Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / O processo de desgaste por cavitação e corrosão em componentes e sistemas hidrodinâmicos reduz drasticamente a eficiência operacional, levando a grandes perdas econômicas. O uso de revestimentos de alta resistência ao desgaste tem sido estudado como solução para o problema de corrosão e cavitação no ambiente industrial. Os processos de aspersão térmica são reconhecidos como uma excelente abordagem para aplicação de revestimentos de alta resistência, pois permitem depositar revestimentos com menor alteração do substrato. O processo oxi-combustível de alta velocidade (HVOF) produz revestimentos de altas densidade e coesão. O processo ar-combustível de alta velocidade (HVAF) é atualmente um processo alternativo ao HVOF, apresentando propriedades equivalentes e muitas vezes superiores às deste processo e com menor custo operacional. Esta pesquisa apresenta o uso dos processos HVOF e HVAF para deposição de revestimentos FeMnCrSi, com o objetivo de estudar os efeitos do processo de aspersão térmica e da composição química na morfologia, microestrutura e resistência à cavitação e corrosão dos revestimentos. Para isso, dividiu-se o trabalho duas partes, a primeira estudou revestimentos de mesma composição depositados por HVAF e HVOF quanto à sua morfologia e resistência à cavitação e corrosão. A segunda parte estudou a influência da composição química de quatro ligas experimentais na morfologia e resistência à cavitação e corrosão dos revestimentos. Foram realizadas a preparação metalográfica dos revestimentos, análise da morfologia e defeitos em microscópio ótico e microscópio eletrônico de varredura, ensaio de microdureza Vickers, ensaio de cavitação acelerada e de corrosão eletroquímica. Os revestimentos depositados pelo processo HVOF apresentaram maior quantidade de oxidação, relacionado ao uso de oxigênio como comburente neste processo. O processo HVAF apresentou menor oxidação de seus revestimentos, pelo uso de ar-comprimido como comburente ao invés de oxigênio, além de maiores valores de tenacidade à fratura, devido às maiores velocidades de partícula. Isto providenciou maior resistência à cavitação dos revestimentos HVAF. A resistência à corrosão dos revestimentos HVAF também foi superior à dos HVOF, devido a uma menor presença de óxidos nos revestimentos, por estes facilitarem a penetração de íons no revestimento, levando à corrosão interna. A composição química dos revestimentos depositados por HVAF teve menor influência na oxidação dos mesmos, assim como na tenacidade à fratura destes. A adição de Boro não foi benéfica para a resistência à cavitação. A resistência à corrosão dos revestimentos foi positivamente influenciada pela presença de Níquel. Já para a corrosão localizada, um maior teor de Cromo foi determinante na maior resistência dos revestimentos. / The cavitation and corrosion wear process on hydrodynamic components and systems dramatically reduces operational efficiency, leading to great economic losses. The use of wear resistant coatings has been studied as a solution to the problem of corrosion and cavitation in the industrial environment. The thermal spray processes are recognized as excellent approach to implementing high strength coatings as they allow the deposition of coatings with lower substrate change. The high velocity oxy-fuel (HVOF) process produces coatings with high density and cohesion. The high velocity air-fuel process (HVAF) is currently an alternative process to the HVOF, presenting equivalent and often superior properties to this process and at a lower operational cost. This research presents the use of HVOF and HVAF processes for the deposition of FeMnCrSi coatings, with the intent of studying the effects of the thermal spraying process and the chemical composition on the morphology, microstructure and resistance to cavitation and corrosion of the coatings. The work was divided in two parts, the first studied coatings of the same composition deposited by HVAF and HVOF as its morphology and resistance to cavitation and corrosion. The second part studied the influence of the chemical composition of four experimental alloys on the morphology and resistance to cavitation and corrosion of the coatings. The metallographic preparation of the coatings, analysis of morphology and defects in optical microscope and scanning electron microscope, Vickers microhardness test, accelerated cavitation and electrochemical corrosion tests were performed. The coatings deposited by the HVOF process presented higher amount of oxidation, related to the use of oxygen as oxidizer in this process. The HVAF process presented less oxidation of its coatings, by the use of compressed air as oxidizer instead of oxygen, besides higher values of fracture toughness, due to the higher particle velocities. This provided greater resistance to cavitation of the HVAF coatings. The corrosion resistance of HVAF coatings was also higher than HVOF coatings, due to a lower presence of oxides in the coatings, as they facilitate the penetration of ions into the coating, leading to internal corrosion. The chemical composition of the coatings deposited by HVAF had less influence on their oxidation and fracture toughness. The addition of boron was not beneficial to cavitation resistance. The corrosion resistance of coatings was positively influenced by the presence of Nickel. As for localized corrosion, a higher Chromium content was determinant in the higher resistance of the coatings.

