Made available in DSpace on 2014-06-11T19:31:04Z (GMT). No. of bitstreams: 0 Previous issue date: 2007-10-19Bitstream added on 2014-06-13T18:41:35Z : No. of bitstreams: 1 alves_mcs_dr_bauru.pdf: 4541684 bytes, checksum: 03e1d27ea6b721a409bebc9862b0e67f (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / É analisada a influência das técnicas de mínima quantidade de lubrificante (MQL), refrigeração otimizada e refrigeração convencional, com diferentes vazões e velocidade de aplicação do fluido de corte, na qualidade das peças produzidas (acabamento, erros de forma, trincas, queima, perda da dureza) com aços endurecidos, no processo de retificação cilíndrica externa de mergulho com a utilização de rebolos superabrasivos com baixa concentração de CBN. Utilizou-se fluidos de corte de origem vegetal, que representam menos riscos à saúde e ao meio. A análise da qualidade das peças foi realizada através da avaliação das variáveis de saída do processo como o comportamento da força tangencial de corte, energia específica de retificação, rugosidade, desvio de circularidade, emissão acústica, tensão residual, análise de microscopias eletrônicas de varredura e microdureza. Com a análise das formas de aplicação e das várias vazões e velocidades do fluido de corte utilizadas encontraram-se condições de lubri-refrigeração que propiciam a diminuição do volume de fluido de corte, diminuição do tempo de usinagem sem prejudicar os parâmetros geométicos, dimensionais, o acabamento superficial e a integridade superficial dos componentes. Em relação as diferentes formas de aplicação do fluido de corte notou-se o melhor desempenho da aplicação otimizada para maiores velocidades mostrando a eficiência de um novo conceito de bocal utilizado. O processo otimizado e o processo MQL foram capazes de manter a dureza superficial e a integridade superficial das peças produzidas. Exceção somente para a condição MQL com vazão de fluido de corte de 40ml/h que produziu trincas e retêmpera superficial. O desvio de circularidade e a rugosidade proporcionada pelos métodos estão dentro de valores recomendados para a retificação sendo que a técnica otimizada... / The influences on surface integrity of the parts (finishing, geometrical errors, cracks, burn, microhardness) and grinding wheel (wear) have been analyzed in this research by employing the minimum quantity of lubrication (MQL), optimized and conventional cooling for hardened parts of steel and superabrasives grinding wheel in the cylindrical plunge grinding process. This study was carried out through the assessment of the process output variables such as the behavior of the tangential cutting force, specific energy, surface roughness, circularity errors, acoustic emission, residual stress, scanning electronic microscopy (SEM) and microhardness. The cutting fluid derived from vegetal oil has been utilized in order to comply with the environmental requirements and thus offering less risk to the health. It could be observed from the analysis on different ways of cutting fluid applications that there are cooling conditions which facilitate the decrease in cutting fluid volume, decrease in grinding time without impairing the geometrical and dimensional parameters, the surface finish and surface integrity of the parts. It could be noted the optimized application for higher velocities has presented the best performance regarding the different applications of cutting fluids. The optimized and MQL processes were able to maintain the hardness and surface integrity of the ground parts. Exception occurend only for MQL condition with flow rate of 40ml/h, which led to cracks and quench on the workpiece surface. Roundness errors and surface roughness are within recommended valus for grinding with the best results obtained for the optimized method (2'mü' for roundness error and 0.5'mü'm for surface roughness) compared with the MQL technique (6.8'mü'm for roundness error and 1.2'mü'm for surface roughness). The process of minimum quantity of lubrication, however, has showed possible... (Complete abstract click electronic access below)

