A iminente escassez de recursos naturais e de fontes energéticas não renováveis são forças motrizes para a adoção de práticas sustentáveis. Dentre os processos industriais que fazem uso intensivo de recursos naturais, estão os que utilizam processos de usinagem baseados em ferramentas abrasivas para desbaste, esmerilhamento, corte, entre outros. A partir deste panorama geral, é possível enxergar a necessidade de estudar os processos de usinagem com ferramentas abrasivas a fim de aumentar a compreensão sobre eles e de torná-los sustentáveis. Sendo assim, o objetivo deste trabalho é avaliar, por meio do comportamento mecânico de compósitos abrasivos resinoides, o potencial de reciclagem de grãos de alumina oriundos de ferramentas abrasivas. No presente trabalho, foi estudada a preparação e caracterização de compósitos abrasivos resinoides reforçados com grãos alumina reciclada e virgem. Uma das aluminas recicladas é oriunda de rebolos e discos de corte resinoides, outra alumina é oriunda de rebolos vitrificados, e a última, composta por alumina branca, é recuperada de rebolos vitrificados refugados ou usados. As amostras de grãos de alumina reciclada e a de grãos de alumina marrom virgem foram caracterizadas por meio das técnicas de fluorescência de raios X (FRX), difratometria de raios X (DRX), microscopias óptica (MO) e eletrônica de varredura (MEV). Corpos de prova de compósitos utilizando os quatro tipos de alumina foram preparados por meio da mistura, prensagem e tratamento térmico de grãos de alumina e resinas fenólicas resol e novolaca. Por fim, os compósitos foram caracterizados por meio das técnicas de calorimetria exploratória diferencial (DSC), módulo elástico por excitação por impulso, impacto Izod, flexão em quatro pontos, análise térmica dinâmico-mecânica (DMTA), dureza por Sand Blasting Penetration (SBP), porosidade pelo método de Arquimedes e microscopias óptica e eletrônica de varredura. Os resultados dos ensaios mecânicos mostraram que os compósitos de alumina reciclada apresentaram depreciação em todas as propriedades estudadas em relação ao compósito de alumina virgem, exceto a resistência ao impacto Izod, no qual todas as amostras apresentaram baixa resistência. A razão desta baixa resistência ao impacto deveu-se à estrutura formada pelo grão de alumina, ligante (resina fenólica) e porosidade, na qual a baixa proporção de resina fenólica (10% m.) foi a responsável pelo resultado. Por outro lado, a causa da depreciação nas propriedades mecânicas apresentadas pelos compósitos de alumina reciclada foi a menor concentração em alumina e a presença de impurezas oriundas da produção das ferramentas abrasivas. Neste caso, o compósito de alumina branca reciclada apresentou melhores resultados das propriedades mecânicas em relação aos compósitos de alumina oriunda de rebolos vitrificados e os de alumina oriunda de rebolos e discos resinoides. Concluindo, o potencial de reciclagem dos grãos de alumina oriundos de ferramentas abrasivas visando o seu reaproveitamento no processo de fabricação destas ferramentas é limitado pela sua pureza, de modo que se no processo de reciclagem dos grãos for aumentada a concentração de alumina haverá possibilidade de seu reaproveitamento. / The imminent scarcity of natural resources and nonrenewable energy sources are driving forces for the adoption of sustainable practices. Among the industrial processes that make intensive use of natural resources, there are those that use machining processes based on abrasive tools for roughing, grinding, cutting, among others. From this general panorama, it is possible to see the need to study the machining processes with abrasive tools in order to increase the understanding about them. Thus, the objective of this work is to evaluate, through the mechanical behavior of resin-bound abrasive composites, the recycling potential of alumina grits from abrasive tools. In the present work, the preparation and characterization of resinoid abrasive composites reinforced with recycled and virgin alumina grits was studied. One of the recycled aluminas comes from resin-bound grinding wheels and thin wheel cut-off discs, another alumina comes from vitrified grinding wheels, and the latter, composed of white alumina, is recovered from scrapped or used glazed grinding wheels. The samples of recycled alumina grits and virgin brown alumina grits were characterized by X-ray fluorescence spectroscopy (XRF), X-ray diffractometry (XRD), optical microscopy (OM) and scanning electron microscopy (SEM). Composite test bodies using the four types of alumina were prepared by mixing, pressing and heat treatment of alumina grits and resol and novolak phenolic resins. Finally, the composites were characterized by differential scanning calorimetry (DSC), impulse excitation elastic modulus, Izod impact, four-point flexing, dynamic-mechanical thermal analysis (DMTA), Sand Blasting Penetration hardness (SBP), porosity by the Archimedes method and optical and scanning electron microscopy. The results of the mechanical tests showed that the recycled alumina composites presented depreciation in all the studied properties in relation to the virgin alumina composite, except the Izod impact resistance, in which all the samples presented low resistance. The reason for this low impact strength was due to the structure formed by the alumina grit, binder (phenolic resin) and porosity, in which the low proportion of phenolic resin (10% m) was responsible for the result. On the other hand, the reason for the depreciation in the mechanical properties presented by the recycled alumina composites was the lower concentration in alumina and the presence of impurities from the production of the abrasive tools. In this case, the recycled white alumina composite presented better mechanical properties in relation to alumina composites from vitrified grinding wheels and those from alumina from grinding wheels and resinoid disks. In conclusion, the recycling potential of the alumina grits from abrasive tools aiming at their reuse in the process of manufacturing these tools is limited by their purity, so that if in the grit recycling process the alumina concentration increases it will make possible its reuse.

