Fundação de Amparo a Pesquisa do Estado de Minas Gerais / The main goal of this work is the development of techniques for application of acoustic emission signal in tool wear monitoring in face milling operation. In this work a Sensis (DM 42) equipment for acquisition of the acoustic emission signal was used during the milling of a high strength low alloy steel (Din 38MnS6). A milling cutter with 125 mm diameter for eight inserts with specification R245 125Q40-12M was used. The ISO specification of the inserts were SEMN 12 04 AZ TiN coated. The tests were divided into two parts. In the first part, wear and some other machining phenomena were monitored through the construction of a luminous intensity map. For these tests it was used one, two, four or eight inserts simultaneously. In this stage the acoustic emission signal was evaluated using the RMS values. In the second part of this work the acoustic emission raw signal was used. Amongst the statistical parameters that correlate to tool wear extracted from the raw signal, the best fit ones were selected to train and validate a Probabilistic Neural Network. The results of the PNN indicate that the acoustic emission signal can be used to recognition of tool wear levels in the milling process. / O principal objetivo deste trabalho é o desenvolvimento de técnicas para a aplicação da emissão acústica no monitoramento de desgaste de insertos de metal duro no fresamento frontal. Neste trabalho foi utilizado um equipamento da Sensis (DM 42) para aquisição do sinal de emissão acústica durante o fresamento frontal de um aço microligado perlítico de forja (Din 38MnS6). Foi utilizada uma fresa com especificação R245 125Q40-12M, de 125 mm de diâmetro e com possibilidade de montagem de até oito insertos. Os insertos utilizados são de metal duro R245-12 T3 M-PM 4030 revestidos com TiN. A fresa e os insertos foram fabricados pela Sandvik Coromant. Os testes foram divididos em duas partes. A primeira consistiu no monitoramento do desgaste e também de alguns fenômenos que ocorrem na usinagem através da construção de um mapa de intensidade luminosa. Nestes testes foram utilizados um, dois, quatro e oito insertos simultaneamente. Nesta etapa foi empregado o sinal RMS da emissão acústica. Na segunda etapa dos ensaios utilizou-se o sinal bruto de emissão acústica. Foram estimados parâmetros estatísticos destes sinais e destes foram escolhidos os que melhor se relacionavam com o fenômeno estudado. Este procedimento foi realizado através da ferramenta estatística boxplot. Finalmente, os parâmetros escolhidos foram usados para treinar e validar uma Rede Neural Probabilística, que teve a função de reconhecer e classificar os estágios de desgaste da ferramenta. Os índices de acerto nas classificações da rede indicam que a emissão acústica apresenta bons resultados no reconhecimento de níveis de desgaste das ferramentas na operação de fresamento. / Doutor em Engenharia Mecânica

This research develops an analytical scientific approach for investigating the high precision surface generation and the quantitative analysis of the effects of direct factors in precision machining. The research focuses on 3D surface characterization with particular reference to the turning process and associated surface generation. The most important issue for this research is surface functionality which is becoming important in the current engineering industry. The surface functionality should match with the characterization parameters of the machined surface, which can be expressed in formula form as proposed in chapter 4. Modelling and simulation are extensively used in the research. The modelling approach integrates the cutting forces model, thermal mode% vibration model, tool wear model, machining system response model and surface topography model. All of those models are integrated as a whole model. The physical model with such as direct inputs is formed. The major inputs to the model are tooling geometry and the process variables. The outputs from the modelling approach are cutting force, surface texture parameters, dimensional errors, residual stress and material removal rate. MATLAB and Simulink are used as tools to implement the modelling and simulation. According to the simulation results, it is found that the feed rate has the most profound effect on in surface generation. The influence of the vibrations between the cutting tool and the workpiece on the surface roughness may be minimised by the small feed rate and large tool nose radius. Surface functionality simulation has been developed to model and simulate the surface generation in precision turning. The surface functionality simulation model covers the material and tool wear as well. It shows that chip formation is resulted from cutting forces. Cutting trials are conducted to validate the modelling and simulation developed. There are positive results that show the agreement between the simulation and experimental results. The analysis of the results of turning trials and simulations are conducted in order to find out the effects of process variables and tooling characteristics on surface texture and topography and machining instability. From the research, it can be concluded that the investigation on modelling and simulation of precision surfaces generation in precision turning is performed well against the research objectives as proposed. Recommendations for future work are to improve the model parameters identification, including comprehensive tool wear, chip formation and using Neural Networks modelling in the engineering surface construction system.