Nowadays, the need for three-dimensional miniaturized components is increasing in many areas, such as electronics, biomedics, aerospace and defence, etc. To support the demands, various micro-scale fabrication techniques have been further introduced and developed over the last decades, including micro-electric-mechanical technologies (MEMS and LIGA), laser ablation, and miniature machine tools (mMTs). Each of these techniques has its own benefits, however miniature machine tools are superior to any others in enabling three-dimensional complex geometry with high relative accuracy, and the capability of dealing with a wide range of mechanical materials. Thus, mMTs are emerging as a promising fabrication process. In this work, various researches have been carried out based on the mMTs. The thesis presents micro-machining, in particular, micro-milling force model and three relevant subsystems for miniature machine tools (mMTs), to enhance machining productivity/efficiency and dimensional accuracy of machined parts. The comprehensive force model that predicts micro-endmilling dynamics has been developed. Unlike conventional macro-machining, the cutting mechanism in micro-machining is complex with high level of non-linearity due to the combined effects of edge radius, size, and minimum chip thickness effect, etc., resulting in no chip formation when the chip thickness is below the minimum chip forming thickness. Instead, part of the work material deforms plastically under the edge of a tool and the rest of the material recovers elastically. The developed force model for micro-endmilling is effective to understand the micro-machining process. As a result, the micro-endmilling force model is helpful to improve the quality of machined parts. In addition, three relevant subsystems which deliver maximum machining productivity and efficiency are also introduced. Firstly, ultrasonic atomization-based cutting fluid application system is introduced. During machining, cutting fluid is required at the cutting zone for cooling and lubricating the cutting tool against the workpiece. Improper cutting fluid application leads to significantly increased tool wear, and which results in overall poor machined parts quality. For the micro-machining, conventional cooling methods using high pressure cutting fluid is not viable due to the potential damage and deflection of weak micro-cutting tools. The new atomization-based cutting fluids application technique has been proven to be quite effective in machinability due to its high level of cooling and lubricating. Secondly, an acoustic emission (AE)-based tool tip positioning method is introduced. Tool tip setting is one of the most important factors to be considered in the CNC machine tool. Since several tools with different geometries are employed during machining, overall dimensional accuracy of the machined parts are determined by accurate coordinates of each tool tip. In particular, tool setting is more important due to micro-scale involved in micro-machining. The newly developed system for tool tip positioning determines the accurate coordinates of the tool tip through simple and easy manipulation. At last, with the advance of the 3D micro-fabrication technologies, the machinable miniaturized components are getting complex in geometry, leading to increased demand on dimensional quality control. However, the system development for micro-scale parts is slow and difficult due to complicated detection devices, algorithm, and fabrication of a micro-probe. Consequently, the entire dimensional probing system tends to become bulky and expensive. A new AE-based probing system with a wire-based probe was developed to address this issue with reduced cost and size, and ease of application. / Graduate

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / Hardened steel is usually machined under dry condition. Application of an overhead flood cooling generally leads to premature tool failure because the heat generated that helps the shearing process needed to form the chips is reduced by its cooling action. This work proposes to study the application of MQF (Minimum Quantity of Cutting Fluid) when turning the heat treated hardened AISI D6 steel with PCBN (Polycrystalline Cubic Boron Nitride) tools and compare with the dry machining. The spray of a vegetable based cutting fluid was applied between the workpiece and the flank face of the tool. Overhead direction of the MQF and between the secondary flank face of the tool and the workpiece were also tested. Tool wear (VB), surface roughness (Ra, Rz e Rq) and cutting forces (Fx, Fy e Fz) were considered the output variables and the results were compared to those obtained when cutting in dry condition. The influence of the input parameters: cutting speed and feed rate, as well as their interactions were statistically analyzed. Considering the tool wear and the surface roughness, the application of the cutting fluid by the MQF technique in the direction between the flank face and the workpiece showed better results than the dry condition when employing the lowest feed rate of 0.05 mm/rev, regardless the cutting speed used. This cutting fluid application technique also presented good results when the cutting speed of 310 m/min was tested, regardless the feed rate employed. Therefore, this cutting speed should be recommended for high production in turning of AISI D6 steel