Este trabalho teve como objetivo analisar os cavacos de dimensões reduzidas inseridos em cozimentos que se utilizam de menores tempos e maiores temperaturas, de maneira a se obter as bases para o estabelecimento de um novo processo e/ou a otimização dos sistemas atualmente utilizados em escala industrial. Amostras de cavacos de referência (3,6 mm, obtidas pelo processo convencional de picagem) e de cavacos com espessura de 0,5 mm, 1 mm e 2 mm (obtidas por um gerador de partículas), do híbrido de Eucalyptus urophylla x Eucalyptus grandis com 7 anos foram analisadas quanto à densidade básica, composição química e morfologia das fibras. Após a caracterização, os materiais foram submetidos à polpação kraft pelo processo convencional e foram testados três níveis de fator H com quatro níveis de álcali ativo de maneira a se estabelecer uma equação que representasse o processo e pudesse ser utilizada em cozimentos futuros. Através das equações obtidas foi possível calcular os parâmetros de rendimento depurado, álcali ativo residual, álcali ativo consumido, teor de sólidos secos, fator H e álcali ativo em função de um número kappa 18. Os resultados mostram que a densidade básica, a composição química e a morfologia das fibras da madeira não foram afetadas pelo processo de picagem. No entanto, a densidade a granel foi afetada pela espessura dos cavacos, sendo de 0,037, 0,081, 0,110 e 0,141 g.cm-³ para os cavacos de 0,5 mm, 1 mm, 2 mm e 3,6 mm respectivamente. No processo de polpação, as espessuras se comportaram de maneira semelhante, no entanto, a espessura de 2 mm apresentou o melhor número kappa para o fator H de 451, o de maior interesse, com o mesmo rendimento que as demais espessuras. Na análise de regressão, a espessura de 2 mm apresentou melhor rendimento, menor teor de sólidos e menor fator H (de 461), compatível com o que se pretende utilizar em processos de polpação com tempo reduzido de cozimento. / The objective of this work was to evaluate the performance of thin chips inserted on a short time and higher temperatures in cooking process, to obtain the basis for the establishment of a new process and / or the optimization of the currently systems used on an industrial scale. Samples of the reference chips (3,6 mm obtained by the conventional process of chipping) and thin chips with 0,5 mm, 1 mm and 2 mm (obtained by a particle generator) of the Eucalyptus urophylla x Eucalyptus grandis hybrid with 7 years of age had their density, chemical composition and fibers morphology evaluated. After the characterization, the materials were submitted to conventional kraft pulping process and three levels of H factor with four levels of active alkali were tested to establish an equation to represent the process that can be used on future cookings. Yield, residual active alkali, consumed active alkali, dry solids, H factor and active alkali were calculated through equations, according to a kappa number 18. The results show that the basic density, chemical composition and morphology of the wood fibers were not affected by the chipping process. However, the bulk density of 0,037, 0,081, 0,110 and 0,141 g.cm-³ for the 0,5 mm, 1 mm, 2 mm and 3,6 mm chips, respectively, was affected by the chip thickness. On the pulping process, the different chips had the same behavior, however, 2 mm chips showed the best kappa number to H factor 451, with the same yield as the other thickness. On the regression analysis, the 2 mm chips showed better performance, lower solids content and lower H factor (461), consistent with a short time pulping process.

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

Brittle materials such as silicon, germanium, glass and ceramics are widely used in semiconductor, optical, micro-electronics and various other fields. Traditionally, grinding, polishing and lapping have been employed to achieve high tolerance in surface texture of silicon wafers in semiconductor applications, lenses for optical instruments etc. The conventional machining processes such as single point turning and milling are not conducive to brittle materials as they produce discontinuous chips owing to brittle failure at the shear plane before any tangible plastic flow occurs. In order to improve surface finish on machined brittle materials, ductile regime machining is being extensively studied lately. The process of machining brittle materials where the material is removed by plastic flow, thus leaving a crack free surface is known as ductile-regime machining. Ductile machining of brittle materials can produce surfaces of very high quality comparable with processes such as polishing, lapping etc. The objective of this project is to develop a comprehensive predictive model for ductile machining of brittle materials. The model would predict the critical undeformed chip thickness required to achieve ductile-regime machining. The input to the model includes tool geometry, workpiece material properties and machining process parameters. The fact that the scale of ductile regime machining is very small leads to a number of factors assuming significance which would otherwise be neglected. The effects of tool edge radius, grain size, grain boundaries, crystal orientation etc. are studied so as to make better predictions of forces and hence the critical undeformed chip thickness. The model is validated using a series of experiments with varying materials and cutting conditions. This research would aid in predicting forces and undeformed chip thickness values for micro-machining brittle materials given their material properties and process conditions. The output could be used to machine brittle materials without fracture and hence preserve their surface texture quality. The need for resorting to experimental trial and error is greatly reduced as the critical parameter, namely undeformed chip thickness, is predicted using this approach. This can in turn pave way for brittle materials to be utilized in a variety of applications.