Durante o processo de usinagem, o conhecimento da temperatura é um dos fatores mais importante na análise do estado da ferramenta. Permite o controle dos fatores mais importantes que influenciam, no uso, na vida e no desgaste da ferramenta. A temperatura na região de contato entre a peça e a ferramenta é resultante do processo de remoção de material durante a operação de corte e é difícil de se obter uma vez que, ou a peça, ou a ferramenta estão em movimento. Uma maneira de se medir a temperatura nessa situação é detectando a radiação de infravermelho. Este trabalho tem objetivo de apresentar uma nova metodologia de diagnóstico e monitoramento de operações de usinagem com o uso de imagens de infravermelho. A imagem de infravermelho fornece um mapa em tons de cinza da temperatura dos elementos participantes do processo: ferramenta, peça e cavaco. Cada tom de cinza na imagem corresponde a uma temperatura para cada material. A correspondência entre tons de cinza e a temperatura é dada pela prévia calibração da câmera de infravermelho para os materiais participantes do processo. O sistema desenvolvido neste trabalho usa uma câmera de infravermelho, uma frame grabber e um software composto por 3 módulos: o primeiro módulo faz a aquisição da imagem de infravermelho e o processamento; o segundo módulo faz a extração e o cálculo do vetor de características das imagens. Finalmente o terceiro módulo usa um algoritmo fuzzy e fornece como saída o diagnóstico do estado da ferramenta. / During machining process the temperature knowledge is one of the most important factors in tool analysis. It allows to control main factors that influence tool use, life time and wear. The temperature in the contact area between the work piece and the tool is resulting from the material remova! in cutting operation and it is too difficult to be obtained because the tool, or the work piece is in motion. One way to measure the temperature in this situation is detecting the infrared radiation. This work presents a new methodology for diagnosis and monitoring of machining processes with the use of infrared images. The infrared image provides a map in gray tones of the elements temperature in the process: tool, work piece and chips. Each gray tone corresponds to a certain temperature for each one of those materials and the relationship between the gray tones and the temperature is goven by previous infrared camera calibration. The system developed in this work uses an infrared camera, a frame grabber board and a software composed by three modules. The first module provides the image acquisition and processing. The second one does the image feature extraction and calculates the feature vector. Finally, the third module uses fuzzy logic to evaluate the feature vector and to supply the tool state diagnostic as output.

