The project, prepared by the engineering study compares the welding abrasive steel HARDOX 400, fiber laser welding method, which will be compared with a MAG welding method and using different protective gases (argon and helium). In the theoretical part, i worked both welding technology's and the issue of high-strength steel. In the experimental part were performed and evaluated by destructive mechanical testing and bending test, the transverse tension test, test macrostructure and microstructure of welds. In conclusion the thesis deduced the final results of the experiment.

The aim of this thesis is to determine the area where there is no random step change in cutting edge roughness. This area is established on the basic of samples created by the abrasive water jet cutting method with variation of technologic parameters.

Under år 2008 uppskattades den totala produktionen av kugghjul inom bilindustrin till 2000 – 2500 miljoner detaljer, varav 1000 - 1400 miljoner av dessa är av hög kvalité [1]. För precisionskugghjul med modul under 1 mm kan tidsbegränsning och kostnader kopplade till design av skärverktyget elimineras genom att tillämpa en flexibel tillverkningsmetod som tillexempel abrasiv vattenskärning (AWJM). Denna studie undersöker designen av ett hybridtillverkningssystem konfigurerat kring AWJM samt föreslår finbearbetningsprocess via konventionella bearbetningsmetoder. Den tekniska möjligheten att producera kuggring av hög precision testas med en 5-axlig vattenjetmaskin och utvärderas enligt kvalitets nivåer för DIN-standard. För detta ändamål studerades ett kugghjul med modul 0,55 mm, 199 tänder, 110 mm i ytterdiameter och 72 mm i innerdiameter samt en tjocklek på 6 mm gjord av Armox T500, höghållfast stål. Resultaten visar på hög potential att uppnå ISO standardkvalité för kugghjul. Vissa kvalitetsegenskaper, definierade i DIN- och ISO-standarder, till exempel ytfinhet med låga värden; Ra 0,8 μm, uppnås vid användning av AWJM. Andra kvalitetskännetecken som profilavvikelse är relaterade till parametrar som skäreffekt, matningshastighet, mängd abrasivmedel, etc. Framtagna värden sträcker sig från Q10 och Q11 enligt DIN3967 vilket möjliggör slutoperationer som till exempel slipning. Geometrisk avvikelse, på ovansidan, gav en maximalt värde på 7 μm med en standardavvikelse på 4 μm. Jetstrålens eftersläpning observerades och kan kompenseras för medan resultatet av rundade hörn existerar i alla skärning med AWJ. Radiell förskjutning, tandtjocklek och index avvikelser visar värden som kan förbättras tillsammans med processoptimering, maskinkalibrering och eliminering av inneboende positionsavvikelser i maskinen. Varje enskild geometri kräver specifika processparametrar och CAM-programmens algoritmer behöver vidare optimeras för arbeten med tämligen små geometrier. / Production of gears for the automotive industry during 2008 is estimated to have been between 2000 – 2500 million pieces, from which 1000 to 1400 million pieces were high quality gears [1]. For precision gears with module below 1 mm, the time limitations and costs associated with the design of the cutting tool can be eliminated by using a flexible manufacturing technology such as Abrasive WaterJet Machining (AWJM). This project investigates the design of a hybrid manufacturing system configured by use of AWJM and proposed finishing processes using conventional machining methods. The technical feasibility is analysed to produce high precision ring gears using a 5-axes AWJM system to achieve DIN standards quality levels. For this purpose, a gear with a module of 0.55 mm, 199 teeth and 110 mm in the outer diameter and 130 teeth and 72 mm in the inner diameter with a thickness of 6 mm is studied; the selected material is Armox T500, a high strength steel. The results indicate high potential of producing ISO quality standard gears. Certain quality characteristics defined in DIN and ISO standards, for instance surface roughness – values as low as Ra 0.8 μm, are possible to achieve accurately by using AWJM. Others quality features as profile deviation, are related to parameters as cutting power, feed rate, abrasive feed rate, etc. The displayed values ranged Q10 and Q11 according to DIN3967 which allows for use of further finishing operations such as grinding. The top geometry deviations of a 0.3 mm cut, display a maximum value of 7 μm with an average value of 4 μm. Observed jet lag effects can be improved. Rounded corner effect exists in all AWJ cuts. Runout, tooth thickness and index deviations show values that can be improved together with process optimization, machine calibration and elimination of machine inherent positioning deviations. Each particular geometry needs specific process parameters and CAM software algorithms need further optimization for working with rather small design geometries.

