The chip formation process in machining is accompanied by heat generation. The heat generated influences both the workpiece physical properties as well as the cutting tool. High temperatures accelerate tool wear and thermal softening which are not desirable because they alter the accuracy of the machined surface and tool life. Many studies have been done to lower the heat generated in cutting. A first approach is to use a cutting fluid but its effectiveness is limited by its ability to penetrate between the tool and the chip. A second approach is to remove the heat generated through a cooling cycle as in interrupted cutting. The idea is either to translate a wide tool to the side as it moves forward relative to the workpiece, which allows the dissipation throughout the body of the tool or to use a cutting edge in the form of a disk that rotates about its principal axis. The latter, known as a rotary tool, provides a rest period for the cutting edge, thus enabling the edge to be cooled and a continuously fresh portion of the edge to be engaged with the workpiece. The rotary tool can be either driven by an external power source or self-propelled. This thesis focuses on the self-propelled rotary tool (SPRT) process for machining of difficult-to-machine material such as bearing steels, where tool life is of particular concern. Since the cutting temperatures are known to influence tool life significantly, the first task in this investigation involved developing a model to analyze heat transfer and temperature distribution in the cutting tool during SPRT turning of the hardened 52100 steel (58 HRC). Both rotary and equivalent fixed tool processes are compared in terms of cutting tool temperatures generated. The model is based on the moving heat source theory of conduction and employs the Finite Element Method (FEM) for its solution. The model is experimentally verified through measurement of the cutting temperature distribution using an Infra-Red imaging camera under different cutting conditions. Predicted and measured temperatures show good overall agreement when they are measured along the cutting edge and measured temperatures are up to 50??ower in rotary tool cutting than in fixed tool cutting under the same conditions.

Ballistic testing is a vital part of the armor design. However, it is impossible to test every condition and it is necessary to limit the number of tests to cut huge costs. With the intro- duction of hydrocodes and high performance computers / there is an increasing interest on simulation studies to cutoff these aforementioned costs. This study deals with the numerical modeling of ballistic impact phenomena, regarding the ballistic penetration of hardened steel plates by 7.62 mm AP (Armor Piercing) projectile. Penetration processes of AP projectiles are reviewed. Then, a survey on analytical models is given. After the introduction of fun- damentals of numerical analysis, an intensive numerical study is conducted in 2D and 3D. Johnson Cook strength models for the four different heat treatments of AISI 4340 steel were constructed based on the dynamic material data taken from the literature. It was found that 2D numerical simulations gave plausible results in terms of residual projectile velocities, con- sidering the literature review. Then, 3D numerical simulations were performed based on the material properties that were selected in 2D studies. Good agreement was obtained between the numerical and test results in terms of residual projectile velocities and ballistic limit thick- nesses. It was seen that the ballistic protection efficiency of the armor plates increases with the increasing hardness, in the examined range. This study is a part of T&uml / ubitak project 106M211 of MAG.

The theme of this diploma thesis is application of modern methods of cutting on selected parts in a concrete company. The base for technical - economical classification were both the real and the normative times. The conclusion of the thesis includes evaluation and the consequent results.

Diploma thesis deals with machining of hardened steels. In the introductory section it is described the physical process of cutting and basic used technologies of machining. The next chapter provides an overview of cutting materials. Other chapters deal with the workpiece material and heat treatment. Furthermore, there is made a comparison of the cutting conditions while machining of hardened steels by tools from selected manufacturers. As the conclusion there is the economic evaluation.

The thesis deals with machining of rotating parts made from hardened steel. The introductory chapter describes the problems of turning and grinding. The next chapter deals with heat treatment and machined materials. The next lists the used cutting materials. Criteria for evaluating the quality of the surface. A selection of cutting materials for the machining of hardened steels from selected manufacturers. The final chapter is a comparison of the described technologies.

Atlas Copco Secoroc AB are searching after new bulk materials for drill heads that are used in percussive drilling in order to improve their strength and durability. The aim of this project is to assist Atlas Copco in this search and provide them with further information regarding material properties, alloying elements, suppliers, etc. A literary study was carried out in order to identify materials that had UTS and KIC more than or equal to 1700 MPa and 70 MPa*m1/2, respectively. Materials that fulfilled these criteria were T250 grade maraging steel, Cobalt free maraging steel, High cobalt maraging steel, 300 grade maraging steel, AerMet 100, AF1410, S53, M54, 300M, 4340M and PremoMet. These were categorized into maraging steels, high alloy secondary hardened steels, and low alloy steels, and were then further researched.  The material with the highest combination of UTS and KIC was M54 followed by AerMet 100; while AF1410 had the highest KIC but a low UTS, and PremoMet had the highest UTS but a low KIC. Maraging steels and HASH steels have a similar price range, while low alloy steels are much cheaper.