O custo de qualquer produto forjado para indústria automobilística é altamente influenciado pelos custos envolvidos durante o projeto e construção das ferramentas de conformação. Idealmente, essas ferramentas devem durar um número significativo de ciclos de conformação, de forma a diluir seu custo no maior número de peças possível. Diversos parâmetros afetam o comportamento do desgaste das ferramentas, sendo que as indústrias de forjados abordam as questões tribológicas de formas distintas. Além disso, um mal entendimento desses parâmetros pode levar a um desgaste de ferramenta prematuro. Esse trabalho analisa o efeito da rugosidade no desgaste de punções de conformação a frio. O tribossistema adotado é a segunda operação de uma prensa mecânica horizontal e consiste em um punção de aço M2 endurecido em movimento relativo contra uma peça de aço SAE 10B22 normalizado. Foram fabricados quinze punções com três níveis de rugosidade e seus desgastes foram medidos após 52.000 e 102.000 ciclos de conformação. Um perfilômetro óptico 3D e um microscópio eletrônico de varredura foram utilizados para acessar as características superficiais dos punções, antes e após dos lotes de produção. Também foram realizadas análises na contra-peça e no meio interfacial \"óleo\". Os resultados obtidos mostraram que os punções de maior rugosidade falharam prematuramente enquanto os punções polidos e os de rugosidade intermediária apresentaram desgaste equivalentes. Considerando que o processo de polimento contribui significativamente para o custo de fabricação dos punções, espera-se que uma forjaria que consuma tais ferramentas em larga escala obtenha grandes benefícios econômicos com o presente trabalho. / The cost of any forged product for the automotive industry is highly influenced by the costs involved during the design and manufacturing of the forging tools. Ideally, these tools shall withstand a significant number of forging cycles, in order to distribute their manufacturing cost in as many parts as possible. There are several parameters that affect the tool wear behavior and forging companies have different approaches to address the tribological issues. Moreover, a misunderstanding of these parameters may lead to an undesirable premature tool wear. This work analyses the effect of roughness on the wear of cold forming punches. The adopted tribosystem is the second stage of a horizontal press and consists of a punch of M2 hardened steel in relative movement against a working piece of SAE 10B22 normalized steel. Fifteen punches were manufactured with three roughness levels and their wear was measured after 52.000 and 102.000 forging cycles. A 3D optical profiler and a Scanning Electronic Microscope (SEM) were used to access the surface characteristics of the punches before and after the production batches. Analysis of the counter body as well as of the interfacial element (oil) were also conducted. The results showed that all punches with higher roughness failed prematurely, while the polished ones as well as the intermediate ones presented equivalent wear. Considering that the polishing process contributes significantly to the manufacturing cost of the punches, it is expected that a forgery that consumes those tools in large-scale can get great economic benefits with this work.

A viabilização do conceito de manufatura enxuta depende da redução da necessidade de intervenções do operador no processo. Na usinagem dos metais, uma das principais situações onde está a intervenção se faz necessária é a determinação da condição de fim de vida das ferramentas de corte, a qual é muitas vezes subjetiva e não pode ser prescrita com segurança. Sendo a emissão acústica (EA) um sinal gerado pelos principais fenômenos envolvidos na usinagem, um sistema de monitoramento de desgaste de ferramentas baseado neste tipo de sinal foi avaliado em operação de torneamento de eixo de saída de transmissão mecânica caracterizado por geometria complexa. Verificou-se que há uma relação entre a trajetória da ferramenta e a \"assinatura\" do processo (tensão RMS plotada contra o tempo). Além disso, há uma forte correlação destes mais a adesão de material da peça à ferramenta determinaram pequena diferença de amplitude do sinal entre os estágios iniciais e finais de vida das ferramentas. Além disso, a influência do sistema de fixação na EA mostrou-se diversas vezes maior que a influência do desgaste. Portanto, um sistema de monitoramento de desgaste baseado apenas em emissão acústica não seria adequado para a situação estudada. / The Lean Manufacturing concept depends on the reduction of the necessity of interventions in the process by the operators. ln metal machining, one situation where these interventions are necessary is the determination of tool life, which is subjective. Besides that, the toollife prediction is not reliable. Acoustic emission signals are generated by many activities involved in machining. Therefore an acoustic emission based tool wear monitoring system was evaluated in a turning operation of a mechanical transmission main shaft characterised by complex geometry. lt was found that there is a relationship between the tool track and the AE \"signature\" of the process (RMS voltage plotted versus time). Furthermore, there is a strong correlation between crater and flank tool wear and the AE signal, but the combination of them plus adhesion phenomena determine low amplitudes between initial and final stages of the tool life. Besides that, the influence of the fixture system was found to be several times higher than the influence of the wear. Therefore, a tool wear monitoring system based on acoustic emission only would not be adequate for this application.