The concrete mixer industry is affected by abrasive wear under both dry and wet conditions. An upgrade of the material inside the drums to high abrasion resistant steel grades can improve the lifetime and offer the possibility to reduce the weight of the drum. A new wear testing apparatus was designed to simulate the wear conditions in a concrete mixer truck with the aim to investigate the relative wear resistance for a number of steel grades. Three tests were performed under wet conditions using 16-25 mm crushed granite. The tests focused on the wear resistance under sliding and impact wear for 30 different steel grades. All of the steel grades were analyzed regarding hardness profile, microstructure and chemical composition prior to testing. Wear losses were investigated by weighing before, during and after testing. Hardness profile and SEM investigations were performed at Swerea Kimab on worn surface and cross-section after testing. Relationship between hardness and wear resistance was found over a certain hardness level. Higher hardness show better wear resistance for this type of application. The shape and degradation of abrasives were found to affect the wear rate. / Betongblandare är en applikation som är utsatt för ett abrasivt slitage under både torra och våta miljöer. Genom att uppgradera materialet inuti trumman till ett slitstarkt stål kan livslängden förlängas och vikten på trumman reduceras. En ny testutrustning utformades för att simulera slitaget och miljöerna inuti en betongbil. Slitstyrkan undersöktes genom att mäta det relativa slitaget för totalt 30 stycken stålsorter. Tre stycken slitagetester genomfördes med en blandning av krossad granit, av storleken 16-25 mm, och vatten. Testerna fokuserade på att simulera både ett glidande slitage och ett lätt stötslitage. Innan testet påbörjades analyserades samtliga stålsorter med avseende på hårdhetsprofilen, mikrostrukturen och kemisk sammansättning. Materialförlusten undersöktes genom vägning före testet, under testet och efter testet. Efter testet analyserades provernas slityta i SEM och hårdheten i tvärsnittet på Swerea Kimab. Ett samband mellan hårdhet och slitstyrka kunde ses över en viss hårdhetsnivå. Testerna visade att en högre hårdhet ger en bättre slitstyrka samt att formen och nötningen av de abrasiva materialet påverkade nötningshastigheten.

During the past several decades, the water jet cutting concept has developed from a novel concept into a well-accepted machine cutting tool. With the addition of abrasive particles and the improvement of high pressure pumps, the water jet stream is currently capable of cutting through metal, concrete, and composite materials. Water jet systems have been utilized at a wide range of different pressures. Research performed at Brigham Young University has revealed that low pressure water jets have the ability to cut human teeth. Experiments have shown that when abrasive particles are added to the water jet stream, an greater amount of tooth material can be removed at lower input pressures. Many different methods have been proposed to entrain and suspend particles in a high pressure water jet system. The abrasive particles can be entrained before the water is pressurized, while the water is being pressurized, or after the water jets stream exits the pressurized system. Each method has its advantages and disadvantages. Unfortunately, keeping abrasive particles homogeneously entrained and suspended in a water jet stream has proven to be difficult. Research at Brigham Young University has encountered similar problems. Researchers are attemping to place abrasive particles in a low pressure water jet stream, but have not been able to maintain a suspended homogeneous slurry. It is the objective of this research to investigate and suggest several possible methods to entrain and suspend abrasive particles into a low pressure water jet system intended for a dental cutting application. A broad review of methods to entrain abrasives in high pressure water jet systems was performed. A list of methods and concepts as possible solutions to entrain abrasives in a low pressure system has been generated. Product design principles were applied to screen, score, and rank these generated concepts to narrow down the list to the most viable concepts for BYU's low pressure dental water jet. Several tests and experiments were also performed to validate the suggested concepts and to provide useful information for future research. It is anticpated that one or more of these methods will be applicable for the proposed dental application as well as other similar applications.

No description available.