This study was aimed at understanding the environmental performance of two abrasives, coal slag and garnet which are commonly used by shipyards and many other industries in surface preparation of metallic surfaces. Environmental performance evaluated in this study included, (1) productivity (ft2/hr), (2) consumption and or used-abrasive generation rate (ton/2000 ft2; lb/ ft2), (3) particulate emission factors (mg/ft2; mg/lb; lb/lb; lb/kg; lb/ton). In order to achieve the study objectives, an emission test facility was built and necessary equipment and materials were procured. Blasting was performed on rusted steel panels inside the test facility and emissions were measured using EPA Source Test Method to quantify particulate emissions. By measuring the area cleaned, blasting time, and the abrasive consumed, environmental performance of coal slag and garnet was evaluated. Simple mathematical models were developed to predict performance based on feed rate and blast pressure. Garnet was observed to be more productive, less consuming, and more environmentally-friendly compared to coal slag. These study findings will valuable in reducing costs, improving productivity, and protecting the environment.

O objetivo deste trabalho é o desenvolvimento de um sistema de monitoramento capaz de identificar em processo o mecanismo de desgaste ao qual o rebolo está sendo submetido durante a retificação. Assim, inicialmente foram pesquisados os meios físicos, os tipos de sensores e estratégias utilizadas nos sistemas de monitoramento, o estágio atual de desenvolvimento e suas aplicações. Para que este sistema seja confiável e eficiente foi necessário estudar detalhadamente a fenomenologia dos mecanismos de desgaste do rebolo. Este estudo permite definir parâmetros para identificação do tipo de desgaste que está ocorrendo, baseado em indicações fornecidas pelo monitoramento de variáveis cujo comportamento é conhecido, como potência consumida pelo motor do rebolo e vibração ou ainda por medições metrológicas. Dois sistemas ópticos de mapeamento da superfície do rebolo são apresentados e estes sistemas serviram como base para o desenvolvimento de um novo sistema de mapeamento da Distribuição da Energia Acústica de Retificação no rebolo, DEAR. Realizaram-se experimentos com o novo sistema, monitorando simultaneamente outros meios físicos. Procurou-se desta forma relacionar o padrão gráfico do mapa gerado pelo novo sistema com o tipo de desgaste que estava ocorrendo, baseado nas informações obtidas no estudo dos mecanismos de desgaste. A análise dos resultados mostraram que o mapa DEAR pode ser utilizado para identificar o tipo de mecanismo de desgaste predominante que está ocorrendo no rebolo, em processo. Esta informação é muito útil na escolha de ações corretivas para problemas da retificação. / The objective of this work is the development of a monitoring system able to identify in process the grinding wheel wear mechanism. Thus, initially the physical quantities, sensors types and monitoring systems strategies, developing status and their applications were researched. To get a reliable and efficient system was necessary a detailed study of the grinding wheel wear mechanism phenomenology. This study allows to define parameters in order to identify which type of wear is occurring, using indication obtained by the monitoring variables whose behavior is known, such as grinding power, vibration or metrological measurement. Two grinding wheel surface optical mapping systems are presented, those systems were utilized as base to developing a new mapping system of Grinding Acoustic Energy Distribution (DEAR). Experiments have been done with the new system, monitoring simultaneously other physical quantities, looking for a way to link the mapping graphic patterns generates by the new system with the wear type which was occurring, based on information obtained from the wear mechanism study. The results and analysis have shown that the DEAR map can be used to identify the predominant wear mechanism type which is occurring on a grinding wheel, in process. This information is very useful in the corrective actions when facing a grinding problem.