This thesis is focused on a production of injection molds. It contains some analyses of the various parts of the injection molds, a description of their functions and the possibility of structural design. A summary of existing technologies for the production of these molds, their advantages and disadvantages is included. This thesis deals with design of the component parts for injection of plastics, strategy of machining and a simulation of machining.

This Master's thesis deals with the issue of high-speed turning of the 100Cr6 material. The aim is to identify and experimentally validate an innovative production process for a particular component. The thesis includes theoretical basis of high-speed machining, analysis of the current state of the manufacturing process, innovation design and experimental verification. At the end of the thesis, parameters of the machined surfaces of specimens are evaluated.

L’usinage 5 axes à grande vitesse est de plus en plus utilisé dans l’industrie pour réaliser des pièces de géométrie complexe à forte valeur ajoutée avec pour contrainte de respecter la qualité géométrique tout en maximisant la productivité. Dans ce contexte, la FAO et plus particulièrement la génération des trajectoires d’usinage jouent un rôle prépondérant. Ces travaux proposent de définir des trajectoires en fonction de la pièce à réaliser mais aussi de la structure poly articulée et de ses performances cinématiques. La grande diversité des structures en termes d’architecture et de cinématique impose une méthode de calcul générique facilitant la définition de trajectoires adaptées pour leur suivi. L’état de l’art des travaux réalisé dans les domaines de l’usinage et de la robotique pour répondre à cette problématique conduit à utiliser des polytopes de manipulabilité cinématique pour modéliser les contraintes cinématiques. L’analyse de ces polytopes et de la géométrie de la pièce à usiner permet de générer des trajectoires avec une vitesse outil/pièce maîtrisée et un temps de parcours réduit dans le cas de l’usinage 5 axes positionné et de l’usinage 5 axes continu. Ce formalisme met en avant les fortes dépendances entre les différents paramètres de la stratégie d’usinage (positionnement de la pièce, direction d’avance et orientation de l’outil) et permet de privilégier certaines combinaisons de ces paramètres pour maîtriser la vitesse d’exécution de la trajectoire. / 5 axes high speed milling is increasingly used for manufacturing high addedvalue parts with complex forms in order to respect surface quality while maximizing productivity. In this context, CAM and more specifically toolpath computations play a major part. This work proposes to define toolpath depending on the workpiece but also onkinematical capacities of the polyarticulated structure.The large variety of structure in terms of architecture and kinematic enforce a generic calculation method to simplify adaptative toolpath generation. A state of the art realized in machining and robotics proposes to investigate the use of kinematical manipulability polytopes to represent kinematical capacities. An analysis of the polytopes and of the workpiece allows to generate toolpaths with a controlled feedrate and a decreasing time in 5 axes positionned milling and in 5 axes continous milling. This formalism highlights strong interactions between milling strategy parameters (workpiece setup, feed direction, tool orientation) and allows to prioritize specific parameters mix to have a controlled execution feedrate.

Stainless steel is a metal material widely used in many industries because of its high tensile strength, toughness, and corrosion resistance. Machining stainless steel is challenging due to its high work hardening tendency, low thermal conductivity, and ductility of the material resulting in built-up edge formation. Machining stainless steel at lower cutting speeds must be performed with coolant, which adds to the cost of the process and increases concerns for the environment and the operator's health and safety. Industries such as the aerospace and die-mold industries demand high-speed machining to realize productivity targets. Therefore, a cermet tool material was selected for the present study because of its high temperature resistance, high bending strength, and fracture toughness. The study focused on investigating wear mechanisms and developing a coating on a cermet tool for dry high-speed machining stainless steel to increase tool life. The wear mechanisms of tools were investigated at a fixed cutting interval in relation to the tool's composition and microstructure. Scanning Electron Microscope (SEM) was used to study the microstructure and identify elements on the tool. X-ray diffraction (XRD) was used to identify the phases and concentrations of key elements on the tool. The new advanced in-house coating was developed with Super Fine Cathode (SFC) technology on a Kobelco AIP-20 Physical Vapour Deposition (PVD) coater. The micromechanical properties of the commercial coating and in-house coatings were investigated with the help of nanoindentation and scratch tests. Atomic Force Microscopy (AFM) and SEM were used to investigate the coating microstructure and surface topography. An Alicona variable focus 3D microscope was used to investigate wear volume and wear behaviour. It was discovered that various secondary carbides used by manufacturers to manufacture cermet tools change the microstructure, which affects the machining performance of the cermet tool material. Microchipping at the depth of cut (DOC) causes catastrophic notch wear. It was found that the developed in-house coatings were able to delay the initial wear (microchipping), which improved the tool's life by 318%. This research contributes to meeting the manufacturing industry's challenging demand for dry-high speed machining with reduced manufacturing costs. / Thesis / Doctor of Philosophy (PhD) / Cutting is the process of removing unwanted material from the bulk material to obtain the desired shape. Each metal material has unique mechanical properties that lead to various machining challenges. The cutting process is done with the help of a cutting tool that wears out during the process, and a coating layer is often used to protect the tool. Stainless steel 304 is a widely used material that is difficult to machine. This study includes a systematic approach to understanding the wear mechanisms of tools and existing commercial coatings during the dry machining of stainless steel 304. An in-house coating was developed and deposited on the selected cutting tool to protect it, reduce tool wear and extend its working life. The research results will help reduce machining costs by reducing tool and coolant costs and meet the current industry demand for dry high-speed machining. It will also reduce environmental impact by reducing waste and hazardous chemicals and addressing occupational health and safety concerns.

