Orientador: Marcos Valério Ribeiro / Banca: Marcelo dos Santos Pereira / Banca: José Vitor Candido dos Santos / Resumo: Neste trabalho, foram analisados os resultados do processo de furação da chapa de GLARE®. O que motivou este estudo foi a necessidade cada vez maior para as empresas de realizar furos em materiais compósitos com brocas especiais e comerciais em quantidades cada vez mais crescentes. Outros fatores chamam a atenção em relação aos resultados obtidos a partir destas operações tais como: a qualidade das superfícies geradas na usinagem, o acabamento dos furos, geometria, deformação, tolerância dimensional e possíveis defeitos gerados. Neste estudo os testes foram realizados sem a presença de fluído refrigerante. Foram executados vários ensaios totalizando sete diferentes condições, e foi possível conseguir eliminar o defeito de delaminação, deformação, desfibramento e manter uma uniformização na usinagem dos furos. Foram identificamos os melhores parâmetros de furação com broca de metal duro inteiriça comercial, para o material compósito GLARE®. A velocidade de corte ideal para o material foi de 157m/min, nesta condição foi possível manter a ferramenta com sua integridade com o mínimo de desgaste por abrasão totalizando 248 furos e a ferramenta ainda com condições de continuar a cortar normalmente / Abstract: In this work, the results of the drilling process of the GLARE® sheet were analyzed. What motivated this study it was the need every time larger for the companies of accomplishing holes in materials composites with special drills and you trade more and more in amounts growing. Other factors get the attention in relation to the results obtained starting from these such operations as: the quality of the surfaces generated in the machining, the finishing of the holes, geometry, deformation, dimensional tolerance and possible generated defects. In this study the tests were accomplished without the presence of cutting fluid. Several rehearsals were executed totaling seven different conditions, and it was possible to get to eliminate the delamination defect, deformation, disfibration and to maintain an uniformization in the holes machining. Were identified the best drilling parameters with integral cemented carbide drill from commercial trade, for the material composite GLARE®. The better cutting speed for the material was of 157m/min, in this condition it was possible to maintain the tool with its integrity with the minimum of wear for abrasion still totaling 248 holes and the tool with conditions of continuing to cut usually / Mestre

Orientador: Marcos Valério Ribeiro / Banca: Marcelo dos Santos Pereira / Banca: João Roberto Ferreira / Resumo: Os aços inoxidáveis martensíticos, essencialmente ligas Fe - Cr - C, são largamente utilizados na fabricação de componentes de Turbinas Hidráulicas devido à elevada resistência ao ataque químico e a sua maior resistência mecânica, quando comparado aos outros tipos de aços inoxidáveis. A proposta deste trabalho é estudar o acabamento superficial do aço inoxidável AISI 410 sob diferentes condições de corte, visto que este requisito é de suma importância para o funcionamento de alguns componentes de Turbinas Hidráulicas. Serão avaliados também os diferentes tipos de cavacos obtidos, os desgastes nas ferramentas de corte e comparados os resultados de rugosidade obtidos experimentalmente com os valores obtidos através da utilização da equação proposta pela literatura. Durante os ensaios foram variados os parâmetros de corte, sendo eles a velocidade de corte, o avanço por volta, a profundidade de corte e o tipo de pastilha, e medida a rugosidade para cada condição. Com os valores de rugosidade obtidos experimentalmente foi possível, através de uma regressão linear, propor uma equação para o seu cálculo e comparar estatisticamente os erros encontrados da utilização de ambas as equações. Os resultados mostraram que as condições de acabamento não são severas a ponto de desgastar as pastilhas, que a formação da APC influencia diretamente na rugosidade, que a pastilha com geometria Wiper fornece baixos valores de rugosidade quando empregados altas taxas de avanço e que são observadas grandes variações quando comparados os resultados de rugosidade obtidos nos ensaios com os calculados pela equação teórica da rugosidade. / Abstract: The martensitic stainless steel, essentially alloys Fe - Cr - C, are widely used for the manufacture of Hydraulic Turbines components due to its high resistance to chemical attack and its greater mechanical resistance, when compared to other stainless steels. The proposal of this work is to study surface roughness on the AISI 410 stainless steel under different cutting conditions, since this requirement is very important to the correct functioning of some components of Hydraulic Turbines, the different types of chips, the wears on the cutting tools and to compare the results of roughness obtained experimentally and calculated by using the equation proposed by the literature. During the tests was varied the cutting parameters, witch were the cutting speed, the feed rate, the depth of cut and the tool, measuring the superficial roughness for each condition. With the values of roughness obtained experimentally was possible, using a linear regression, to purpose an equation to calculate the surface roughness and the comparison between the errors when used both equation. The results has shown that the finishing conditions are not severe enough to initiate the wear on cutting tools, the BUE influences the roughness, the Wiper geometry results in low values of roughness when using high feed rates and it is observed great variations when compared roughness results obtained experimentally and the results from the theoretical equation for roughness calculation. / Mestre