<p>Wear of hardmetals is a complicated topic because the wear resistance and the wear mechanisms are influenced by microstructural factors. Although edge wear resistance has a vital importance, most of the researches made in laboratories are related to flat wear resistance using coarse abrasive paper. This situation produces problems with the prediction of abrasive wear behaviour and with the estimation of the lifetime of cutting edges of different kinds of tooling.</p><p>Several studies have been done in order to clarify edge wear behaviour. It has been published correlations of the edge toughness to the load and to the bulk fracture toughness. In those publications coarse abrasive or Vickers indenter were used.</p><p>In the present research, edge shaped specimens of WC-6wt%Co grades were investigated. In order to compare the obtained results for flat sliding and edge wear behaviour two test arrangements, pin on flat disc and edge on flat disc were employed. The specimens were tested using 120, 320, 800 and 2400 mesh SiC abrasive paper and the worn surfaces were investigated using SEM instrument to evaluate wear mechanisms. The edge wear was observed was discussed in relation to wear mechanisms investigated and correlated to the flat wear behaviour.</p><p>The obtained results showed limited applicability of the results obtained with the pin on the flat disc test arrangement for prediction of the edge wear resistance, especially in the case when size of the abrasive particles is close to the WC grain size. However, both edge and flat wear results were similar in; 1) large WC grain sized hard metals wore more than fine grain sized against coarse abrasive paper whereas the reverse occurred against fine abrasives, and 2) wear mechanisms were mainly ploughing (or grooving) for fine grain sized hardmetals in all cases, whereas wear mechanisms changed from ploughing to binder removal and carbide pull-out going from coarse to fine abrasive paper.</p>

Wear of hardmetals is a complicated topic because the wear resistance and the wear mechanisms are influenced by microstructural factors. Although edge wear resistance has a vital importance, most of the researches made in laboratories are related to flat wear resistance using coarse abrasive paper. This situation produces problems with the prediction of abrasive wear behaviour and with the estimation of the lifetime of cutting edges of different kinds of tooling. Several studies have been done in order to clarify edge wear behaviour. It has been published correlations of the edge toughness to the load and to the bulk fracture toughness. In those publications coarse abrasive or Vickers indenter were used. In the present research, edge shaped specimens of WC-6wt%Co grades were investigated. In order to compare the obtained results for flat sliding and edge wear behaviour two test arrangements, pin on flat disc and edge on flat disc were employed. The specimens were tested using 120, 320, 800 and 2400 mesh SiC abrasive paper and the worn surfaces were investigated using SEM instrument to evaluate wear mechanisms. The edge wear was observed was discussed in relation to wear mechanisms investigated and correlated to the flat wear behaviour. The obtained results showed limited applicability of the results obtained with the pin on the flat disc test arrangement for prediction of the edge wear resistance, especially in the case when size of the abrasive particles is close to the WC grain size. However, both edge and flat wear results were similar in; 1) large WC grain sized hard metals wore more than fine grain sized against coarse abrasive paper whereas the reverse occurred against fine abrasives, and 2) wear mechanisms were mainly ploughing (or grooving) for fine grain sized hardmetals in all cases, whereas wear mechanisms changed from ploughing to binder removal and carbide pull-out going from coarse to fine abrasive paper.

