M.Eng. (Mechanical Engineering) / High speed machining (HSM) has the potential to greatly increase productivity and to lower manufacturing costs if workpiece surface integrity can be controlled. The surface fmish of a biomaterial is vitally important for proper implant functioning, and is the focus of this study. Grade 4 titanium was turned on a lathe with cutting speeds increasing from the conventional to the high speed range. The surface finish was assessed using profilometry, atomic force microscopy, and contact angle measurement. The ability of the material to bond directly with bone was predicted by cell adhesion studies. Results indicate that there is a general relationship between cutting speed, surface roughness, contact angle, and cell adhesion. Turning grade 4 titanium at cutting speeds between 150m/min and 200m/min may provide an optimal surface for osseointegration.

Le processus de fabrication des pièces usinées arrive à maturité concernant la fabrication assistée par ordinateur et la maîtrise du procédé d’usinage. Aujourd’hui, les perspectives d’améliorations importantes sont liées à l’optimisation de la commande numérique et de ses interactions avec le reste du processus de fabrication. L’objectif de cette thèse est donc de maîtriser les briques de base de la commande numérique pour optimiser le processus d’usinage 5 axes grande vitesse des surfaces complexes. La création d’une commande numérique ouverte nécessite le développement des algorithmes qui transforment le programme d’usinage en consignes échantillonnées pour les axes de la machine. La première partie des travaux consiste à rendre la géométrie suffisamment continue notamment pour les trajets interpolés linéairement en 5 axes qui présentent des discontinuités en tangence. Ensuite, l’interpolation temporelle du trajet crée la trajectoire d’usinage respectant les contraintes cinématiques et en particulier le jerk de chacun des 5 axes de la machine. L’implémentation matérielle de ces algorithmes permet de piloter une machine d’usinage grande vitesse 5 axes avec une commande numérique ouverte. Ainsi, les verrous technologiques associés aux commandes numériques industrielles sont levés et la chaîne numérique est entièrement contrôlée de la CFAO jusqu’au déplacement des axes. La maîtrise complète de la commande numérique offre la possibilité de définir exactement le trajet d’usinage à partir de la CAO sans introduire les écarts géométriques inhérents aux formats de description standards. L’interpolation de la trajectoire d’usinage directement sur la surface à usiner améliore de manière significative la qualité et la productivité de l’usinage des surfaces complexes. La commande numérique PREMIUM-OpenCNC permet la validation expérimentale de ces travaux et ouvre de nombreuses autres voies d’amélioration du processus de fabrication. / The manufacturing process reaches maturity concerning Computer Aided Manufacturing and cutting process performances. Nowadays, major improvements are linked to the optimization of the Computer Numerical Control and its interactions with the rest of the manufacturing process. The aim of this thesis is to control the basic components of a CNC in order to optimize the 5-axis high speed machining process of complex surfaces. The realization of an open CNC requires the development of algorithms which transform the machining program into command setpoints for the machine drives. The first part of this thesis allows to round the 5-axis discontinuities caused by the linear tool path interpolation commonly used. Then, a feedrate interpolation algorithm computes the trajectory while respecting the kinematical constraints of the machine and especially the jerk of each axis. The implementation of this work allows to control a 5-axis high speed machine with an open CNC. Hence, the technological barriers that prevent CNC optimizations are removed and the manufacturing process is under control from CAD/CAM to axis displacement. The complete control over the CNC offers the possibility to define the tool path exactly from Computer Aided Design entities without introducing any geometrical deviation generally induced by standard NC code. The direct interpolation of the trajectory on the machined surface significantly improves the quality and the productivity of complex surface machining. The PREMIUM-OpenCNC allows to prove experimentally the efficiency of this work and opens new ways for future manufacturing process improvements.