Este trabalho teve como objetivo analisar os cavacos de dimensões reduzidas inseridos em cozimentos que se utilizam de menores tempos e maiores temperaturas, de maneira a se obter as bases para o estabelecimento de um novo processo e/ou a otimização dos sistemas atualmente utilizados em escala industrial. Amostras de cavacos de referência (3,6 mm, obtidas pelo processo convencional de picagem) e de cavacos com espessura de 0,5 mm, 1 mm e 2 mm (obtidas por um gerador de partículas), do híbrido de Eucalyptus urophylla x Eucalyptus grandis com 7 anos foram analisadas quanto à densidade básica, composição química e morfologia das fibras. Após a caracterização, os materiais foram submetidos à polpação kraft pelo processo convencional e foram testados três níveis de fator H com quatro níveis de álcali ativo de maneira a se estabelecer uma equação que representasse o processo e pudesse ser utilizada em cozimentos futuros. Através das equações obtidas foi possível calcular os parâmetros de rendimento depurado, álcali ativo residual, álcali ativo consumido, teor de sólidos secos, fator H e álcali ativo em função de um número kappa 18. Os resultados mostram que a densidade básica, a composição química e a morfologia das fibras da madeira não foram afetadas pelo processo de picagem. No entanto, a densidade a granel foi afetada pela espessura dos cavacos, sendo de 0,037, 0,081, 0,110 e 0,141 g.cm-³ para os cavacos de 0,5 mm, 1 mm, 2 mm e 3,6 mm respectivamente. No processo de polpação, as espessuras se comportaram de maneira semelhante, no entanto, a espessura de 2 mm apresentou o melhor número kappa para o fator H de 451, o de maior interesse, com o mesmo rendimento que as demais espessuras. Na análise de regressão, a espessura de 2 mm apresentou melhor rendimento, menor teor de sólidos e menor fator H (de 461), compatível com o que se pretende utilizar em processos de polpação com tempo reduzido de cozimento. / The objective of this work was to evaluate the performance of thin chips inserted on a short time and higher temperatures in cooking process, to obtain the basis for the establishment of a new process and / or the optimization of the currently systems used on an industrial scale. Samples of the reference chips (3,6 mm obtained by the conventional process of chipping) and thin chips with 0,5 mm, 1 mm and 2 mm (obtained by a particle generator) of the Eucalyptus urophylla x Eucalyptus grandis hybrid with 7 years of age had their density, chemical composition and fibers morphology evaluated. After the characterization, the materials were submitted to conventional kraft pulping process and three levels of H factor with four levels of active alkali were tested to establish an equation to represent the process that can be used on future cookings. Yield, residual active alkali, consumed active alkali, dry solids, H factor and active alkali were calculated through equations, according to a kappa number 18. The results show that the basic density, chemical composition and morphology of the wood fibers were not affected by the chipping process. However, the bulk density of 0,037, 0,081, 0,110 and 0,141 g.cm-³ for the 0,5 mm, 1 mm, 2 mm and 3,6 mm chips, respectively, was affected by the chip thickness. On the pulping process, the different chips had the same behavior, however, 2 mm chips showed the best kappa number to H factor 451, with the same yield as the other thickness. On the regression analysis, the 2 mm chips showed better performance, lower solids content and lower H factor (461), consistent with a short time pulping process.