The effect of particle size, velocity, and angle of attack was investigated on the roughness and erosion rate of unmasked channels machined in borosilicate glass using abrasive jet micro-machining (AJM). Single impact experiments were conducted to quantify the damage due to the individual alumina particles. Based on these observations, an analytical model from the literature was modified and used to predict the roughness and erosion rate. A numerical model was then developed to simulate the brittle erosion process leading to the creation of unmasked channels as a function of particle size, velocity, dose, impact angle and target material properties. For the first time, erosion was simulated using models of two damage mechanisms: crater removal due to the formation and growth of lateral cracks, and edge chipping. Accuracy was further enhanced by simulating the actual relationship between particle size, velocity and radial location within the jet using distributions measured with high-speed laser shadowgraphy. The process of post-blasting AJM channels with abrasive particles at a relatively low kinetic energy was also investigated in the present work by measuring the roughness reduction of a reference unmasked channel in borosilicate glass as a function of post-blasting particle size, velocity, dose, and impact angle. The numerical model was modified and used to simulate the post-blasting process leading to the creation of smooth channels as a function of particle size, velocity, dose, impact angle, and target material properties. Finally, the effect of alumina particle kinetic energy and jet impact angle on the roughness and erosion rate of channels machined in borosilicate glass using abrasive slurry jet micro-machining (ASJM) was investigated. The analytical and numerical models derived for AJM, were found to predict reasonably well the roughness and the erosion rate of ASJM channels, despite the large differences in the fluid media, flow patterns, and particle trajectories in AJM and ASJM.

The effect of particle size, velocity, and angle of attack was investigated on the roughness and erosion rate of unmasked channels machined in borosilicate glass using abrasive jet micro-machining (AJM). Single impact experiments were conducted to quantify the damage due to the individual alumina particles. Based on these observations, an analytical model from the literature was modified and used to predict the roughness and erosion rate. A numerical model was then developed to simulate the brittle erosion process leading to the creation of unmasked channels as a function of particle size, velocity, dose, impact angle and target material properties. For the first time, erosion was simulated using models of two damage mechanisms: crater removal due to the formation and growth of lateral cracks, and edge chipping. Accuracy was further enhanced by simulating the actual relationship between particle size, velocity and radial location within the jet using distributions measured with high-speed laser shadowgraphy. The process of post-blasting AJM channels with abrasive particles at a relatively low kinetic energy was also investigated in the present work by measuring the roughness reduction of a reference unmasked channel in borosilicate glass as a function of post-blasting particle size, velocity, dose, and impact angle. The numerical model was modified and used to simulate the post-blasting process leading to the creation of smooth channels as a function of particle size, velocity, dose, impact angle, and target material properties. Finally, the effect of alumina particle kinetic energy and jet impact angle on the roughness and erosion rate of channels machined in borosilicate glass using abrasive slurry jet micro-machining (ASJM) was investigated. The analytical and numerical models derived for AJM, were found to predict reasonably well the roughness and the erosion rate of ASJM channels, despite the large differences in the fluid media, flow patterns, and particle trajectories in AJM and ASJM.