with the MQF technique. The application of MQF through other directions (overhead and between the secondary flank face and the workpiece) also showed competitive results. / Aços temperados são geralmente usinados na condição a seco. A aplicação de uma refrigeração geralmente conduz a uma falha prematura da ferramenta porque o calor gerado durante o processo, que ajuda o cisalhamento, é reduzido pela ação refrigerante do fluido de corte. Este trabalho propõe estudar a aplicação do método de MQF (Minima Quantidade de Fluido) ao tornear o aço tratado termicamente, classe AISI D6, utilizando ferramenta de PCBN (Nitreto Cúbico de Boro Policristalino) e comparar com a condição a seco. A pulverização de um fluido de corte de base vegetal foi aplicada entre a peça de trabalho e a superfície de folga da ferramenta. A direção sobre-cabeça e entre a superfície de folga secundária e a peça também foram testadas em algumas condições de corte. O desgaste da ferramenta (VB), a rugosidade superficial (Ra, Rz e Rq) e as forças de usinagem (Fx, Fy e Fz) foram utilizadas como parâmetros de saída e seus resultados foram comparados com os resultados obtidos nos testes na condição a seco. As influências dos parâmetros de entrada: velocidade de corte e avanço, bem como suas interações, nas variáveis de saída (desgaste da ferramenta, rugosidade superficial e forças de usinagem) foram analisados através de métodos estatísticos. Considerando o desgaste da ferramenta e a rugosidade superficial da peça, a aplicação do fluido de corte pela técnica MQF na direção da superfície de folga principal apresentou melhores resultados que a condição a seco, quando se utilizou o menor avanço testado de 0,05 mm/rev, independente da velocidade de corte. Esta técnica também apresentou bons resultados quando a velocidade de corte de 310 m/min foi testada, independente do avanço. Assim, esta velocidade de corte deve ser recomendada para uma boa produção no torneamento do Aço AISI D6 com a técnica MQF. A aplicação do MQF nas outras direções (sobrecabeça e na superfície de folga secundária) também mostrou resultados competitivos. / Mestre em Engenharia Mecânica

Made available in DSpace on 2014-06-11T19:28:21Z (GMT). No. of bitstreams: 0 Previous issue date: 2010-08-02Bitstream added on 2014-06-13T20:17:59Z : No. of bitstreams: 1 biscioni_rpb_me_bauru.pdf: 662612 bytes, checksum: 0ffafb03e1fbe94047f45b65deb9ebd0 (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Um processo muito utilizado na indústria metal-mecânica em geral para fabricação de componentes de responsabilidade é a operação de retificação cilíndrica interna de precisão, este processo é utilizado, por exemplo, na fabricação de anéis de rolamento e outros componentes. Atualmente a evolução das máquinas permitiu o aprimoramento deste processo no que diz respeito ao posicionamento e à rigidez do sistema máquina-peça-ferramenta, porém ainda são enfrentados grandes problemas quanto à lubrificação e refrigeração, principalmente no que diz respeito à utilização de fluidos de corte. Este trabalho visa o estudo do comportamento da operação de retificação cilíndrica interna de mergulho a alta velocidade, no processo de acabamento de um aço endurecido SAE 52100, utilizando-se um rebolo convencional e dois métodos de refrigeração: o método de refrigeração convencional e com um bocal modificado. O motivo para o emprego de um bocal modificado reside no fato de se encontrar uma alternativa viável para uma possível substituição do método convencional que consome grande quantidade de fluido, já que estes têm se tornando nas últimas décadas um grande problema para as indústrias, devido aos enormes dados ambientais e humanos que causam. Para efetivar a comparação entre os métodos de refrigeração foram analisados os dados a respeito da rugosidade, erros de circularidade e desgaste diametral do rebolo, além de análise de microdureza e MEV das amostras retificadas para os métodos de refrigeração citados anteriormente. Analisando os resultados a quebra de barreira aerodinâmica e a melhor eficiência da penetração do fluido de corte na região de contato entre o rebolo e a peça foi maior quando se utilizou o bocal modificado com vazão de 21 1/min (25 m/s); os resultados de rugosidade, erro de circularidade e desgaste do rebolo foram sempre... / Precision internal plunge grinding is a process much used in the mechanical industry in general

