The main result of underground mining extraction is creating of large underground voids (mine stopes). These empty openings are typically backfilled with an engineering cementitious material called cemented paste backfill (CPB). The main purpose of CPB application in underground mining is to provide stability and ensure the safety of underground openings, maximize ore recovery, and also provide an environmental-friendly means of underground disposal of potential acid generating tailings. CPB is a mixture of mine tailings, cement binder and water. CPB has a complex geotechnical behaviour when poured into mine voids. This is because of the different thermal (T), hydraulic (H), mechanical (M) and chemical coupled processes and interactions that take place in CPB soon after placement. In addition to these THMC behaviours, various external factors, such as stope geometry, drainage condition and arching effects add more complexity to its behaviour. In order to acquire a full understanding of CPB behaviour, there is a need to consider all of these THMC factors and processes together. So far, there has not been any study that addresses this research need. Indeed, fundamental knowledge of the THMC behaviour of CPB provides a key means for designing safe and cost-effective backfill structures, as well as optimizing mining cycles and productivity of mines. Innovative experimental tools and CPB testing methods have been developed and adopted in this research to fulfill the objectives of this research. In the first phase of the study, experiments with high columns are developed to study the THMC behaviour of CPB from early to advanced ages with respect to height of the column and curing time. The column experiments simulate the mine stope and filling sequence and provide an opportunity to study external factors, such as evaporation, on the THMC behaviour of CPB. However, an important factor is the overburden pressure from the stress due to self-weight that cannot be simulated through column experiments. Therefore, in the second phase of this study, a novel THMC curing under stress apparatus is developed to study the THMC behaviour of CPB under various pressures due to the self-weight of the CPB, drainage conditions, and filling rate and sequence. Comprehensive instrumentation and geotechnical testing are carried out to obtain fundamental knowledge on the THMC behaviour of CPB in different curing conditions from early to advanced ages. The results of these studies show that the THMC properties of CPB are coupled. Important parameters, such as curing stress, self-desiccation due to cement hydration, temperature, pore water chemistry, and mineralogical and chemical properties of the tailings, have significant influence on the shear strength and compressive strength development of CPB. Factors such as evaporation and drying iii shrinkage can also affect the hydro-mechanical properties of CPB. The curing conditions (such as curing stress, drainage and filling rate) also has significant impact on CPB behaviour and performance. The THMC interactions and the degree of influence of each factor should be included in designing backfill structures and planning mining cycles. This innovative curing under stress technique can be replaced the conventional curing of CPB (curing under zero stress and no THMC loadings), in order to optimize CPB mechanical strength assessment, increase mine safety and enhance the productivity.

In this thesis, drill bit buttons with cobalt, nickel and iron binders in different compositions have been tested against granite and sandstone and the wear and friction have been measured. Furthermore, the wear and degradation of the buttons have been categorized. Buttons with cobalt binder were tested against granite and sandstone and buttons with alternative binders (Ni, Fe, Co) were tested against granite. Cobalt buttons were used as a reference and the wear and friction of the alternative binders was compared to the reference. The amount of worn rock was also measured. Furthermore, post treated drill bit buttons with a composition of Fe-Ni-Co were compared to buttons with the same composition that had not been post treated The results show that buttons with an alternative composition of Fe-Co-Ni and Fe- Ni wears less than the cobalt reference. The post treatment process does not decrease the wear of the drill bit but lowers the deviation from the mean wear. The amount of worn rock does not differ between the samples except for between the post treated and not post treated buttons with a composition of Fe-Ni-Co. The post treated buttons produces more rock debris than the not post treated. No apparent difference could be seen on the surface of the tested buttons after the test. However, composition specific cracks could be found underneath the surface of the samples. EDS-analysis showed signals of oxygen inside of all of the investigated cracks. For some compositions at depths of 20 micrometers. The curves of friction shows similar appearance but the values of the coefficient of friction differs. No apparent correlation was found between the wear and friction of the samples. Furthermore, no apparent correlation was found between the hardness and the wear of the buttons.

