wheel, a novel grinding wheel measurement system was developed. This system consists of a white light chromatic sensor, a custom designed positioning system and software. The resulting wheel scanning system was capable of measuring an entire grinding wheel with micron level accuracy. The system was used to investigate the effects of fine, medium and course dressing on grinding wheel surface topology and the resulting workpiece surface. New techniques were also developed to simulate metal removal in grinding. The simulation software consisted of a stochastic wheel model, dressing model and metal removal model. The resulting software could determine the uncut chip thickness, contact length for every cutting edge on a grinding wheel as well as the resulting surface roughness of the grinding wheel. The simulation was validated by comparing the wheel model used in the simulation to grinding wheel measurements and by comparing the simulated surface finish to the measured surface finish. There was excellent agreement between the predicted and experimentally measured surface topology of the workpiece. The results suggested that only 22 to 30% of the cutting edges exposed on the grinding wheel are active and that the average grinding chip is as much as 10 times thicker and 5 times shorter than would be produced by a grinding wheel with a regular arrangement of cutting edges as assumed by existing analytical approaches.

Surface integrity is of great significance in grinding performance since grinding process is often used as a finishing step. For metallic materials, residual stresses play an important role in surface integrity for its strong effect on fatigue life, corrosion resistance, and part distortion. For ceramic materials, the surface damage induced by grinding process could greatly affect the mechanical strength and surface finish of the component. The functional behavior of machined components can be enhanced or impaired by the grinding process. Because of this, understanding the surface integrity imparted by grinding is very important. The use of fluid is common in grinding process, however, the high cost and environmental impact of the conventional flood cooling is very undesirable. The minimum quantity lubrication (MQL) have been introduced in industry for about two decades as a promising alternative to conventional flood cooling for economical and environmental advantages. A comprehensive understanding of the MQL effect on the process performances and surface integrity is of great value to the implementation of MQL technique in industrial situation. Grinding-induced residual stress prediction has been a topic of research since the 1970’s while the studies of MQL grinding is still on the early stage with experimental investigations. A comprehensive study and quantitative description of MQL effect on the residual stress generation in grinding is highly demanded. On the other hand, although there has been significant research in the area of surface damage in ceramic grinding, there are still opportunities for advancing predictive methods. Therefore, the objectives of the current research are set as follows: (1) develop a method of predicting residual stress based on an analytical description of the grinding process under MQL condition, (2) develop a method of predicting surface finish and damage in ceramic grinding, and (3) validate the model with experimental data. The research will first focus on predicting residual stresses in MQL grinding based on first principles. This includes predictive models of grinding forces, and grinding temperature stemmed from grinding kinematics and dynamics principles as part of the overall modeling effort. The effect of MQL on both lubrication and cooling aspects has been integrated into these models. The mechanical and thermal output parameters will serve as the basis for determining the loading history which generate residual stresses. The research will also aim at surface roughness modeling in ceramic grinding. A ductile-brittle mixed surface generation is predicted based on the nature of ceramic materials and grinding kinematics. The crack system developed from indentation fracture mechanics approach will be utilized in evaluating the brittle mode surface generation. The modeling techniques will be applied to a range of grinding conditions and materials. This research would aid in evaluating various surface integrities in grinding of metallic and ceramic materials with little experimental efforts. The output could be used to machine these materials effectively to order to improve the functionality of the component.

published_or_final_version / abstract / Industrial and Manufacturing Systems Engineering / Master / Master of Philosophy

published_or_final_version / abstract / Industrial and Manufacturing Systems Engineering / Master / Master of Philosophy

Large optical systems fabrication is a demanding task due to the tight requirements and big scales. To make mirrors up to 8.4m in diameter necessitates technological development in materials, tooling, and metrology. These advancements are designed to not only produce optics on a near-unheard of scale, but to improve fabrication methods with each piece.For an optical surface to be properly polished, the amount of material removed during polishing must be greater than the volume of damage left behind by the grinding process. Mixed-mode grinding, which combines bound abrasives with a compliant binder material, is a valuable tool at this stage as it creates less damage while maintaining a fast and uniform cutting rate than traditional loose abrasive grinding.These materials are challenging for large optical surfaces due to the honeycomb structures used to lightweight the mirrors. Development is done to adapt the abrasive to handle the very low pressures and speeds required to avoid imprinting structure on the optical surface.We take a comprehensive approach in measuring mixed-mode behavior using 3M Trizact™. Prior works on bound abrasives have focused on specific properties: removal rates, subsurface damage, etc. None have yet to look at the entire scope of the material and its benefits. These properties will be analyzed along with different behaviors regarding surface scattering, Twyman effect bending moments, glazing, manufacturing expenses, and failure mechanisms. This comprehensive understanding of the abrasive allows manufacturers to create better grinding schedules and reduce overall expenses in fabrication.Trizact shows up to a three times faster removal rate while producing 30\% less subsurface damage than loose abrasives of similar size. Additionally, the surface has scatters less light which can be adapted through changes in processing to create a specular reflection for optical surface metrology.Based on our findings, this type of abrasive integrates into current optical fabrication processes as a pre-polishing material. Here, the transition to these abrasives becomes cost effective by rapidly eliminating damage created during the generating of the surface and reducing the amount of polishing required.