Att använda stora mängder skärvätskor vid en bearbetningsprocess har potentiellt negativ inverkan inte bara för operatören men också på miljön. Utöver detta tillkommer ökade kostnader för tillverkningsprocessen. För att minska skärvätskekonsumtionen under maskinbearbetning införs en teknik som kallas minimalsmörjning(MQL=Minimum Quantity Lubrication) som använder mycket mindre mängd skärvätska men ändå är effektivare än standard kylspolning med skärvätska. Denna avhandling fokuserar på att bestämma konvektionen över ett skär med en konstant värmekälla placerad inuti ett kvadratiskt hölje och beräkningsdomänen för den CFD-modell som presenteras, vilken består av flytande och fasta domäner och interaktion mellan dessa. Möjligheten att använda MQL då lågtemperatur- och högtryckskylmedel appliceras undersöks och hur temperaturen sjunker efter applicering av kylmedel/kylvätskor observeras genom att simulera förhållandena i ANSYS flytande arbetsbänk. Denna tekniks effektivitet bestäms med avseende på huruvida högtrycks- och lågtemperaturkylvätska kan avleda värme och transportera bort spånor från ingreppszonen. Slutligen sammanställs resultaten och därpå dragna slutsatserna. / Employing huge amount of cutting fluids in machining process has potential negative impacts not only to the operator but also to the environment along with increased cost of manufacturing process. To reduce the cutting fluid consumption during machining, a technique called Minimum Quantity Lubrication (MQL) is introduced which uses very less amount of cutting fluid yet being effective than flood cooling. This thesis focuses on determining the convection over a cutting insert with a constant heat source inside a square enclosure and the computational domain of the CFD model presented consists of fluid and solid domains with fluid-solid interaction. The feasibility of MQL using low temperature and high-pressure coolant and observing how temperature is dropping after the application of coolant/coolants by simulating the conditions in ANSYS fluent workbench. The effectiveness of this technique is determined in terms of whether high pressure and low temperature coolant can dissipate heat and remove chips from the cutting interface. Finally drawing conclusion based on results.

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No. of bitstreams: 1 ruzzi_rs_me_bauru.pdf: 21281490 bytes, checksum: 10fa99d212e46ed1283477b7d4f4821b (MD5) Previous issue date: 2017-02-16 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Em meio à atual busca por adequações dos processos produtivos em função da saúde humana e preservação do ambiente, sem abrir mão da preocupação com os custos e a qualidade dos produtos, é preciso pesquisas a tentar novas técnicas de lubri-refrigeração eficientes como alternativas às convencionais. Assim, busca-se técnicas modernas que possam substituí-las, nesse sentido, a técnica MQL (Mínima Quantidade de Lubrificante) vem sendo uma alternativa pois utiliza baixo fluxo de óleo com ar em alta pressão, diminuindo a quantidade de resíduos gerados no processo. A técnica de MQL já se consolidou no mercado como solução para determinadas operações de usinagem como a de torneamento, porém encontra dificuldades no processo de retificação devido à formação de uma “borra” de óleo com cavacos que se forma na superfície do rebolo prejudicando os resultados do processo. A fim de superar este desafio, foi desenvolvido um sistema de ar comprimido para promover a limpeza da superfície do rebolo através da retirada da camada de borra ou resíduo que se impregna a ele durante o processo de retificação com MQL. Assim, o presente trabalho visou a análise do desempenho dos fluidos biodegradáveis LB 1100 (óleo puro) e BIOCUT 9000 (diluído em água na proporção de 1:5) aplicados a zona de corte via técnica de MQL com um sistema auxiliar de limpeza da superfície de corte do rebolo, em relação à técnica convencional. Os ensaios de retificação cilíndrica externa de mergulho foram realizados no aço endurecido ABNT 4340 utilizando um rebolo convencional de óxido de alumínio. Foram avaliados três avanços radiais distintos, 0,25, 0,50 e 0,75 mm/min. O desempenho da técnica MQL com sistema de limpeza foi avaliado com base nos parâmetros de rugosidade, desvios de circularidade, potência de usinagem, desgaste diametral do rebolo, microdureza e micrografia. Os resultados mostraram que a usinagem com a técnica MQL com o sistema de limpeza da superfície do rebolo e fluido LB 1100, de modo geral, proporcionou um desempenho superior às demais técnicas nas mesmas condições analisadas, apresentando peças sem danos, com os melhores valores de Rugosidade (Ra) e desvios de circularidade e com o menor consumo de potência e rebolo, ressaltando o potencial do uso desta técnica no processo de retificação. / Currently seeking for suitability of the production processes due to the preservation of the environment and human health, without abandoning the concern with cost and quality of products, research is needed to try new efficient cooling-lubrication techniques as alternatives to conventional ones. Thus, modern