A necessidade de se usinar materiais de alta dureza e garantir bom acabamento superficial é um desafio para as atuais indústrias metal/mecânica. Além disso, coloca-se também a necessidade de fazê-lo de forma técnica e economicamente viável. Diante desse desafio o torneamento duro surge como uma opção. Com o uso dos parâmetros (velocidade de corte, avanço e profundidade de corte) e ferramentas adequadas o torneamento duro possibilita uma adequada rugosidade superficial e pode substituir a necessidade de retificação, simplificando e reduzindo custos no processo de fabricação. Para que seja possível alcançar tais resultados, é necessária a pesquisa e validação de parâmetros que permitam a execução do torneamento de materiais de alta dureza. Por meio de ensaios, de desbaste interno, realizados com peças de metal duro H11N e com ferramentas de diamante, foram feitos testes preliminares com o uso da ferramenta de projeto de experimentos (DOE), para selecionar os melhores conjuntos de parâmetros (velocidade de corte e avanço). Foi realizado um segundo grupo de testes, finais, para garantir estatisticamente os melhores resultados, as informações obtidas foram rugosidade, desgaste e número de passes. Com a análise dos resultados preliminares obtidos utilizando a ferramenta estatística de projeto de experimentos (DOE), foi identificado alta quebra de ferramentas (54%). Com a realização de micrografias, a possibilidade do problema estar relacionado com a estrutura do material e ou com o tamanho do grão foi descartada. Foram detectadas ainda, marcas na superfície usinada dos corpos de prova que são indicadores da existência de vibrações durante o processo, o que justifica o número elevado de quebras das arestas de corte de forma prematura. Os testes finais não apresentaram quebra prematura de ferramentas, e sim uma vida maior que o esperado. Foi estabelecido parâmetros viáveis para o processo, velocidade de corte de 22,1 m/min e avanço de 0,09 mm/rev. Através da análise do desgaste foi possível estabelecer um critério para troca de ferramenta, que foi o desgaste de flanco (Vb) de 0,2mm. / The necessity of machining materials with high hardness to ensure a good surface finish is a challenge for metal mechanic industries these days. Furthermore, it has the necessity to achieve this goal in a technical way and be economically viable. An option to tackle this challenge is hard turning. Through the use of parameters (speed cutting, feed rate and cut depth) and adequate tools, the hard turning enables a good surface roughness and can replace the need for grinding, making the fabrication process simpler and reducing the cost. In order for these results to be achieved, research is required and validation of parameters, which allow the realization of turning materials with high hardness. Through trials of internal thinning, with pieces made of H11N material and diamonds tools, Design of experiments (DOE) preliminary tests were carried out to select the best parameters group (cutting speed and feed rate). Secondary tests were done to ensure statically the best results in this case, the data obtained was of roughness, wear and tool life. When analyzing the preliminary results obtained using the statistic tool, design of experiments (DOE), it was identified that a high breakage of tools was occurring (54%). Through micrograph tests, the possibility of the problem being with the material structure and grain size was discarded. Traces were detected in the machining surface on the machined piece, these are indicators of the chance of vibration during the process, which can justify the high premature tool breakage. The final tests didnt show premature tool breakage, they showed the life span of the tool was longer than what was expected. Viable parameters were established for this process, cutting speed of 22.1 m/min and feed rate of 0.09 mm/rev. Through the wear analysis it was possible to establish a criterion of tool change, it was flank wear (Vb) of 0.02mm.

In the thesis is solved manufacturing technology of step drill from material of cemented carbide. At first is made review of existing shank cutting tool types, after that follows an analysis of cemented carbide tool material. In the next part of thesis is manufacturing technology of this tool, including review of grinding wheels, designed. Output of this work is procedure of program designing for manufacturing this tool in software Numroto. Next output is techno-economic evaluation of step hole manufacture with combined tool and comparison to conventional type of manufacture.

This thesis deals with coated cemented carbides, which are used for the manufacture of cutting tools. The introductory section provides an overview of the most common tool materials. The main part focuses on the production of coated SK, coating methods, types and properties of coatings. The final section deals with coated cemented carbide product range in the world's leading producer of tools and tool materials, tools and recommended working conditions for their effective use.

Theoretical analysis of the possibility of manufacturing a metal sealing ring on the CNC machine tool. Selecting the most appropriate technology and manufacturing process analysis, involving selection of materials, tools and machining conditions.

The report aims to investigate the influence of chemical reactions on comb crack formation and propagation in coated cemented carbide milling inserts with different compositions. A series of novel experimental techniques have been developed and applied to understand oxidation and corrosion effects on comb cracks. Furthermore microstructure changes in the region of the comb cracks on worn milling inserts were studied by high resolution microscopy. It has been observed that the main effect of the oxidation and corrosion on comb cracks is connected to an attack of the binder phase, affecting its composition, distribution and morphology. Different comb crack types for dry and wet milling have been observed. In the presence of cooling media (wet machining) inserts present lateral cracks (fatigue induced) connected to the principal comb crack, which form at regions where the binder has been strongly corroded. Despite the addition of Cr and (Ta,Nb)C enhance both the oxidation and corrosion attack resistance have a minor effect on the formation and propagation of comb cracks. Schematic models based on the experimental results and scientific discussions are presented to understand the influence of oxidation and corrosion in the formation and propagation of comb cracks.