O material, metálico ferro fundido cinzento, é muito utilizado industrialmente, principalmente na área automobilística. Usinagem com alta velocidade tem sido uma tendência atual para aumentar a produtividade, com a possibilidade de se ober ótima qualidade superficial, possivelmente eliminando processos subseqüentes. Aliado à questão de qualidade ambiental, as operações de usinagem têm-se voltado para usinagem a seco ou com mínima quantidade de lubrificante (MQL - minimal quantity of lubricant). Este trabalho estuda o torneamento com alta velocdidade de ferro fundido cinzento GG25 através de usinagem a seco e com MQL. Utiliza-se, em operação de faceamento, ferramenta de cerâmica mista (Al2O3+ TiC) e metal duro com cobertura (TiCN/Al2O3/TiN), usando velocidades de corte muito acima dos valores tradicionais. Comparativamente o desgaste é significativamente menor na cerâmica. O tipo de desgaste predominante é o desgaste de flanco. Os principais mecanismos de desgaste encontrados são abrasão mecânica e delaminação. O aumento do avanço diminui o desgaste de flanco. Existe uma razão entre a vazão de óleo e a vazão de ar na lubrificação MQL que viabiliza sua aplicacão com relação ao desgaste de flanco. Em todas as condições testadas, o sistema MQL mostra ser capaz de reduzir a rugosidade superficial Ra. / The gray cast iron material is very used industrially, mainly in the automotive industry. High speed machining is the current tendency to increase the productivity, with the possibility of obtaining good surface quality, possibly eliminating subsequent operations. Due to regulations on the subject of environrnental quality, the machining operations have been turned to dry machining or minimal quantity of lubricant (MQL). This work studies the turning process at high speed of gray cast iron GG25 with dry machining and MQL techniques. The operation uses face turning with coated carbide (TiCN/Al2O3/TiN) and mixed alumina ceramic (Al203+ TiC) with cutting speeds much higher than the traditional recommended values. Comparatively, the wear is significantly smaller in the mixed alumina ceramic tools. The predominant type of wear is the flank wear. The main wear mechanisms are mechanical abrasion and delamination. The increase of feed values shows some reduction on the flank wear. It seems to exist an ideal ratio of oil to air in the MQL system, which makes possible its application for reducing flank wear on the tools. In all conditions tested, the MQL system shows to be able to reduce surface roughness (Ra).