techniques are sought to replace them, in this way, the MQL (Minimum Quantity of Lubricant) technique has been an alternative because it uses low oil flow with high pressure air, reducing the amount of waste generated in the process. The MQL technique has already consolidated itself in the market as a solution for certain machining operations such as turning, but it encounters difficulties in the grinding process due to the formation of an oil slurry with chips that forms on the surface of the grinding wheel, damaging the results of the process. To overcome this challenge, a compressed air system has been developed to promote the cleaning of the grinding wheel surface by removing the layer of sludge or residue which is impregnated thereto during the grinding process with MQL. Thus, the present research had as objective the performance analysis of the biodegradable fluids LB 1100 (pure oil) and BIOCUT 9000 (diluted in water in a ratio of 1:5) applied to the cutting zone through the MQL technique with an auxiliary cleaning system of the grinding wheel cutting surface, in relation to the conventional technique. External cylindrical plunge grinding trials were performed on AISI 4340 hardened steel using a conventional aluminum oxide grinding wheel. Three distinct feed rates were evaluated: 0.25, 0.50 and 0.75 mm/min, respectively. The performance of the MQL technique with the cleaning system was evaluated based on the parameters of roughness, roundness error, grinding power, diametric wheel wear, microhardness and micrograph. The results showed that the machining with the MQL technique with the grinding wheel cleaning system and the fluid LB 1100, in general, provided the best performance in relation to the other techniques in the same analyzed conditions, presenting parts without damages, with the best values of roughness (Ra) and roundness error and with the lowest expenditure of power and wheel wear, highlighting the potential of the use of this technique in the grinding process.

This thesis investigates the current state of tool wear prediction models in machining, focusing on their limitations in accurately incorporating the complex dynamics of cutting fluids and their industrial applicability. It proposes a comprehensive evaluation framework to classify and evaluate a wide range of models, including empirical, physical, computational, and data-driven models. The study identifies the key limitations and strengths of each model category. It proposes enhancements by integrating advanced fluid dynamics and predictive modeling techniques to improve tool wear predictions' accuracy and industrial applicability. A structured literature review was conducted to investigate and evaluate existing tool wear models and their integration with cutting fluid dynamics. This review included defining search criteria, selecting relevant studies, and assessing their quality and relevance. The study uses thematic analysis and model evaluation frameworks to classify and evaluate the models, leading to the identification of critical limitations and strengths. The literature review and model evaluation findings revealed that empirical models, while simple and quick to implement, showed moderate accuracy and limited fluid dynamics integration. Physical models provided high accuracy in specific conditions but were computationally intensive. Computational models, particularly those using techniques like Finite Element Analysis (FEA) and Computational Fluid Dynamics(CFD), offered detailed insights and high accuracy but required significant computational resources. Data-driven models demonstrated exceptional predictive capabilities and comprehensive fluid dynamics integration but relied heavily on data availability and quality.  The proposed enhancements include introducing non-linear elements into empirical models, incorporating simplified fluid models or empirical correlations into physical models, exploring reduced-order models (ROMs) or surrogate models for computational models, and developing robust data preprocessing and augmentation techniques for data-driven models. These enhancements aim to improve the accuracy and applicability of tool wear models in industrial machining processes, ultimately contributing to more efficient and cost-effective machining operations. The study emphasizes the importance of a systematic and holistic approach to model evaluation and enhancement. Future research should focus on validating these proposed enhancements through empirical studies and real-world applications, ensuring their relevance and robustness in diverse industrial settings. This research offers significant potential to advance tool wear modeling, providing valuable insights for both academia and industry.