Les techniques d’usinage avancées sont un élément indispensable du développement des industries manufacturières. L’une de ces techniques, l’usinage à grande vitesse, constitue le sujet principal de cette thèse de doctorat. Ainsi, l’objectif majeur des travaux vise à améliorer la précision de contour dans le contexte de l’usinage multiaxes à grande vitesse de surfaces de forme libre, en agissant directement au niveau des boucles de commande d’axe. Pour cela, une première étape consiste à élaborer une stratégie permettant d’estimer le plus précisément possible l’erreur de contour pour différentes configurations de l’outil. Cette erreur de contour est ensuite minimisée grâce à l’adaptation hors ligne, pour un profil de pièce donné, des gains proportionnel et d’anticipation des régulateurs des boucles d’asservissement de la position de chaque axe. L’adaptation de ces gains est réalisée via un algorithme d’optimisation à l’aide d’un modèle non-linéaire du comportement de la machine, en considérant en particulier les frottements sur chacun des axes. L’optimisation permettant d’obtenir les gains des correcteurs des boucles de régulation tient compte des contraintes en termes de limitations cinématiques des axes (vitesse, accélération et jerk), de stabilité des boucles d’asservissement et de limites au niveau des courants des moteurs. Afin d’en faciliter la mise en oeuvre dans un cadre industriel, les stratégies développées s’avèrent directement implantables au sein des commandes numériques actuellement sur le marché, exploitant toutes les possibilités de la structure de commande classique de l’entraînement d’axe. / The advanced machining techniques are always the backbone of the manufacturing industries. Among such techniques, high speed machining is the main subject of this PhD thesis. Indeed, the main objective of this work is to improve the contouring accuracy in multi-axis high speed machining of free-form surfaces, directly acting inside the axis control loops. To do that, a first step aims at elaborating a strategy to estimate as accurately as possible the contour error for different tool configurations. This contour error is then minimized by means of an off-line adaptation for a given profile of the proportional and feedforward gains of the axis position loop controllers. This gain adaptation is performed via an optimization algorithm that considers a nonlinear model of the machine behaviour, in particular including friction related to each axis. This optimization leading to the controllers gains takes into account several constraints, including the axis kinematic (velocity, acceleration and jerk) limitations, the stability of the controlled loops and the motor current limits. Finally, to help their integration within an industrial framework, the developed strategies can be directly implemented in commercial CNC, by exploiting all possibilities of the classical control structure of axis drive.

Diploma work deal winth resolution automatic heads for high-speed shaping centers exchangas, so there was not those exchanges need of the human factor. It meaning that will using element automatic interface directly to programme as are Ball screw drives, ball rail systems, hydraulic element atc.

Dans les approches numériques pour l'usinage à grande vitesse, le comportement rhéologique des matériaux usinés est généralement décrit par une loi de Johnson Cook et le frottement à l’interface par un coefficient constant de type Coulomb. Une première approche propose de déterminer une loi de frottement à paramètres multiples pour des basses températures combinées à des vitesses de glissement élevées au moyen d'un tribomètre. Les résultats expérimentaux sont comparés à un modèle numérique et une méthode inverse est utilisée pour minimiser l'erreur entre des simulations numériques et expérimentales sur les forces tangentielles et normales. Cette méthode permet de récupérer un coefficient de frottement de type Coulomb qui est associé à la pression locale, la température et la vitesse de glissement. La réalisation de plusieurs essais fournit une loi de frottement à paramètres multiples pour des vitesses de glissement élevées et des basses températures. Une seconde étude est menée sur les phénomènes microstructuraux intervenant à l’interface outil-copeau. De nombreuses études ont montré que les phénomènes de recristallisation dynamique apparaissent lors de l'usinage dans l'interface outil-copeau. La loi de Johnson Cook ne comprend pas de tels phénomènes. Ainsi, les modèles rhéologiques spécifiques basés sur la métallurgie sont introduits pour tenir compte de ces phénomènes de recristallisation dynamique. Un modèle éléments finis de la coupe orthogonale à deux dimensions est développé avec le logiciel Abaqus Explicit en utilisant une formulation ALE. Ce modèle éléments finis peut alors prédire la formation des copeaux, les températures d'interface, les longueurs de contact et les forces de coupe. De nombreux essais spécifiques sont réalisés sur un banc d'essai de coupe orthogonale et un tribomètre grande vitesse sur un acier AISI 1045 et avec un outil en carbure non revêtu. Les résultats expérimentaux sont ensuite comparés aux simulations numériques. Ces deux approches montrent qu’il est nécessaire, afin d’optimiser les modèles de coupe orthogonale, de prendre en compte une loi de frottement à paramètres multiples qui tient compte des pressions, températures et vitesses de glissement locales et d’intégrer une loi de comportement rhéologique à base métallurgique. / In numerical approaches for high speed machining, the rheological behavior of machined materials is generally described by Johnson Cook law and the friction at the interface by a constant coefficient of Coulomb. A first approach proposes to determine a multiparameter friction law for low temperatures in combination with high sliding speeds by means of a tribometer developed by Meresse et Al. [Mer11]. The experimental results are compared to a numerical model and a inverse method is used to minimize the error between the numerical and experimental simulations on tangential and normal forces. This method allows to recover a Coulomb friction coefficient. This one is associated with the local pressure, temperature and sliding velocity. Several tests provide a multiparameter friction law for higher sliding speeds and low temperatures. A second study is conducted on the microstructural phenomena occurring at the tool-chip interface. Numerous studies have shown that the dynamic recrystallisation phenomena appear during machining at the interface. Johnson Cook law excludes such phenomena. Thus, specific rheological models based on metallurgy are introduced to take into account the dynamic recrystallization phenomena. Two empirical models proposed by Kim et al. [Kim03] and Lurdos [Lur08] are studied. A two-dimensional finite element model of the orthogonal cutting is developed with Abaqus Explicit software using an ALE formulation. This finite element model can predict chip formation, interface temperatures, contact lengths and cutting forces. Many specific tests are performed with an orthogonal cutting test bench and with an high speed tribometer on an AISI 1045 steel. The experimental results are then compared with numerical simulations. Both approaches show that it is necessary to optimize the orthogonal cutting model, to take into account a multi-parameter friction law that considers the local pressures, temperatures, and sliding velocities and to integrate a rheological behavior law based on mettalurgy.