In machining, tool life is the chief determinant of cost, tool changing frequency, machining efficiency, and machining precision. Application of a proper cutting edge with optimized geometry and suitable edge properties is an effective way to improve tool performance and machining quality. The majority of the reported work is limited to the effect of edge geometry on tool life. In this thesis, cutting edges were prepared using three different methods which were evaluated in terms of tool edge geometry produced, tool surface quality and topographies, edge hardness and residual stresses. Furthermore, the influence of cutting edge preparation techniques on the tool performance of uncoated tungsten carbide cutting inserts with different average cutting edge rounding (S¯), different form factor (K), as well as the different edge preparation methods used underwent experimental investigation through the orthogonal turning of AISI 4140 alloy steel. Results show that the performance of the prepared edge depends on the combined effect of micro-geometry and edge properties. For symmetric edges (K=1), the preferable range for S¯ was found to be 20 µm to 30 µm. Drag finishing was determined to be the best edge preparation process which is able to produce cutting edges with the best performance. The experimental investigations provided guidelines and evidence for future study of the cutting tool life and wear behavior of prepared cutting inserts and PVD-coated carbide inserts. / Thesis / Master of Applied Science (MASc)

In diploma thesis there is elaborated the analysis of assumed development of water jet technology and there is analyzed the level of water jet method in production. There are introduced the possibilities of new applications of water jet machining and the possibilities of it’s future development. There is think over the enlargement of this method in next 5 years. Simultaneously there is solved the question of techno economic operation severity of this technology.

[pt] Incrustações em trocadores de calor são inevitáveis e provocam a redução da sua efetividade térmica e aumento nos custos de bombeamento. Esta dissertação objetiva validar um dispositivo alternativo de limpeza de trocadores de calor, que automatiza o processo e não requer a interrupção do processo industrial que faz uso de trocadores. A motivação da pesquisa resultou do desafio imposto ao Programa de Metrologia da PUC-Rio para conceber uma solução inovadora para realizar a limpeza on-line de trocadores de calor de hidrogeradores, viabilizada com financiamento do setor elétrico e que motivou esta dissertação. A metodologia de desenvolvimento da pesquisa de mestrado perseguiu duas estratégias de otimização: (i) aprimorar a hidrodinâmica dos circuitos hidráulicos do dispositivo de limpeza concebido, visando reduzir custos de bombeamento e (ii) simular o número de ciclos mínimos de limpeza para assegurar que todos os tubos do trocador de calor sejam visitados por artefatos de limpeza. Dentre os resultados consolidados, destacam-se: (i) melhoria dos fluxos hidrodinâmicos nos distintos tramos hidráulicos do dispositivo servo-hidráulico de limpeza; (ii) confiabilidade metrológica do sistema de medição embarcada no equipamento e (iii) desenvolvimento de modelagem probabilística capaz de prever o número de ciclos de limpeza capaz de assegurar eficácia do procedimento de limpeza do trocador, o que contribui para o seu entendimento. Os ensaios de desempenho realizados em laboratório suportam a conclusão de que a pesquisa de mestrado foi capaz de validar e disponibilizar uma versão hidrodinamicamente mais eficiente e operacionalmente mais eficaz do dispositivo de limpeza originalmente concebido. / [en] Fouling in heat exchangers is inevitable and causes a reduction in their thermal effectiveness and an increase in pumping costs. This dissertation aims to validate an alternative heat exchanger cleaning device, which automates the process and does not require the interruption of the industrial process that uses exchangers. The motivation for the research resulted from the challenge imposed on the Metrology Program at PUC-Rio to devise an innovative solution to perform the online cleaning of hydrogenerator heat exchangers, made possible with financing from the electricity sector and which motivated this dissertation. The master s research development methodology pursued two optimization strategies: (i) improving the hydrodynamics of the hydraulic circuits of the designed cleaning device, aiming to reduce pumping costs and (ii) simulating the number of minimum cleaning cycles to ensure that all the tubes of the heat exchanger are visited by cleaning artefacts. Among the consolidated results, the following stand out: (i) improvement of hydrodynamic flows in the different hydraulic sections of the servo-hydraulic cleaning device; (ii) metrological reliability of the measurement system embarked in the equipment and (iii) development of probabilistic modeling capable of predicting the number of cleaning cycles capable of ensuring the efficiency of the exchanger cleaning procedure, which contributes to its understanding. The performance tests performed in the laboratory support the conclusion that the master s research was able to validate and make available a hydrodynamically more efficient and operationally more effective version of the cleaning device originally designed.