Nowadays technology development places increasing demands on miniature and micro components and products, and micro-milling is one of the most flexible machining processes in manufacturing 3D structures and complex structured surfaces. A thorough and scientific understanding on fundamentals of the micro-milling process is essential for applying it in an industrial scale. Therefore, in-depth scientific understanding of the micro-cutting mechanics is critical, particularly on size effect, minimum chip thickness, chip formation, tool wear and cutting temperature, etc. so as to fulfil the gap between fundamentals and industrial scale applications. Therefore, three key fundamental research topics are determined for this research, and a comprehensive study on those topics is conducted by means of modeling, simulation, experiments. The topics include chip formation process in micro-milling, novel cutting force modeling in multiscale and study on the tool wear and process monitoring. The investigation into chip formation process in micro-milling consists of three stages; the micro-cutting process is firstly simulated by means of FEA with a primary focus on finding the minimum chip thickness for different tool/material pair and explaining the size effect; the simulation results are then validated by conducting micro-cutting experiment on the ultra-precision lathe. Experiments are carried out on aluminium 6082-T6 with both natural diamond and tungsten carbide tool. By knowing the minimum chip thickness for different tool/material pair, the chip formation process is investigated by performing comparative study by using the diamond and tungsten carbide micro-milling tools. As the minimum chip thickness for diamond micro-milling tool is smaller than that for tungsten carbide tool compared to nominal chip thickness, MCT is ignored in diamond micro-milling. Thus the comparative study is conducted by utilizing both tools with perfectly sharpened cutting edge and tools with the rounded cutting edge in micro-milling. The chips are inspected and associated with cutting force variations in the micro-milling process. The findings are further consolidated by comparing with research results by other researchers. The cutting force modeling is developed in three different aspects, e.g. cutting force on the unit length or area and cutting force on the unit volume in order to better understand the micro-cutting mechanics in aspects of size effect, tool wear mechanism and the cutting energy consumption. The mathematical modeling firstly starts with a novel instantaneous chip thickness algorithm, in which the instantaneous chip thickness is computed by taking account of the change of tool geometry brought about by the tool runout; then the collected cutting forces are utilized to calibrate the model coefficients. For accurate measurement on cutting forces, the Kalman Filter technique is employed to compensate the distortion of the measured cutting force. Model calibration is implemented using least-square method. The proposed cutting force model is then applied in micro-milling to represent the conditions of tool wear and the cutting energy consumption. Further study on the surface generation simulation is based on force model and its comparison with the machined surface is also performed. Cutting experiments using the new tungsten carbide tool are carried out and the tool wear is monitored offline at different machining stages. The dominant tool wear types are characterised. Tool wear is investigated by mainly analysing cutting force at different tool wear status. Frequency analysis by Fourier Transform and Wavelet Transform are carried out on the force signals, and features closely related to the tool wear status are identified and extracted. The potential of applying these features to monitoring the tool wear process is then discussed. Experimental studies to machine the structured surface and nano-metric level surface roughness are presented, the machining efficiency, dimensional accuracy and tool-path strategies are optimised so as to achieve the desired outcomes. Moreover, investigation on cutting temperature in micro-cutting is also studied to some extent by means of simulation; the influence of cutting edge radius on cutting temperature is particularly investigated. Investigation on above aspects provides systematic exploration into the micro-milling process and can contribute substantially to future micro-milling applications.

In this work, measurements and simulations were used to investigate the effects of grinding wheel topography on the geometric aspects of the grinding process. Since existing methods for measuring the grinding wheels were either not accurate enough or could only measure a small portion of a grinding wheel, a novel grinding wheel measurement system was developed. This system consists of a white light chromatic sensor, a custom designed positioning system and software. The resulting wheel scanning system was capable of measuring an entire grinding wheel with micron level accuracy. The system was used to investigate the effects of fine, medium and course dressing on grinding wheel surface topology and the resulting workpiece surface. New techniques were also developed to simulate metal removal in grinding. The simulation software consisted of a stochastic wheel model, dressing model and metal removal model. The resulting software could determine the uncut chip thickness, contact length for every cutting edge on a grinding wheel as well as the resulting surface roughness of the grinding wheel. The simulation was validated by comparing the wheel model used in the simulation to grinding wheel measurements and by comparing the simulated surface finish to the measured surface finish. There was excellent agreement between the predicted and experimentally measured surface topology of the workpiece. The results suggested that only 22 to 30% of the cutting edges exposed on the grinding wheel are active and that the average grinding chip is as much as 10 times thicker and 5 times shorter than would be produced by a grinding wheel with a regular arrangement of cutting edges as assumed by existing analytical approaches.