abstract: In this research, a new cutting edge wear estimator for micro-endmilling is developed and the reliabillity of the estimator is evaluated. The main concept of this estimator is the minimum chip thickness effect. This estimator predicts the cutting edge radius by detecting the drop in the chip production rate as the cutting edge of a micro- endmill slips over the workpiece when the minimum chip thickness becomes larger than the uncut chip thickness, thus transitioning from the shearing to the ploughing dominant regime. The chip production rate is investigated through simulation and experiment. The simulation and the experiment show that the chip production rate decreases when the minimum chip thickness becomes larger than the uncut chip thickness. Also, the reliability of this estimator is evaluated. The probability of correct estimation of the cutting edge radius is more than 80%. This cutting edge wear estimator could be applied to an online tool wear estimation system. Then, a large number of cutting edge wear data could be obtained. From the data, a cutting edge wear model could be developed in terms of the machine control parameters so that the optimum control parameters could be applied to increase the tool life and the machining quality as well by minimizing the cutting edge wear rate. In addition, in order to find the stable condition of the machining, the stabillity lobe of the system is created by measuring the dynamic parameters. This process is needed prior to the cutting edge wear estimation since the chatter would affect the cutting edge wear and the chip production rate. In this research, a new experimental set-up for measuring the dynamic parameters is developed by using a high speed camera with microscope lens and a loadcell. The loadcell is used to measure the stiffness of the tool-holder assembly of the machine and the high speed camera is used to measure the natural frequency and the damping ratio. From the measured data, a stability lobe is created. Even though this new method needs further research, it could be more cost-effective than the conventional methods in the future. / Dissertation/Thesis / Doctoral Dissertation Mechanical Engineering 2019

In recent years, there has been a substantial growth in the application of carbon fiber reinforced plastic (CFRP) composite materials in automobile and aerospace industries due to their superior properties such as lightweight, high strength, excellent corrosion resistance, and minimal fatigue concerns. The present study evaluates the drilling performance of woven carbon fiber reinforced plastics under both dry and cryogenic cooling conditions using uncoated solid carbide drill with a through-hole for coolant application. The effects of the cooling conditions and the cutting parameters on drilling performance in drilling CFRP were evaluated in terms of generated thrust force, torque, cutting edge radius, outer corner flank wear, hole quality (including surface roughness, diameter error, roundness, delamination, burr formation, sub-surface quality). Both cooling conditions and cutting parameters were found to influence the thrust force and torque at different levels. The thrust force and the torque are higher in cryogenic cooling under all cutting parameters. In most of the cases, cryogenic drilling gives better bore-hole quality with lower surface roughness, more accurate diameter, less burr generation, better sub-surface quality, etc. Also, the tool-wear rates measured in drilling shows that cryogenic drilling produces less tool-wear than dry drilling does.

To survive in today's manufacturing environments companies must push the standards of accuracy and speed to the highest levels possible. Electro Discharge Machining (EDM) has been used for over 50 years and recent developments have seen the use of EDM become much more viable. The goal of this research is to produce and evaluate electrodes produced by different manufacturing methods. The use of electroforming and spray-metal deposition has only recently become viable methods of producing usable rapid tooling components. The speed and accuracy as well as the cost of manufacture play a vital role in the tool and mould manufacturing process. Electroforming and spray-metal deposition offer an alternate option to traditional machining of electrodes. Electroforming is one method of producing electrodes for EDM. The fact that electroforming can be used to produce multiple electrodes simultaneously gives it the advantage of saving on costs when multiple electrodes are needed. Spray-metal deposition offers another alternative that is much cheaper and relatively faster to manufacture. The used of these non-traditional manufacturing methods in this research are compared to the performance of traditional solid electrodes in terms of machining time, material removal rate, tool wear rates and surface roughness at several standard machining settings. The results of this research are presented in this thesis along with conclusions and comments on the performance of the different methods of electrode manufacture. The major findings of the research include the solid electrodes performed better than the electroformed electrodes in Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (Ra) at all machine settings. However it was found that the production cost of the solid electrodes was six times that of the electroformed electrodes. The production of spray metal electrodes was unsuccessful. The electrode shell walls were not an even thickness and the backing material broke through the shell making them unusable. It is concluded that with further refinements and research, electroforming and spray metal processes will become an extremely competitive method in electrode manufacture and other rapid tooling processes.