O material, metálico ferro fundido cinzento, é muito utilizado industrialmente, principalmente na área automobilística. Usinagem com alta velocidade tem sido uma tendência atual para aumentar a produtividade, com a possibilidade de se ober ótima qualidade superficial, possivelmente eliminando processos subseqüentes. Aliado à questão de qualidade ambiental, as operações de usinagem têm-se voltado para usinagem a seco ou com mínima quantidade de lubrificante (MQL - minimal quantity of lubricant). Este trabalho estuda o torneamento com alta velocdidade de ferro fundido cinzento GG25 através de usinagem a seco e com MQL. Utiliza-se, em operação de faceamento, ferramenta de cerâmica mista (Al2O3+ TiC) e metal duro com cobertura (TiCN/Al2O3/TiN), usando velocidades de corte muito acima dos valores tradicionais. Comparativamente o desgaste é significativamente menor na cerâmica. O tipo de desgaste predominante é o desgaste de flanco. Os principais mecanismos de desgaste encontrados são abrasão mecânica e delaminação. O aumento do avanço diminui o desgaste de flanco. Existe uma razão entre a vazão de óleo e a vazão de ar na lubrificação MQL que viabiliza sua aplicacão com relação ao desgaste de flanco. Em todas as condições testadas, o sistema MQL mostra ser capaz de reduzir a rugosidade superficial Ra. / The gray cast iron material is very used industrially, mainly in the automotive industry. High speed machining is the current tendency to increase the productivity, with the possibility of obtaining good surface quality, possibly eliminating subsequent operations. Due to regulations on the subject of environrnental quality, the machining operations have been turned to dry machining or minimal quantity of lubricant (MQL). This work studies the turning process at high speed of gray cast iron GG25 with dry machining and MQL techniques. The operation uses face turning with coated carbide (TiCN/Al2O3/TiN) and mixed alumina ceramic (Al203+ TiC) with cutting speeds much higher than the traditional recommended values. Comparatively, the wear is significantly smaller in the mixed alumina ceramic tools. The predominant type of wear is the flank wear. The main wear mechanisms are mechanical abrasion and delamination. The increase of feed values shows some reduction on the flank wear. It seems to exist an ideal ratio of oil to air in the MQL system, which makes possible its application for reducing flank wear on the tools. In all conditions tested, the MQL system shows to be able to reduce surface roughness (Ra).

Dans l’industrie de fabrication mécanique et notamment pour l’utilisation des centres d’usinage haute vitesse, la connaissance des propriétés dynamiques du système broche-outil-pièce en opération est d’une grande importance. L’accroissement des performances des machines-outils et des outils de coupe a œuvré au développement de ce procédé compétitif. D’innombrables travaux ont été menés pour accroître les performances et les remarquables avancées dans les matériaux, les revêtements des outils coupants et les lubrifiants ont permis d’accroître considérablement les vitesses de coupe tout en améliorant la qualité de la surface usinée. Cependant, l’utilisation rationnelle de cette technologie est encore fortement pénalisée par les lacunes dans la connaissance de la coupe, que ce soit au niveau microscopique des interactions fines entre l’outil et la matière coupée, aussi bien qu’au niveau macroscopique intégrant le comportement de la cellule élémentaire d’usinage, si bien que le comportement dynamique en coupe garde encore une grande part de questionnement et exige de l’utilisateur un bon niveau de savoir-faire et parfois d’empirisme pour exploiter au mieux les capacités des moyens de production. Le fonctionnement des machines d’usinage engendre des vibrations qui sont souvent la cause des dysfonctionnements et accélère l’usure des composantes mécaniques (roulements) et outils. Ces vibrations sont une image des efforts internes des systèmes, d’où l’intérêt d’analyser les grandeurs mécaniques vibratoires telle que la vitesse ou l’accélération vibratoire. Ces outils sont indispensables pour une maintenance moderne dont l’objectif est de réduire les coûts liés aux pannes / In machining field, chatter phenomenon takes a lot of interest because manufacturing enterprises are turning to the automation system and the development of reliable and robust monitoring system to provide increased productivity, improved part quality and reduced costs. Chatter occurrence has several negatives effects: a) Poor surface quality, b) Unacceptable inaccuracy, c) Excessive noise, d) Machine tool damage, e) Reduced material removal rate, f) Increase costs in terms of production time, g) Waste of material, h) Environmental impact in terms of materials and energy. Moreover, chatter monitoring is not an easy task for various reasons. Firstly, the non linearity of machining processes and the time-varying of systems complicate this task. Secondly, the sensitivity and the dependency of acquired signals from sensors on different factors, such as machining condition, cutting tool geometry and workpiece material. Thirdly, at high rotating speeds, the gyroscopic effects on the spindle dynamics in addition to the centrifugal force on the bearings and thermal effects become more relevant thus affecting the stability of the system. For these reasons, demands for an advanced automatic chatter detection and monitoring system for optimizing and controlling machining processes becomes a topic of enormous interest. Several researches in this field are performed. Advanced monitoring and detection methods are developed mostly relying on time, frequency and time-frequency analysis. In order to detect chatter in milling centers, three new methods are studied and developed using advanced techniques of signal processing and exploiting cyclostationarity property of signals acquired