Increasing productivity is a constant demand for the manufacturing industry. Low-carbon-steel is one of the most commonly used ferrous materials in the part manufacturing market. Improving productivity as well as making the process eco-friendly by implementing a dry machining condition is the essential goal of this study. Built-up-edge (BUE) is often formed in the low-carbon-steel machining process, which, results in poor surface finish and short tool life. The high-speed-machining technique can be used to reduce the BUE formation and realize an increase in productivity. Cubic boron nitride (CBN) tools are most commonly used in hard turning and cast-iron machining at high cutting speeds. There are a limited number of studies regarding low-carbon-steel machining with CBN under a high-speed and with a dry machining condition. In this study, the investigation shows the preferable type of CBN tool and the wear mechanisms involved during finish turning operations of AISI 1018 under high speed and dry machining conditions. Test results show that a low CBN content with a TiCN binder and smaller grain size offers the best tool life and surface integrity of the final part. Currently manufacturers use coated carbide tools with a recommended cutting speed of 200-300m/min with coolant to complete the finishing process for turning low carbon steel parts. In this study, by implementing CBN tools under the dry condition at 500 m/min cutting speed (speed was selected from the preliminary test performed using the uncoated CBN from 500 to 1200 m/min), the buildup edge formation has been reduced, tool life was measured to increase by 307% compared to the benchmark tool (Coated Carbide), and surface finish was measured in the range of 0.8-1.6μm Ra. / Thesis / Master of Applied Science (MASc)

Trata do estudo experimental da energia específica de corte e sua relação com parâmetros de usinagem, características geométricas e tribológicas das ferramentas, e material da peça usinada. Dentre as variáveis investigadas são destaques a profundidade de usinagem, velocidade de corte, raio de ponta, geometria de quebra-cavaco, tipo de revestimento das ferramentas, dureza, microestrutura e composição química do material da peça. Os seguintes materiais foram empregados nos ensaios: aços SAE 1213, 1020, 1045, ASTM H13 recozido e temperado, e liga de alumínio 2024. As medições de energia específica foram realizadas em uma máquina Charpy instrumentada por meio de um dinamômetro piezelétrico e um encoder ótico rotacional. Vários resultados puderam ser comparados aos obtidos em torno e centro de usinagem CNC devidamente instrumentados. Testes na condição HSM foram implementados nas máquinas-ferramentas. Todas as variáveis pesquisadas mostraram exercer influência sobre a energia específica. O aumento da profundidade de usinagem em 2,3 vezes causou diminuição da energia específica em 21%, na usinagem da liga de alumínio 2024. A elevação da velocidade de corte em torno de 70% conduziu a uma queda da energia específica de 24% para o aço SAE 1020. A geometria da ferramenta influiu mais decisivamente na energia específica sob velocidades de corte convencionais que na condição HSM. Pequenas variações na geometria do quebra-cavaco dos insertos causaram diminuição da energia específica de até 29%, para velocidade de corte convencional, e de 14% para HSM, na usinagem do aço H13 temperado. Diversos resultados de energia específica de corte medidos pelo ensaio Charpy proposto por este trabalho apresentaram boa concordância com os valores equivalentes fornecidos pela literatura científica / This thesis presents an experimental study about the specific cutting energy and its relation with cutting parameters, geometrical and tribological characteristics of tools, and workpiece material. Depth of cut, cutting speed, tool nose radius, chip-breaker geometry, tool coating, hardness, microstructure and chemical composition of the workpiece material are some investigated variables. The following workpiece materials were tested: SAE 1213, 1020, 1045, annealed and tempered ASTM H13 steels, and 2024 aluminum alloy. The specific cutting energy values were measured by using a Charpy machine instrumented through piezoelectric dynamometer and incremental optical encoder. Several results could be compared to ones from instrumented CNC lathe and machining center. Tests under HSM condition were carried out in machine-tools. All researched variables have influence over specific cutting energy. The depth of cut rise in 2.3x caused a decrease of specific cutting energy around 21% when machining 2024 aluminum alloy. The elevation of the cutting speed about 70% leaded to reduction of specific cutting energy around 24% when machining SAE 1020 steel. The tool geometry present more influence on specific cutting energy under conventional cutting speed than at high speed cutting. Small variations of tool chip-breaker geometries caused diminution of the specific cutting energy up to 29% for conventional cutting speed, and 14% on average for HSM condition when machining tempered ASTM H13 steel. Various specific cutting energy results obtained from the Charpy test proposed by this work presented a good concordance with equivalent ones provided by scientific literature