To manufacture a high precision component, the aircraft industry in particular, employs computer numerical control machining to produce the aircraft components. However, it has often been found that problems of distortion occur when thin and slender components are manufactured this way. It is believed that the distortion arises due to the re-distribution of the residual stress field that was present in the original component in addition to the effects of cutting forces and temperatures that were induced during the machining process. At present, the process to produce a component with acceptable tolerance limits is one of trial and error. This often consumes a lot of time and produces considerable material wastage. The finite element method has been used to develop a methodology to model the actual machining process that produced the aircraft component. The finite element model that has been developed so far was able to demonstrate the effects of redistribution of the residual stresses on the distortion of the final machined component. It was found that the final component distorted differently when the materials were simply removed from a solid billet with different material removal sequences. A preliminary investigation on the effects of cutting temperature and forces has also been made. The investigation showed that such effects could not be totally ignored as they significantly affect the distortion of the final component. In addition to modelling the machining process, a methodology has also been developed to introduce and simulate the clamps and machine worktable that are part of the machining process. Although there is a considerable amount of work relating to modelling machining processes, there has not been any previous attempt to address the problem as a whole as described in this thesis. It is hope that the work undertaken here would be able to provide a stepping-stone to such attempts in future. However, further experimental data would be required to complement a more refined model in the attempt to accurately predict the distortion in machined components. It is believed that it would be possible to then extend the developed methodology to minimise the distortion by changing the machining sequence and the shape of the material to be removed. This would reduce the timescales involved to correct the problems of distortion and eliminate material wastage.

M.Ing. / This report documents the steps taken to gain insight into the phenomena of high speed machining (HSM) of titanium alloys. This was done by firstly studying titanium alloys and the problems associated with machining titanium alloys. An experimental set-up and procedure was developed for measuring and recording both the machining temperature and component forces. A sufficient set of experimental data was collected through extensive experimentation. The cutting temperatures and component forces in HSM of Ti-6Al-4V were examined simultaneously. The cutting speed was found to be the most influential and limiting parameter on the machining temperature and component forces. A new approach for modeling the temperatures in HSM of titanium alloys was developed. Analytical predictions of the cutting temperatures were performed and used to evaluate the influence of a variation in the process parameters on the cutting temperature. The research provides insight for future work into the phenomena of HSM of titanium alloys . The results of the analytical model were found to be representative and comparable to the experimental data. It is however expected that the deviation between the predicted and measured result may be significantly reduced by changing the experimental approach. It is recommended that a complete set of experiments be done, using a new tool insert for every cut, thus removing the effect of possible tool wear on the experimental data obtained. In addition it is recommended that the iterative solution be improved through more in depth programming, considering the change in both the thermal and mechanical materials properties with a change in temperature. Ultimately the assumptions made in order to simplify the problem addressed in this report needs to be improved upon, in order to analyze data trends and even magnitudes to a greater degree of certainty.