Cemented paste backfill (CPB) is a novel technology developed in the past few decades to better manage mining wastes (such as tailings) in environmentally friendly way. It has received prominent interest in the mining industry around the world. In this technology, up to 60% of the total amount of tailings is reused and converted into cemented construction material that can be used for secondary support in underground mine openings (stopes) and to maximize the recovery of ore from pillars. CPB is an engineered mixture of tailings, water, and hydraulic binder (such as cement), that is mixed in the paste plant and delivered into the mine stopes either by gravity or pumping. During and after placing it into the mine stopes, the performance of CPB mainly depends on the role of the hydraulic binder, which increases the mechanical strength of the mixture through the process of cement hydration. Similar to other fine-grained soils undergoing cementations, CPB’s behavior is affected by several conditions or factors, such as cement hydration progress (curing time), chemistry of pore water, mixing and curing temperature, and filling strategy. Also, it has been found that fresh CPB placed in the mine stopes can be susceptible to many geotechnical issues, such as liquefaction under ground shaking conditions. Liquefaction-induced failure of CPB structure may cause injuries and fatalities, as well as significant environmental and economic damages. Many researches studied the effect of the aforementioned conditions on the static mechanical behavior of CPB. Other researches have evaluated the liquefaction behavior of natural soils and tailings (without cement) during cyclic loadings using shaking table test technique. Only few studies investigated the CPB liquefaction during dynamic loading events using the triaxial tests. Yet, there are currently no studies that addressed the liquefaction behavior of CPB under the previous conditions by using the shaking table technique. In this Ph.D. study, a series of shaking table tests were conducted on fresh CPB samples (75 cm × 75 cm ×70 cm), which were mixed and poured into a flexible laminar shear box (that was designed and build for the purpose of this research). Some of these shaking table tests were performed at different maturity ages of 2.5 hrs, 4.0 hrs, and 10.0 hrs, to investigate the effect of cement hydration progress on the liquefaction potential of CPB. Another set of tests were conducted to assess the effect of the chemistry (sulphate content) of the pore-water on the cyclic response of fresh CPB by exposing cyclic loads on couple of CPB models that contain different concertation of sulphate ions of 0.0 ppm and 5000 ppm. Moreover, as part of this study, series of shaking table test was conducted on CPB samples that were prepared and cured at different temperatures of 20oC and 35oC, to evaluate the effect of temperature of the cyclic behavior of CPB. Furthermore, the effect of filling strategy on the cyclic behavior of fresh CPB was assessed by conducting set of shaking tables tests on CPB models that were prepared at different filling strategies of continuous filling, and sequential or discontinuous (layered) filling. The results obtained show that CPB has different cyclic behavior and performance under these different conditions. It is observed that the progress of cement hydration (longer curing time) enhances the liquefaction resistance of CPB, while the presence of sulphate ions diminishes it. It is also found that CPB mixed and cured in low temperature is more prone to liquefaction than those prepared at higher temperatures. Moreover, the obtained results show that adopting the discontinuous (layered) filling strategy will improve the liquefaction resistance of CPB. The finding presented in this thesis will contribute to efficient, cost effective and safer design of CPB structures in the mine areas, and will help in minimizing the risks of liquefaction-induced failure of CPB structures.

In a diffusion couple, the intimacy of the contact between the two parts is of high importance for the results. In a tribological contact, matter can transfer from one part to another and a very intimate contact is formed. A new method for investigating a tribological diffusion couple created in this way and consisting of rock and a cemented carbide (CC) drill bit button, is developed in this thesis. This is done as further studies of this couple can contribute to the understanding of drill bit wear in rock drilling. A complete experimental route, including sample preparation, tribological contact, heat treatment and analysis of samples, is presented. Heat treatment of samples was conducted both in an atmosphere of flowing argon and inside an evacuated and sealed quartz vacuum ampule. Heat treatment in flowing argon was rejected as an oxide formed on the sample surface.  Samples in quartz ampules were heat treated at either 1000 °C for 2 h or 21 h, or at 1100 °C for 2 h. Samples were repeatedly imaged with Scanning Electron Microscopy (SEM) and analysed with Energy Dispersive X-ray Spectroscopy (EDS) during the process. As Si and W have characteristic X-ray peaks in close proximity, the need for a detection method other than EDS to detect diffused Si in CC arose. Wavelength Dispersive X-ray Spectroscopy (WDS) performed well in that respect. Diffused Si could be found in the superficial Co pockets of the CC structure, by analysis with WDS.

High performance cutting tools are essential in many industry areas. Cemented carbides (WC-Co) are common materials used for these applications due to the excellent mechanical properties. The mechanical properties of the material are manly dependent on the WC grain size distribution.To be able to tailor the material properties it is important to be able to characterize and control the WC grain size.In this study a quantitative method for WC grain size distribution measurements has been developed using the automated electron backscatter diffraction (EBSD) technique. The EBSD system was optimized for a fast and accurate measurement. Using the method approximately 2000-3000 WC grains can be measured in approximately 25 minutes. This will give reliable statistics and information about the material.The method was used to compare materials produced with three different milling methods; traditional 30l ball mill, method A and B. Two WC raw materials with different initial particle sizes, one coarser and one finer, was milled aiming for similar grain sizes in the sintered structure. The results showed some tendency for a larger fraction of large grains in the materials produced using the ball mill compared to the materials produced with method A and B. The difference between the milling methods was larger using a raw material with a coarser initial particle size.The developed quantitative method was successfully used to compare grain size distributions of different materials in a fast and quantitative way. The differences between the materials were small and materials with similar grain size distribution and mechanical properties could be produced using both the traditional ball mill method and method A and B.