This diploma thesis is concerning about summarizing and describing types of vibrations, their causes and influences to the machining. The stable conditions of machining were pointed out. The experiment was conducted in which the frequency response function of specific milling machine was measured. Than the stability lobe diagram was constructed.

CAPES - Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / CNPq - Conselho Nacional de Desenvolvimento Científico e Tecnológico / FAPEMIG - Fundação de Amparo a Pesquisa do Estado de Minas Gerais / O aumento crescente da procura por produtos que necessitam de componentes cada vez menores impulsiona o desenvolvimento da microusinagem, considerada altamente necessária para os avanços tecnológicos na área metal mecânica. Neste contexto, o microfresamento é uma alternativa viável para a fabricação destes microcomponentes, permitindo a usinagem de geometrias complexas em diversos materiais tais como: metais e ligas, compósitos, polímeros, cerâmicas e alguns aços inoxidáveis, sendo que estes últimos despertam grande interesse para a indústria devido à sua característica de grande resistência à corrosão e à oxidação. No entanto, adaptar o conhecimento do fresamento de aços inoxidáveis em escala convencional para a microescala exige o entendimento dos fenômenos específicos que surgem com a redução das dimensões envolvidas nas operações. Diante desse contexto, este trabalho tem como principal objetivo a investigação da usinabilidade do aço inoxidável duplex UNS S32205 no microfresamento. Para tanto, foram realizados ensaios para fabricação de microcanais, utilizando uma microfresadora CNC de quatro eixos, rotação máxima de 60 000 rpm e resolução de 0,1 μm, usando microfresas de metal duro com diâmetro de 200 µm e 400 µm. A partir dos dados experimentais, foram analisados a evolução do desgaste, as formas e mecanismos de desgaste da ferramenta, a formação de rebarba, a superfície microusinada, a rugosidade superficial e a formação de cavaco. Os resultados mostram que a ferramenta com diâmetro de 200 µm apresentou um excelente desempenho em relação ao comprimento usinado, no entanto o aumento da velocidade de corte levou a um desgaste excessivo e altas rebarbas. Na usinagem utilizando ferramentas de diâmetro 400 µm, o desgaste e altura das rebarbas foi atenuado através da utilização do fluído de corte. E por fim, as ferramentas com maior diâmetro apresentaram rebarbas muito menores quando comparadas às de menor diâmetro, formando cavacos contínuos, além de apresentarem um menor grau de recalque. / The increasing demand for products requiring increasingly smaller components drives the development of micromachining, which is considered to be highly necessary for technological advances in the field of mechanical engineering. In this context, micromilling is a viable alternative for the manufacture of these microcomponents, allowing the machining of complex geometries in various materials such as: metals and alloys, composites, polymers, ceramics and some stainless steels, the latter of which arouse great interest for the industry due to its characteristic of great resistance to corrosion and oxidation. However, adapting the knowledge of milling of stainless steels on a conventional scale to the microscale requires an understanding of the specific phenomena that arise with the reduction of operations. Considering this context, this work has as main objective the investigation of the machinability of duplex stainless steel UNS S32205 in the micromilling operation. For that, tests were made to manufacture microchannels, using a 4-axis CNC micromill machine tool, with maximum spindle rotation of 60 000 rpm and resolution of 0.1 μm, using 200 µm and 400 µm diameter tools. From the experimental data, it was investigated the evolution of tool wear, the forms and mechanisms of tool wear, burr formation, machined surface quality, surface roughness and chip formation. The results show that the tool with diameter 200 µm presented an excellent performance in relation to the machined length, however the increased cutting speed led to excessive wear and high burrs. In the machining tests using tools with diameter 400 µm, the wear and height of the burrs was attenuated through the use of cutting fluid. Finally, the tools with the largest diameter presented minor burrs when compared to the smaller diameter, forming continuous chips, in addition to presenting a lower chip thickness ratio of the chips. / Dissertação (Mestrado)