Cette étude est dédiée à l’influence du fraisage de finition avec outil à extrémité hémisphérique sur l’intégrité de surface et la durée de vie en fatigue de pièces en acier bainitique à haute limite d'élasticité. L'intégrité de surface – microgéométrie, contraintes résiduelles et écrouissage – est caractérisée expérimentalement pour différentes valeurs des paramètres d'usinage, dont l'angle d'inclinaison de l'outil. L'hétérogénéité du champ de contraintes résiduelles perpendiculairement aux sillons générés par l’outil est mise en évidence à différentes profondeurs. Des essais de fatigue en flexion sur éprouvettes brutes d'usinage ou polies, avec ou sans traitement thermique de relaxation des contraintes résiduelles, mettent en évidence l'influence de l’intégrité de surface sur la tenue en fatigue. Des essais de fatigue en traction avec mesures d'auto-échauffement mettent en évidence une compétition entre mécanismes de micro-plasticité et de micro-fissuration. Une approche hybride est proposée pour prévoir l'état mécanique de la pièce usinée après fraisage. L'effet sur la surface usinée d'un chargement thermo-mécanique équivalent à l'opération de coupe et déduit d'essais d'usinage instrumentés est alors simulé numériquement sans modéliser l’enlèvement de matière. Une approche probabiliste est proposée pour prévoir l'influence de l'intégrité de surface sur la tenue en fatigue. Cette approche, restreinte au cas où le mécanisme de microfissuration est prédominant est validée grâce à la prise en compte de la microgéométrie. Le modèle est alors de type mécanique de la rupture et basée sur une mesure de la population de tailles d’entaille au fond des creux générés par l'outil. / This study is dedicated to the influence of ball-end tool finishing milling on surface integrity and fatigue life of components made of high-strength bainitic steels. Surface integrity, defined in terms of microgeometry, residual stresses and hardening, was experimentally characterized for different values of the machining parameters, including the tool inclination. Fluctuations of the residual stresses field – measured by X-ray diffraction – perpendicular to the grooves generated by the tool were exhibited at different depths beneath the surface. Fatigue bending tests performed on machined or polished flat specimens, submitted or not to a heat treatment to relax the residual stresses, exhibited the influence of the surface integrity on fatigue life. Fatigue tension tests and self-heating measurements exhibited a competition between micro-plasticity and micro-cracking mechanisms. A hybrid approach is proposed to predict the mechanical state induced by the milling process. This approach consists in simulating – without modelling the removal of the material- the effect of a thermo-mechanical loading equivalent to the cutting process. This thermo-mechanical loading should be derived from temperature and cutting forces measurements preformed during cutting tests. A probabilistic approach is proposed to predict the influence of surface integrity on fatigue life. This approach was validated for cases when micro-cracking mechanism is predominant. The approach is then based on fracture mechanics and takes account of the micro-geometry via the micro-cracks size population measured in the valleys of the grooves generated by the tool.

L’optimisation des gammes d'usinage n’est pas aisée, car elle souffre de deux lacunes importantes. La première est axée sur l'adaptabilité des gammes existantes aux moyens actuels de production et à leurs évolutions au fil des années pour répondre aux évolutions technologiques. Le second point concerne, l’absence de prise en compte du comportement mécanique de la pièce durant l'usinage dans l'élaboration de la gamme. Ces travaux de thèse abordent ces problématiques dans le cadre du projet FUI OFELIA. Ils étudient, dans un premier temps l'influence de la gamme d’usinage sur la déformation de la pièce. L'objectif est de pouvoir prédire le comportement mécanique de la pièce pour identifier les gammes minimisant les déformations. Le second point s'intéresse à l’évaluation multicritères des gammes de fabrication. Les critères retenus prennent en compte la déformation de la pièce, la productivité à travers une estimation rapide des temps d'usinage et la recyclabilité des copeaux obtenus lors de l'usinage. D’autre part, nous proposons un modèle géométrique des états intermédiaires de la pièce durant l’usinage pour à la fois évaluer les gammes de fabrication et conduire les calculs de simulation de la déformation de la pièce durant l’usinage. / The optimization of machining sequences is not easy because it suffers from two major shortcomings. The first focuses on the adaptability of existing ranges to current production facilities and their evolution over the years to respond to technological developments. The second point concerns the lack of consideration in the mechanical behavior of the part during the development of machining sequence. This thesis addresses these in relation to the FUI OFELIA project. At first, they study the influence of the machining parameters on the deformation of the workpiece. The aim is to predict the mechanical behavior of the part to identify recommendations with minimal distortion. The second issue deals with multi-criteria evaluation of manufacturing ranges. The criteria take into account are the deformation of the workpiece, productivity through a quick estimate of machining time and recyclability of chips produced during machining. On the other hand, we propose a geometric model of the intermediate states of the workpiece during machining in order to both assess the manufacturing recommendations and to drive the simulation calculations of the deformation of the workpiece during machining.