Os Ferros Fundidos de Alto Cromo (FFAC), por apresentarem excelentes propriedades tribológicas, têm sido amplamente utilizados em aplicações específicas envolvendo elevadas perdas de material por abrasão, especialmente no setor da mineração. Entretanto, a demanda por materiais com maior resistência ao desgaste aumenta continuamente, sendo necessárias novas pesquisas nesta área. Portanto, o presente trabalho objetiva avaliar a utilização do nióbio para aumentar, ainda mais, a resistência à abrasão dos FFAC\'s. Por outro lado, quando o FFAC é utilizado na fabricação de peças com geometrias irregulares (por exemplo, rotores de bombas), o componente pode apresentar diferentes níveis de refinamento da microestrutura, entre as regiões finas e espessas, devido às variações na taxa de resfriamento. No presente trabalho foi avaliado, o efeito do grau de refinamento da microestrutura, e a interação do refinamento com a adição de nióbio, na resistência ao desgaste abrasivo dos FFAC\'s. Para tanto, foram desenvolvidos quatro estudos principais: no primeiro estudo foram fabricados blocos de FFAC variando o grau de refinamento da microestrutura e foi mostrado que: grandes incrementos no grau de refinamento resultam em maiores perdas de massa por abrasão. Nas microestruturas menos refinadas, os carbonetos de cromo M7C3, de maior tamanho, são menos susceptíveis ao micro trincamento e podem, ocasionalmente, atuar como barreiras ante os eventos abrasivos. Em uma segunda série de experimentos, foi avaliada a interação do efeito do grau de refinamento da microestrutura com a adição de nióbio em teores baixos (1 %); mostrando que, para microestruturas com alto grau de refinamento, adições de nióbio reduzem as perdas de massa por abrasão em até 50 %. Em uma terceira série de experimentos foi avaliada a interação dos efeitos da adição de nióbio e de molibdênio. Quando comparado com a liga isenta de molibdênio, adições simultâneas de nióbio e molibdênio resultaram em microestruturas mais refinadas, com maior microdureza da matriz, e com carbonetos de nióbio (NbC) de maior dureza. Para condições de desgaste abrasivo por baixos esforços, onde o desgaste foi mais acentuado na matriz, adições simultâneas de nióbio e molibdênio resultaram em aumentos da resistência á abrasão dos FFAC estudados. Na última etapa do trabalho foi adicionado 3 % de nióbio em um liga de FFAC com composição química inicial hipereutética (25%Cr/3%C), a qual apresentaria carbonetos primários de cromo M7C3 de grande tamanho que induziriam comportamento frágil do material quando exposto ao desgaste. Porém, a adição de nióbio resultou em um FFAC com microestrutura mais refinada (eutética), contendo NbC\'s compactos e por conseguinte, mais resistente ao desgaste abrasivo. / High Chromium Cast Irons (HCCI\'s), because of their excellent tribological properties, have been widely used for specific applications involving high wear rates by abrasion, especially in the mining sector. However, the demand for materials with higher wear resistance is continuously growing and thus further research is needed in this area. For that reason, the current work purposes to assess the use of niobium to further increase the wear resistance of HCCI\'s. On the other hand, when HCCI is used for manufacturing components with irregular geometries (e.g. pump impellers), the components thin and thick regions can contain different levels of structure refinement due to variation in their cooling rates. In this work, the effect of structure refinement and the interaction between structure refinement and niobium addition on the abrasion resistance of HCCI\'s were evaluated. For that purpose, four systematic main studies were developed: in the first study, blocks of HCCI were manufactured varying the structure refinement and it was shown that large increases in the degree of structure refinement result in higher wear mass losses by abrasion. In less refined microstructures, the larger M7C3 chromium carbides are less susceptible to microcracking and can occasionally act as a barrier to abrasive particles. In the second series of experiments, the interaction between structure refinement and niobium addition in low concentrations (1 %) was evaluated; showing that for more refined microstructures, niobium additions reduce the mass losses by abrasion up to 50 %. In the third series of experiments, the interaction between niobium and molybdenum additions was evaluated. Compared to molybdenum-free alloy, simultaneous additions of niobium and molybdenum resulted in a more refined microstructure, higher hardness of the matrix and harder niobium carbides (NbC). For Low Stress Sliding Abrasion (LSSA) wear configuration, where wear was more pronounced in the matrix, simultaneous addition of niobium and molybdenum resulted in increase of abrasion resistance in the studied HCCI. In the last stage of this work, 3 % of niobium were added in an HCCI alloy with hypereutectic initial chemical composition (25%Cr/3%C), which presents primary large sized chromium carbides that induce a brittle behavior of the HCCI when subjected to wear. However, the niobium addition resulted in a more refined microstructure (eutectic) HCCI containing compact-shaped NbC carbides, and consequently in more resistance to abrasive wear.