Trata do estudo experimental da energia específica de corte e sua relação com parâmetros de usinagem, características geométricas e tribológicas das ferramentas, e material da peça usinada. Dentre as variáveis investigadas são destaques a profundidade de usinagem, velocidade de corte, raio de ponta, geometria de quebra-cavaco, tipo de revestimento das ferramentas, dureza, microestrutura e composição química do material da peça. Os seguintes materiais foram empregados nos ensaios: aços SAE 1213, 1020, 1045, ASTM H13 recozido e temperado, e liga de alumínio 2024. As medições de energia específica foram realizadas em uma máquina Charpy instrumentada por meio de um dinamômetro piezelétrico e um encoder ótico rotacional. Vários resultados puderam ser comparados aos obtidos em torno e centro de usinagem CNC devidamente instrumentados. Testes na condição HSM foram implementados nas máquinas-ferramentas. Todas as variáveis pesquisadas mostraram exercer influência sobre a energia específica. O aumento da profundidade de usinagem em 2,3 vezes causou diminuição da energia específica em 21%, na usinagem da liga de alumínio 2024. A elevação da velocidade de corte em torno de 70% conduziu a uma queda da energia específica de 24% para o aço SAE 1020. A geometria da ferramenta influiu mais decisivamente na energia específica sob velocidades de corte convencionais que na condição HSM. Pequenas variações na geometria do quebra-cavaco dos insertos causaram diminuição da energia específica de até 29%, para velocidade de corte convencional, e de 14% para HSM, na usinagem do aço H13 temperado. Diversos resultados de energia específica de corte medidos pelo ensaio Charpy proposto por este trabalho apresentaram boa concordância com os valores equivalentes fornecidos pela literatura científica / This thesis presents an experimental study about the specific cutting energy and its relation with cutting parameters, geometrical and tribological characteristics of tools, and workpiece material. Depth of cut, cutting speed, tool nose radius, chip-breaker geometry, tool coating, hardness, microstructure and chemical composition of the workpiece material are some investigated variables. The following workpiece materials were tested: SAE 1213, 1020, 1045, annealed and tempered ASTM H13 steels, and 2024 aluminum alloy. The specific cutting energy values were measured by using a Charpy machine instrumented through piezoelectric dynamometer and incremental optical encoder. Several results could be compared to ones from instrumented CNC lathe and machining center. Tests under HSM condition were carried out in machine-tools. All researched variables have influence over specific cutting energy. The depth of cut rise in 2.3x caused a decrease of specific cutting energy around 21% when machining 2024 aluminum alloy. The elevation of the cutting speed about 70% leaded to reduction of specific cutting energy around 24% when machining SAE 1020 steel. The tool geometry present more influence on specific cutting energy under conventional cutting speed than at high speed cutting. Small variations of tool chip-breaker geometries caused diminution of the specific cutting energy up to 29% for conventional cutting speed, and 14% on average for HSM condition when machining tempered ASTM H13 steel. Various specific cutting energy results obtained from the Charpy test proposed by this work presented a good concordance with equivalent ones provided by scientific literature