QC 351 A7 no. 77 / Because of their light weight and low cost, transparent plastics would seem to be good materials for optical components. This thesis deals primarily with the feasibility of producing large ( >4 -in. -diam) plastic components of moderate precision (surface accuracies 1 fringe per inch of diameter). The structure and the physical and optical properties of plastics are discussed, with emphasis on their advantages and limitations for optical use. A series of experiments on grinding and polishing of plastics was conducted. Data are presented on grinding rates. Several polishing processes were evaluated, and a polishing technique for plastics was developed. Polishing rate data and surface roughness data are presented for several polishing processes. With proper techniques, we estimate that accuracies of about one fringe per inch are obtainable. A series of experiments was conducted on a process called compression forming, in which heat and pressure are applied to machined preforms in an attempt to obtain precision optical surfaces. The process is described in detail, and experimental results are discussed. Based on experimental results, improved processing conditions are suggested. Further experiments would be required to determine the ultimate process capability.

O objetivo deste estudo foi avaliar o efeito de diferentes protocolos de desgaste nas características superficiais e comportamento mecânico da zircônia utilizada para confeccionar infraestruturas e pilares protéticos. Amostras em forma de barra foram obtidas e divididas em três grupos (n=21): Grupo C (controle, não recebeu nenhum tipo de modificação superficial), Grupo A (desgaste realizado com fresas diamantadas de granulação média e acabamento com fresas diamantadas de granulação fina, com caneta de alta rotação sob refrigeração abundante de água) e Grupo B (desgaste realizado com pedras diamantadas de granulação grossa e acabamento realizado com pedras diamantadas de granulação média, com peça de mão acoplada em motor de baixa rotação e sem refrigeração). A topografia e rugosidade superficial (Sa) foram obtidos por microscopia confocal a laser (n=21), o módulo de elasticidade dinâmico (n=21) foi obtido por uma técnica de excitação por impulso, a transformação de fase foi avaliada por meio de difração de raios-X (n=1) e fadiga mecânica acelerada foi realizada pelo método step stress (n=18). A análise estatística para rugosidade superficial e módulo de elasticidade foi ANOVA de um fator e teste complementar de Tukey e a resistência à fadiga foi comparada pela probabilidade de sobrevivência nos diferentes tipos de carregamento, quanto ao número de ciclos e a força. Houve diferença estatística entre os grupos para rugosidade superficial (Grupo A>Grupo B>Grupo C) (p≤0,05)e módulo de elasticidade dinâmico (Grupo B>Grupo A=Grupo C) (p=0,003). A difração de raios-X revelou mudança de fase cristalina para os grupos desgastados, sendo que o Grupo C apresentou conteúdo cristalino somente na fase tetragonal, o Grupo A na fase tetragonal e monoclínica, e o Grupo B na fase tetragonal e cúbica. Não houve diferença estatística entre os grupos quando a taxa de sobrevivência foi comparada quanto ao número de ciclos e a força. Apesar do desgaste ter modificado as características superficiais, não houve prejuízo no comportamento mecânico da zircônia / The purpose of this study was to evaluate the effect of different grinding protocols on surface characteristics and mechanical behavior of Y-TZP used to manufacture copings and abutments. Bar-shaped specimens were obtained and divided into three groups (n=21): Group C (control, untreated), Group A (grinding was performed using medium diamond burs, finishing was performed using fine diamond burs and high-speed hand piece under constant water cooling) and Group B (grinding was performed using coarse diamond stone, finishing was performed using medium diamond stone and slow-speed hand piece without water cooling). After the specimen grinding, topography and surface roughness (n=21) were evaluated on laser confocal microscope, the Youngs modulus (n=21) was performed using the impulse excitation technique, crystallographic phase change was performed using an x-ray diffraction (n=1) and step-stress accelerated life testing (n=18) was performed. One-way ANOVA and Tukeys test were performed to analyze surface roughness and Youngs modulus, and step-stress accelerated life testing was compared by the probability of survival, considering the number of cycles and strength. There was statistically significant difference between groups considering surface roughness (Group A>Group B>Group C) (p≤0,05) and Youngs modulus (Group B>Group A=Group C) (p=0,003). X-ray diffraction data showed that grinding leads to phase change, once Group C showed only tetragonal phase, Group A showed tetragonal and monoclinic phases and Group B showed tetragonal and cubic phases. There was no statistically significant difference among groups when the probability of survival was compared considering the number of cycles and strength. Although tested grinding protocols had modified the surface characteristics, did not damage the mechanical behavior of the zirconia