The world is experiencing a growing demand for miniaturised products. Micro-milling, using carbide micro tools has the potential for direct, economical manufacture of micro parts from a wide range of workpiece materials. However, in previous studies several critical issues have been identified that preclude the direct application of macro machining knowledge in the micro domain through simple dimensional analysis. The research presented in this thesis focused on some of the areas that require development of the scientific knowledge base to enable determining improved microscale cutting performance. In the mechanical micro machining of coarse grained materials, the programmed undeformed chip thickness can be lower than the length scale of the workpiece grains. Moreover, when the microstructure of such materials is composed of more than one phase, the micro cutting process can be undertaken at a length scale where this heterogeneity has to be considered. Driven by this challenge, the material microstructure 'size effect' on micro-machinability of coarse grain steel materials was investigated in this PhD. In this regard, a predominantly single phase ferritic workpiece steel material and another workpiece material with near balanced ferrite/pearlite volume fractions was studied over a range of feedrates. The results suggested that for micro machined parts, differential elastic recovery between phases leads to higher surface roughness when the surface quality of micro machined multiphase phase material is compared to that of single phase material. On the other hand, for single phase predominantly ferritic materials, reducing burr size and tool wear are major challenges. In micro machining the so called 'size effect' has been identified as critical in defining the process performance. However, an extensive literature search had indicated that there was no clear reported evidence on the effect of process variables on driving this size effect phenomenon. It is often assumed in literature that the un-deformed chip thickness was the main factor driving the size effect. This limit manufactures to only altering the feedrate to try and influence size effect. To explore the significance of a range of inputs variables and specifically, cutting variables on the size effect, micro cutting tests were conducted on Inconel 718 nickel alloy. Taguchi methodology along with signal processing techniques were applied to micro milling acoustic emission signals to identify frequency/energy bands and hence size effect specific process mechanism. The dominant cutting parameters for size effect characteristics were determined by analysis of variance. These findings show that despite most literature focussing on chip thickness as the dominant parameter on size effect, the cutting velocity is a dominant factor on size effect related process performance. This suggests that manipulating the cutting speed can also be a very effective strategy in optimising surface finish in micro machining and in breaking the lower limit of micro machining.In micro machining the lower limit of the process window is set by the minimum chip thickness. Identifying this limit is thus important for establishing the process window. Process windows are valuable guidelines for industrial selection of cutting conditions. Additionally, understanding factors that influence the value of minimum chip thickness is even more important for progressing micro machining capability to the nano-scale machining regime. For this reason, in this PhD study, acoustic emission signatures emanating from microscale milling of six different workpiece materials were characterised to identify the rubbing mode and this enabled the identification of the threshold conditions for occurrence of minimum chip thickness. The minimum chip thickness predicted by this novel approach compares reasonably well to the values that exist in published literature. Additionally, the decomposition of raw acoustic signal allowed the determination of energy levels corresponding to deformation mechanisms. The PhD work provides significant and new knowledge on the utility and importance of acoustic emission signals in characterising chip formation in micro machining. A novel method for determining the minimum chip thickness was developed, micro machining chip formation mechanisms were identified and the machinability of coarse grained multiphase material is presented.

The formation of burrs in Machining Operations occurs by three Basic Mechanisms: 1) Lateral Extrusion of material 2) Bending of the chip 3) Tearing of the chip form the workpiece Each of these mechanisms has been studied analytically and compared to experimental results. The agreement between predictions and measurements has been found to be close. Drilling, milling, grinding, and turning burrs were produced in 303Se stainless steel and their properties were related to tool geometry, feedrates, and depth of cut. One thousand measurements were made and subsequently analyzed by analysis of variance techniques. The properties measured include burr length and thickness. Both the theory and the empirical results indicate that burrs cannot be prevented by changing machine variables. Burr size can be minimized, however, by appropriate machining conditions.