La qualité des surfaces des veines fluides fermées des pièces tournantes de turbomachine participe au rendement de la turbomachine. Il est donc essentiel de maîtriser la finition des veines en usinage 5 axes avec une fraise boule. L'alliage de titane Ti6Al4V est l'un des matériaux utilisés et souffre d'une faible usinabilité. Le choix des paramètres de coupe conditionne la qualité de surface et la durée de vie de la fraise. Pour maîtriser le fraisage 5 axes, des méthodes de caractérisation de la coupe sont développées pour des trajectoires linéaire et circulaire. Les diamètres effectifs et l'épaisseur coupée sont à l'origine de plusieurs phénomènes associés à la coupe tels que la vitesse de coupe, la vitesse d'évolution de l'usure d'outil, des modes d'usinage et des efforts de coupe. Des essais font le lien entre les mesures d'efforts de coupe et d'état de surface avec les méthodes de caractérisation de la coupe. Une fois l'usinage 5 axes en fraise boule caractérisé, deux stratégies de finition multiaxes de veines fermées sont développées en gardant constantes la vitesse d'avance du point générateur et l'orientation relative de l'axe de l'outil avec la normale de la surface locale. La stratégie de tréflage se caractérise par une trajectoire continue en courbure. La stratégie de contournage hélicoïdal met en évidence des discontinuités en tangence de la trajectoire. Une méthode de lissage local de trajectoire est alors développée pour assurer un comportement cinématique et dynamique raisonnable de la machine. / The surface quality of closed fluid veins rotating parts of turbo machines participates in the machine output. It is therefore essential to control the finishing of veins in 5-axis machining with a ball end mill. The titanium alloy Ti6Al4V is one of the materials used and suffers from a poor machinability. The choice of cutting parameters affects the surface quality and the life of the cutter. In order to control the 5-axis milling, characterization methods of cutting are developed for linear and circular paths. Effective diameters and the uncut chip thickness is responsible for several phenomena associated with the cut such as the cutting speed, the speed of evolution of the tool wear, the milling modes and cutting forces. Tests are the link between measures of cutting forces and surface quality and characterization methods of cutting. Once the 5-axis machining with ball end mill characterized, two strategies of finishing closed veins in multiaxis are developed keeping constant the feed speed of the contact and the relative orientation of the tool axis with the normal the local surface. The plunge milling strategy is characterized by a curvature continuous trajectory. The helical milling strategy reveals tangent discontinuities of the trajectory. A method of local smoothing trajectory is then developed to provide a reasonable kinematics and dynamics behavior of machine.

The use of pre-hardened mold steels has increased appreciably over the years; more than 80% of the plastic mold steels are used in pre-hardened condition. These steels are delivered to the customer in finished state i.e. there is no need of any post treatment. With hardness around ~40HRC, they have properties such as good polishability, good weldability, corrosion resistance and thermal conductivity. Machinability is a very important parameter in pre-hardened mold steels as it has a direct impact on the cost of the mold. In normal machining operations involving intricate or near net shapes, machining constitutes around 60% of the total mold cost. Efforts are underway to explore every possible way to reduce costs associated with machining and to make production more economical. All the possible parameters which are considered to affect the machinability are being investigated by the researchers. This thesis work focuses on the effect of prior austenite grain size on the machinability of pre-hardened mold steel (Uddeholm Nimax).  Austenitizing temperatures and holding times were varied to obtain varying grain sized microstructures in different samples of the same material. As it was difficult to delineate prior-austenite grain boundaries, experimental and empirical methods were employed to obtain reference values. These different grain sized samples were thereafter subjected to machining tests, using two sets of cutting parameters. Maximum flank wear depth=0.2mm was defined for one series of test which were more akin to rough machining, and machining length of 43200mm or maximum wear depth=0.2mm were defined for second series of tests which were similar to finishing machining. The results were obtained after careful quantative and qualitative analysis of cutting tools. The results obtained for Uddeholm Nimax seemed to indicate that larger grain sized material was easier to machine. However, factors such as retained austenite content and work hardening on machined surface, which lead to degradation of machining operations were also taken into consideration. Uddeholm Nimax showed better machinability in large grained samples as retained austenite(less than 2%) content was minimal in the large grained sample. Small grained sample in Uddeholm Nimax had a higher retained austenite (7+2%) which resulted in degradation of machining operation and a lesser cutting tool life.