Atlas Copco Secoroc AB are searching after new bulk materials for drill heads that are used in percussive drilling in order to improve their strength and durability. The aim of this project is to assist Atlas Copco in this search and provide them with further information regarding material properties, alloying elements, suppliers, etc. A literary study was carried out in order to identify materials that had UTS and KIC more than or equal to 1700 MPa and 70 MPa*m^1/2, respectively. Materials that fulfilled these criteria were T250 grade maraging steel, Cobalt free maraging steel, High cobalt maraging steel, 300 grade maraging steel, AerMet 100, AF1410, S53, M54, 300M, 4340M and PremoMet. These were categorized into maraging steels, high alloy secondary hardened steels, and low alloy steels, and were then further researched. The material with the highest combination of UTS and KIC was M54 followed by AerMet 100; while AF1410 had the highest KIC but a low UTS, and PremoMet had the highest UTS but a low KIC. Maraging steels and HASH steels have a similar price range, while low alloy steels are much cheaper.

Na usinagem de acabamento de superfícies complexas de forma livre, comumente empregada na fabricação de moldes e matrizes, o conhecimento das condições de corte e estratégias adequadas para o fresamento de material endurecido podem proporcionar a obtenção de superfícies de melhor qualidade e controle dimensional, além de uma redução significativa nos tempos e custos de fabricação. O objetivo deste trabalho é analisar a formação da textura no fresamento de materiais endurecidos, através da avaliação quantitativa e qualitativa, quanto a rugosidade, regularidade e formação da superfície. Para estudar este fenômeno foi empregada uma ferramenta de ponta esférica com inserto intercambiável. Os experimentos foram realizados utilizando-se corpos-de-prova de aço AISI H13 na dureza de 54 HRC, posicionados a uma inclinação de 60°, empregando-se condições de corte fixas e quatro diferentes estratégias de usinagem, com trajetórias de corte horizontal e vertical, ascendente ou descendente em relação ao plano inclinado. Para sua caracterização, as superfícies usinadas foram submetidas à medição de rugosidade e métodos distintos para a visualização e obtenção de imagens da textura, sendo eles: microscopia óptica, microscopia eletrônica de varredura (MEV) e microscopia de força atômica (AFM). Foi possível constatar através dos valores de rugosidade e imagens topográficas das superfícies usinadas que as texturas resultantes mostram nitidamente a influência da estratégia de corte empregada, caracterizando-se distintamente. As texturas analisadas revelam um padrão uniforme e repetitivo, com exceção à estratégia vertical ascendente (VS), que originou uma textura irregular e indefinida, onde as marcas de passagem da ferramenta não se apresentam nítidas. Para esta condição observou-se na superfície usinada a presença de material deformado e aderido, apresentando a maior rugosidade, sendo que as menores rugosidades foram medidos para a estratégia vertical descendente (VD). / Submitted by Marcelo Teixeira (mvteixeira@ucs.br) on 2014-05-20T17:28:08Z No. of bitstreams: 1 Dissertacao Gerson Luiz Nicola.pdf: 18583662 bytes, checksum: 3d927824543520a3c9152ab459406152 (MD5) / Made available in DSpace on 2014-05-20T17:28:08Z (GMT). No. of bitstreams: 1 Dissertacao Gerson Luiz Nicola.pdf: 18583662 bytes, checksum: 3d927824543520a3c9152ab459406152 (MD5) / In the final milling process of free form surfaces, commonly employed in the production of molds and dies, the knowledge of the cutting conditions and a strategy for choosing adequate processing routes in the milling of hardened materials can provide superior surface quality and dimensional control and a significant reduction in the manufacturing times and costs. The objective of this work is to understand the texture formation in the milling of hardened materials, through the quantitative and qualitative evaluation of the surface roughness, as well as the formation and the regularity of the surfaces. The tool used in these experiments was an interchangeable insert tungsten carbide, ball nose end mill. AISI H13 steel with a final hardness of 54 HRC was used throughout the experimental work. The workpiece was fixed on a device with an inclination of 60 degrees. The same cutting conditions were used for all the tests and four cutting strategies were considered, as defined by the trajectory of the tool, upward and downward, in the horizontal and vertical directions. To characterize the machined surfaces, the roughness was measured and other different methods for the visualization of the surface texture were employed, such as, the optical microscopy, scanning electron microscopy (SEM) and atomic force microscopy (AFM). It was possible to observe, through the values of roughness and the topographic images of the machined areas, that the resulting textures clearly show the influence of the cutting strategy employ, distinctly characterized. The textures analyzed show a consistent and repetitive pattern, except the vertical upward strategy (VS) that resulted in an irregular and undefined texture, where the tool marks are unclear. For this condition the presence of plastically deformed material and acceded were observed in the machined surface, with presented the highest roughness value. The lowest roughness values were measured for the downward vertical strategy (VD).