Self-excited vibration, known as chatter, limits material removal rate, surface finish and accuracy in machining, and may even cause structural damage to components of the machining system. Machining stability may be enhanced by a variety of methods, from moving machining parameters to stable regions, or using actively actuated tools specially designed to obstruct self-excitation, or even by passively enhancing the stiffness or damping of the system as to soften the critical mode of vibration. Although there are many approaches to reduce chatter, not all of them are always effective in every situation. Moving machining parameters is restricted by workpiece machinability. Active damping mechanisms require large contraptions to function and have limited effectiveness when dealing with high frequency chatter. Passive damping approaches have essentially entailed tuned mass dampers which require delicate finetuning and drastic alterations to the tool structure in order mount the vibration absorber system. This research presents an elegant and innovative application involving electrical discharge texturing for chatter suppression that takes advantage of frictional forces to passively damp self-excited vibrations. This technique proved effective in a frequency range from 100 to 4000 Hz achieving damping enhancements of more than 400% without the need of any tuning and showing repeatable damping values after subsequent assembly and disassembly cycles. When applied to a grooving operation the technique proved effective in increasing the limiting width of cut by more than 120%. / Thesis / Master of Applied Science (MASc)

Laser-assisted machining has been considered as an alternative for difficult-to-machine materials such as metallic alloys and ceramics. Machining of some materials such as high chromium alloys and high strength steels is still a delicate and challenging task. Conventional machines or computer numerical control (CNC) machines and cutting tools cannot adapt easily to such materials and induce very high costs for operations of rough machining or finishing. If laser-assisted machining can be implemented successfully for such materials, it will offer several advantages over the traditional methods including longer tool life, shorter machining time and reduced overall costs. This thesis presents the results of the research conducted on laser assisted machining of hard to wear materials used in making heavy duty mineral processing equipment for the mining industry. Experimental set up using a high power Nd:YAG laser beam attached to a lathe has been developed to machine these materials using cubic boron nitride (CBN) based cutting tools. The laser beam was positioned so that it was heating a point on the surface of the workpiece directly before it passed under the cutting tool. Cutting forces were measured during laser assisted machining and were compared to those measured during conventional machining. Results from the experiments show that with the right cutting parameters and laser beam position, laser assisted machining results in a reduction in cutting forces compared to conventional machining. A mathematical thermal model was used to predict temperatures within the workpiece at depths under the laser beam spot. The model was used to determine the effect of various cutting and laser parameters on the temperature profile within the workpiece. This study shows that laser assisted machining of hard to wear materials such as high chromium white cast iron shows potential as a possible economical alternative to conventional machining methods. Further research is needed before it can be introduced in industry as an alternative to conventional machining.

M.Ing. / A two-axis gimbal system in the form of a pitch-roll gimbal and a motion simulating platform were developed to extend the capability of an existing ground-to-air prototype gun-turret. The objective was to stabilize the line of sight (LOS) of the gimbal system despite disturbances introduced by the motion simulating platform in real time. The main sensor used for the stabilization is a two-axis accelerometer which was mounted directly on the inner gimbal (roll gimbal) to form a direct-mass stabilization architecture. The stabilization control algorithm was designed and executed in the Labview® environment on a PC, and the accelerometer data is used to drive the two DC motors used as the actuators of this control system. The design of the motion simulating platform was based on a simplified Stewart-Platform and uses pneumatic cylinders as actuating limbs. All sensors and actuators in the motion simulating platform and the gimbal system are integrated with the National Instrument’s CompactRio® and Labview®. The result was a simple stabilization controller capable of achieving basic stabilization of the LOS. However, the hardware and software of this project are capable of more complex control algorithms and that forms the bulk of the suggestions for further studies.

The presented diploma thesis deals with the issue of wire electrical discharge machining of SiSiC ceramics. The first part explains the principles of electrical discharge machining, describes the WEDM technology and presents the properties of the advanced ceramics. The second part consists of a detailed analysis of the cutting process of eighteen samples obtained with systematically changing process parameters. Based on the obtained results from EDX analysis, SEM electron microscopy and topography there was performed an analysis of the influence of process parameters on the cutting speed, surface roughness, kerf width and number of wire breaks with usage of the selected brass cutting wire. From the evaluated results it was possible to select a combination of parameters that ensured a stable machining process.