Orientador: Alessandro Roger Rodrigues / Resumo: A microusinagem é um dos processos de fabricação capaz de produzir produtos ou geometrias de precisão e complexidade com detalhes menores que 1 mm. Contudo, para um melhor desempenho do processo de usinagem associado à qualidade do produto, entender a interação peça-ferramenta é fundamental. Esta pesquisa determinou a influência do tipo de corte e do avanço da ferramenta no desgaste da fresa (ferramenta), na energia específica de corte (processo) e na rugosidade (peça), ao empregar a operação de microfresamento de topo no aço COS AR60 de grãos ultrafinos. Os ensaios foram realizados em um centro de usinagem Romi D600 com a adaptação de um cabeçote de alta rotação (60 krpm) sem aplicação de fluido de corte. Microfresas de topo reto (Ø 800 µm) com substrato de metal duro e revestidas com TiAlN foram aplicadas nos testes. A profundidade de usinagem e a velocidade de corte foram mantidas constantes em 160 µm e 60 m/min, respectivamente. Foram variados o avanço por dente (3 e 10 µm/z) e o tipo de corte (simétrico em cheio e em face e assimétrico concordante e discordante). Análise de Variância (ANOVA) com intervalo de confiança de 95% foi aplicada a cada uma das três réplicas. Os resultados indicaram que os níveis de desgaste e a redução do diâmetro da microfresa são influenciados pelo avanço da ferramenta e tipo de corte. As maiores reduções no diâmetro (≈11%) foram devido ao impacto periódico da aresta de corte na peça e não pelo efeito de sulcamento (≈4%). Além disso, para o pe... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: Micro-machining is one of the processes feasible for generating geometries or parts with precision and complexity regarding dimensions smaller than 1 mm. However, the achievement of enhanced machining performance and product quality requires a prior understanding on the tool-workpiece interface. This research detemined the influence of cutting type and cutting feed on wear (tool), specific cutting force (process) and surface roughness (workpiece) when cutting the ultrafine-grained steel COS AR60 under end milling strategy. Machining tests were performed in a CNC machining centre Romi D600 provided with a high-speed spindle (60kpm) without cutting fluid application. TiAlN coated carbide endmill (Ø 800 μm) was used for straight cut with 60 m/min cutting speed, 160 μm depth of cut and feed per tooth of 3 and 10 μm. Analysis of Variance (ANOVA) with confidence interval of 95% was applied to the three runs of each cutting sets. The results have shown that tool wear levels and tool effective diameter are influenced by tool feed and cutting type. Hence, intermittent impact of tool’s cutting edges into the workpiece (≈11%) during cutting revealed to be the major cause of tool wear when compared to cutting mechanism dominated by ploughing (≈4%). Regarding experimental sets with cutting length of 98,018 m there was a predominance of tool edge chipping over abrasion and adhesion when performing face cutting with ploughing at 4.2%. On the other hand, if ploughing increases to 14.3% the m... (Complete abstract click electronic access below) / Mestre

Submitted by Flávio Henrique Manarelli (flaviomanarelli@gmail.com) on 2018-11-01T23:57:49Z No. of bitstreams: 1 Dissertação_Flávio Henrique Manarelli.pdf: 2986064 bytes, checksum: edc4536a4c2ec5e96e1c49c52019885f (MD5) / Approved for entry into archive by Cristina Alexandra de Godoy null (cristina@adm.feis.unesp.br) on 2018-11-08T19:00:53Z (GMT) No. of bitstreams: 1 manarelli_fh_me_ilha.pdf: 2986064 bytes, checksum: edc4536a4c2ec5e96e1c49c52019885f (MD5) / Made available in DSpace on 2018-11-08T19:00:54Z (GMT). No. of bitstreams: 1 manarelli_fh_me_ilha.pdf: 2986064 bytes, checksum: edc4536a4c2ec5e96e1c49c52019885f (MD5) Previous issue date: 2018-09-03 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / A microusinagem é um dos processos de fabricação capaz de produzir produtos ou geometrias