Na usinagem de acabamento de superfícies complexas de forma livre, comumente empregada na fabricação de moldes e matrizes, o conhecimento das condições de corte e estratégias adequadas para o fresamento de material endurecido podem proporcionar a obtenção de superfícies de melhor qualidade e controle dimensional, além de uma redução significativa nos tempos e custos de fabricação. O objetivo deste trabalho é analisar a formação da textura no fresamento de materiais endurecidos, através da avaliação quantitativa e qualitativa, quanto a rugosidade, regularidade e formação da superfície. Para estudar este fenômeno foi empregada uma ferramenta de ponta esférica com inserto intercambiável. Os experimentos foram realizados utilizando-se corpos-de-prova de aço AISI H13 na dureza de 54 HRC, posicionados a uma inclinação de 60°, empregando-se condições de corte fixas e quatro diferentes estratégias de usinagem, com trajetórias de corte horizontal e vertical, ascendente ou descendente em relação ao plano inclinado. Para sua caracterização, as superfícies usinadas foram submetidas à medição de rugosidade e métodos distintos para a visualização e obtenção de imagens da textura, sendo eles: microscopia óptica, microscopia eletrônica de varredura (MEV) e microscopia de força atômica (AFM). Foi possível constatar através dos valores de rugosidade e imagens topográficas das superfícies usinadas que as texturas resultantes mostram nitidamente a influência da estratégia de corte empregada, caracterizando-se distintamente. As texturas analisadas revelam um padrão uniforme e repetitivo, com exceção à estratégia vertical ascendente (VS), que originou uma textura irregular e indefinida, onde as marcas de passagem da ferramenta não se apresentam nítidas. Para esta condição observou-se na superfície usinada a presença de material deformado e aderido, apresentando a maior rugosidade, sendo que as menores rugosidades foram medidos para a estratégia vertical descendente (VD). / In the final milling process of free form surfaces, commonly employed in the production of molds and dies, the knowledge of the cutting conditions and a strategy for choosing adequate processing routes in the milling of hardened materials can provide superior surface quality and dimensional control and a significant reduction in the manufacturing times and costs. The objective of this work is to understand the texture formation in the milling of hardened materials, through the quantitative and qualitative evaluation of the surface roughness, as well as the formation and the regularity of the surfaces. The tool used in these experiments was an interchangeable insert tungsten carbide, ball nose end mill. AISI H13 steel with a final hardness of 54 HRC was used throughout the experimental work. The workpiece was fixed on a device with an inclination of 60 degrees. The same cutting conditions were used for all the tests and four cutting strategies were considered, as defined by the trajectory of the tool, upward and downward, in the horizontal and vertical directions. To characterize the machined surfaces, the roughness was measured and other different methods for the visualization of the surface texture were employed, such as, the optical microscopy, scanning electron microscopy (SEM) and atomic force microscopy (AFM). It was possible to observe, through the values of roughness and the topographic images of the machined areas, that the resulting textures clearly show the influence of the cutting strategy employ, distinctly characterized. The textures analyzed show a consistent and repetitive pattern, except the vertical upward strategy (VS) that resulted in an irregular and undefined texture, where the tool marks are unclear. For this condition the presence of plastically deformed material and acceded were observed in the machined surface, with presented the highest roughness value. The lowest roughness values were measured for the downward vertical strategy (VD).

Diploma thesis on Machining hardened steels is focused on the analysis of longitudinal turning of hardened steel 14 109 by using a tool from PKNB in terms of measuring the force load using a dynamometer and then evaluating the surface quality. The theoretical part deals with the issue of turning technology, cutting materials and heat treatment of steel. In the practical part, the influence of cutting conditions on the resulting values was assessed during the experiment. Twelve samples with different combinations of cutting conditions were tested, then was selected a sample that met the criterion of combining minimum cutting forces values and surface quality. The experiment shows that force load values can be achieved twice less by combining cutting conditions with an appropriate combination.