The present work was conducted in Sandvik Coromant to enhance the knowledge and understanding of general flank wear growth and specifically in this case flank wear growth on the cutting edge of the coated (Ti(C, N)/ Al2O3/ TiN) tool inserts.   Reliable modeling of tool life is always a concern for machining processes. Numbers of wear models studies predicting the tool life length have been created throughout the metal-cutting history to better predict and thereby control the tool life span, which is a major portion of the total cost of machining.   A geometrical contact model defining the geometry of the flank wear growth on the cutting tool inserts was proposed and then compared with four suggested models, which estimates flank wear. The focus of this work is on the initial growth of flank wear process and thereby short cutting-time intervals are measured.   Wear tests on cutting tool inserts were performed after orthogonal turning of Ovako 825 B steel and were analysed by optical instrument, 3D optical imaging in Alicona InfiniteFocus and EDS in SEM. Force measurements for cutting speeds, Vc, 150, 200, and 250 m/min and feed rate, fn, 0.15 mm/rev were recorded as well.   Results show that initial flank wear land, VB, growth is dominated by sliding distance per cutting length for different cutting speeds. A good correlation between the geometrical contact model and estimation models is indentified. The cutting force measurements compared with the flank wear land show proportionality between two parameters. For the machining data in the present study the flank wear rate per sliding distance, dW/dL, is estimated to 2x103 (μ3/m).

Abrasive Waterjet cutting (AWJ) presents many advantages over competing machining techniques, but several issues are related to the high volume of materials (and in particular of abrasive) used in the process. In this study, the environmental impact of the material flows in the abrasive waterjet industry has been analyzed adopting a life cycle perspective in order to individuate which phases place the largest burden on the environment. Moreover, three alternative abrasives (crushed rock, recycled glass and synthetic abrasive) and three disposal practices (in-site recycling, off-site recycling and recycling as construction material) have been also evaluated to estimate the benefits that can be achieved if these could be used in place of garnet abrasives and landfilling. The transportation of the abrasive resulted to be the phase that has the largest influence in every case and thus should be reduced as much as possible. For what concerns the alternative options, the usage of recycled glass and the in-site recycling of the abrasive were the two alternatives with the best environmental performances. However, crushed rock could be the best option for what concerns the global warming potential if carbon sequestration due to carbonation of silicate rocks is taken into account. Off-site recycling and recycling as construction material are good options only if the transportation to the recycling site can be reduced. Synthetic abrasive are instead found to have a much larger impact compared to every other alternative examined.

Abrasive wear occurs when a contact associated with stress between a metal surface and a herd particle (frequently of mineral origin) leads to friction between the two. In a very wide range of industrial applications, abrasive wear is the main reason for component and equipment repair or replacement. In most of these applications, especially those of earth moving, construction and mining equipment, digger teeth are used to improve equipment performance. Digger teeth can be produced in different shapes and sizes (mainly by casting) and a wide range of materials are used. This project is concerned with both a field trial of the wear of digger teeth fixed to the front of a bucket used in a gravel pit, and also a laboratory investigation of abrasive wear mechanisms. It was found that the wear of digger teeth increased with increasing working hours, but the wear rate eventually decreased. The dimensions and shape of the front of the tooth changed and gravel removal became more inefficient. Plastic deformation and phase transformation were observed in the worn surfaces of the teeth. In the laboratory study, many parameters were investigated utilising a pin-on disc technique. Wear rate increases linearly with load and decreases with sliding distance. The effect of attack angle on abrasive wear showed that wear volume increases with increasing attack angle up to a certain value (90°) and then decreases. Corrosion increases the initial wear rate, and the amount of material removed in the wet corrosive test was higher than the corresponding dry test. It was difficult to reproduce the same results from the field trial in the laboratory because of the difference in the conditions in the two cases. Optical and scanning electron microscopy were used to study the worn surfaces, abrasive papers and wear debris. Different abrasive wear mechanisms were observed throughout this investigation. A cutting mechanism associated with spiral debris was observed during short pin-on disc tests and with higher attack angles. A ploughing action associated with plate-like debris was observed during longer tests and at lower attack angles. Fragmentation was observed in brittle materials.