Nespornou vyhodou počítačem podporované výroby (CAM) je výrazná časová úspora při přípravě obráběcího programu. Asociativita je jedním z řešení, její místo v rámci přípravy výrobku se nachází mezi hlavní konstrukcí a technologií podniku. Pro studium asociativity byl použity CAD/CAM modely kompresoru, který díky své komplexní geomtrii posloužil jaky dobrý příklad. Tato práce se podtrhuje omezené možnosti asociativity, především pokud jde o realizaci obráběcího programu pro součást tvořenou více prvky. Dále v této studii budou prezentovány jisté možnosti zlepšení procesu. Studie asociativity v této práci je zaměřena především na obrábění, tedy její aplikace jsou využívány zejména ve oborech jako je automobilový průmysl, letectví, kosmický průmysl či stavebnictví. Kompresor studovaný v této práci je vyroben ze slitiny titanu Ti-6Al-4V a jedná se o součást využívanou v kosmickém průmyslu. Jelikož se jsou jeho rozměry velmi malé, jsou pro jeho obrábění nezbytné velmi přesné nástroje a vysoké řezné rychlosti. Tato práce představuje odlišné strategie obrábění navrhnuté pro výrobu kompresoru, společně s analýzou výsledků. Po počáteční přípravě výroby následují dvě hlavní etpy : editace programu v CATII V5 a jeho ověření v NCSimul8.

Les travaux de recherche présentés dans ce mémoire concernent la prédiction et l’amélioration des performances des machines-outils à structure parallèle dans le but de produire des pièces conformes à la qualité requise en un temps minimal. Le problème abordé permet de déterminer l’influence de la structure sur la productivité et la qualité de la pièce usinée dans le contexte de l’Usinage à Grande Vitesse de pièces automobiles et aéronautiques. Ce travail propose alors des avancées suivant deux axes fondamentaux : - la modélisation du comportement anisotrope de la cellule d’usinage ; - la proposition de nouvelles méthodes d’adaptation du processus.Ces deux axes sont dans un premier temps abordés vis-à-vis d’un objectif d’amélioration des temps de déplacement d’outil hors matière. La méthode développée nécessite l’élaboration d’un modèle cinématique des déplacements hors matière spécifique à chaque structure de machine outil et basé sur l’utilisation d’une loi de commande articulaire. Un outil d’aide à la mise en place d’un usinage sur machine-outil à structure parallèle est ensuite proposé. Cet outil repose sur un modèle numérique de comportement cinématique utilisant une loi de commande de déplacement dans le repère lié à la pièce permettant de prédire le temps d’usinage en fonction des trajectoires. L’optimisation du processus d’usinage s’appuie également sur la prédiction de la qualité d’usinage. Pour cela, un modèle expérimental basé sur une campagne de mesures effectuée sur la machine-outil considérée a été développé. Ces approches sont appliquées à des usinages de pièces industrielles sur la machine-outil PCI Tripteor X7. Leur originalité réside dans l’amélioration des performances des machines-outils à structure parallèle à partir de l’analyse du comportement durant l’usinage et permet, par conséquent, d’étendre leur domaine d’application. / The research works presented here deal with the prediction and the performance improvement of parallel kinematic machine tools in order to produce machine parts with a specified quality level and in a minimum time. The problem treated allows determining the structure influence on the productivity and the machined part quality in the context of High Speed Machining for automotive and aeronautical parts.So, these works propose improvements along two fundamental ways : - modelling of the machine tool anisotropic behaviour ; - new methods of process adaptation. These approaches lead in a first time to a study of the time taken by the linking tool movement between cutting operations. The developed method is based on the definition of a kinematic model of linking tool movements, specific to each machine-tool and based on a command law defined in the joint workspace. A helpful resource for the setting up of machining with a parallel kinematic machine tool is then proposed. It is based on a numerical model of the kinematic behaviour using a command law of the movement defined in the programming workspace and providing a prediction of machining time. The process optimization is also based on the machining quality prediction brought by an experimental model enhanced by a measurement campaign realized on the considered machine tool. These approaches are applied to industrial parts with the PCI Tripteor X7 machine-tool. Their originality lies in the improvement of parallel kinematic machines tool performances from an analysis of the machine behaviour during the machining, and consequently allows extending their application field.