de precisão e complexidade com detalhes menores que 1 mm. Contudo, para um melhor desempenho do processo de usinagem associado à qualidade do produto, entender a interação peça-ferramenta é fundamental. Esta pesquisa determinou a influência do tipo de corte e do avanço da ferramenta no desgaste da fresa (ferramenta), na energia específica de corte (processo) e na rugosidade (peça), ao empregar a operação de microfresamento de topo no aço COS AR60 de grãos ultrafinos. Os ensaios foram realizados em um centro de usinagem Romi D600 com a adaptação de um cabeçote de alta rotação (60 krpm) sem aplicação de fluido de corte. Microfresas de topo reto (Ø 800 µm) com substrato de metal duro e revestidas com TiAlN foram aplicadas nos testes. A profundidade de usinagem e a velocidade de corte foram mantidas constantes em 160 µm e 60 m/min, respectivamente. Foram variados o avanço por dente (3 e 10 µm/z) e o tipo de corte (simétrico em cheio e em face e assimétrico concordante e discordante). Análise de Variância (ANOVA) com intervalo de confiança de 95% foi aplicada a cada uma das três réplicas. Os resultados indicaram que os níveis de desgaste e a redução do diâmetro da microfresa são influenciados pelo avanço da ferramenta e tipo de corte. As maiores reduções no diâmetro (≈11%) foram devido ao impacto periódico da aresta de corte na peça e não pelo efeito de sulcamento (≈4%). Além disso, para o percurso de corte adotado de 98,018 m, com 4,2% da usinagem em sulcamento ou inexistente no corte em face, houve predominância de avarias por lascamento e, para o mesmo percurso, porém, com aproximadamente 14,3% do corte em sulcamento, os fenômenos predominantes no desgaste foram abrasão e adesão. O efeito do sulcamento fez com que os fatores tipo de corte e avanço, bem como suas respectivas interações, fossem significativos sobre a energia específica de corte. Os cortes em cheio e corte concordante com avanço de 3 µm/dente proporcionaram condições mais favoráveis para o microfresamento frontal, com melhor acabamento da peça e menores níveis de desgaste da ferramenta de corte. / Micro-machining is one of the processes feasible for generating geometries or parts with precision and complexity regarding dimensions smaller than 1 mm. However, the achievement of enhanced machining performance and product quality requires a prior understanding on the tool-workpiece interface. This research detemined the influence of cutting type and cutting feed on wear (tool), specific cutting force (process) and surface roughness (workpiece) when cutting the ultrafine-grained steel COS AR60 under end milling strategy. Machining tests were performed in a CNC machining centre Romi D600 provided with a high-speed spindle (60kpm) without cutting fluid application. TiAlN coated carbide endmill (Ø 800 μm) was used for straight cut with 60 m/min cutting speed, 160 μm depth of cut and feed per tooth of 3 and 10 μm. Analysis of Variance (ANOVA) with confidence interval of 95% was applied to the three runs of each cutting sets. The results have shown that tool wear levels and tool effective diameter are influenced by tool feed and cutting type. Hence, intermittent impact of tool’s cutting edges into the workpiece (≈11%) during cutting revealed to be the major cause of tool wear when compared to cutting mechanism dominated by ploughing (≈4%). Regarding experimental sets with cutting length of 98,018 m there was a predominance of tool edge chipping over abrasion and adhesion when performing face cutting with ploughing at 4.2%. On the other hand, if ploughing increases to 14.3% the main wear mechanism observed were abrasion and adhesion. Therefore, there was a significant interaction between specific cutting force and the input parameters of feed per tooth and cutting type. As a result, down-milling and channel-milling at the tool feed of 3 μm/tooth leaded to a valuable cutting performance with better workpiece surface roughness and tool wear at low levels.