The demand for materials with high mechanical performances such as Carbon Fiber Reinforced Plastics (CFRP) is increasing. However, there are major challenges in machining CFRP as it involves delamination, fiber pullouts, and extreme cutting tool wear. Analysis of chip formation mechanisms and prediction of associated cutting forces in CFRP machining enables one to address these challenges. This study proposes a mechanistic cutting force model for milling operations of the CFRP workpiece, considering its non-homogeneity and anisotropy, by taking into account variations of fiber cutting angle during machining. A mechanistic model of cutting force constants is obtained from a number of experimentally measured unidirectional CFRP milling forces. The obtained mechanistic force model predictions are verified against experimentally measured milling forces with arbitrary tool path indicating the accuracy of the proposed mechanistic model in predicting cutting forces. The proposed mechanistic cutting force model is capable of being integrated into the manufacturing process to allow optimized machining of quality certified CFRP work-pieces. / Graduate

Dredge cutting forces produced by the movement of the cutterhead through the sediment have been measured with the laboratory dredge carriage located at the Haynes Coastal Engineering Laboratory. The sediment bed that was used for the dredging test was considered to be relatively smooth and the sediment used was sand with a d50=0.27 mm. Forces on the dredge carriage were measured using five 13.3 kN (3000 lb) one directional load cells placed on the dredge ladder in various places so the transmitted cutting forces could be obtained. The objectives for this study are to determine the vertical, horizontal, and axial forces that are produced by the cutterhead while testing. So, to find these cutter forces, a static analysis was performed on the carriage by applying static loads to the cutterhead in the vertical, horizontal, and axial directions, and for each load that was applied, readings were recorded for all five of the load cells. Then, static equilibrium equations were developed for the dredge carriage ladder to determine loads in the five load cells. Also, equilibrium equations can be applied to a dredging test to find the cutterhead forces by taking the measured data from the five load cells and applying the known forces to the equations, and the cutterhead forces can be determined. These static equilibrium equations have been confirmed by using a program called SolidWorks, which is modeling software that can be used to do static finite element analysis of structural systems to determine stresses, displacement, and pin and bolt forces. Data that were gathered from the experimental procedure and the theoretical calculations show that the force on the dredge cutterhead can be determined. However, the results from the static equilibrium calculations and the results from the SolidWorks program were compared to the experiment procedure results, and from the comparison the procedure results show irregularities when a force of approximately 0.889 kN (200 lb) or above is applied to the cutterhead in a north, south, west, or east orientation. The SolidWorks program was used to determine the results for displacements of the dredge carriage ladder system, which showed that large displacements were occurring at the location of the cutterhead, and when the cutterhead displaces it means that the carriage ladder is also moving, which causes false readings in the five load cells. From this analysis it was determined that a sixth force transducer was needed to produce more resistance on the ladder; and the cell #1 location needed to be redesigned to make the ladder system as rigid as possible and able to produce good testing results. The SolidWorks program was used to determine the best location where the sixth force transducer would give the best results, and this location was determined to be on the lower south-west corner oriented in the direction east to west. The static equilibrium equations were rewritten to include the new redesigned cell #1 location and the new location of the sixth load cell. From the new system of equations, forces on the cutterhead can be determined for future dredging studies conducted with the dredge carriage. Finally, the forces on the laboratory cuttersuction dredge model cutterhead were scaled up to the prototype 61 cm (24 in) cuttersuction dredge. These scaled up cutting forces on the dredge cutterhead can be utilized in the design of the swing winches, swing cable size, ladder supports, and ladder.

Drilling is a standard process for producing holes in metal materials. With an increased hole depth the demands increase on both machine and tool. Deep hole drilling is a complex process which ischaracterized by a high metal removal rate and hole accuracy. A hole deeper than ten times the diameter can be considered a deep hole which requires a specialized drilling technique. During adeep hole drilling process, the forces generated on the deep hole drill give a rise to a resultant radial force. The resultant radial force pushes the drill in a radial direction during a drilling operation. The radial force direction is of crucial importance in regard of tool guidance, stability and hole size accuracy. This force affects tool performance, reduces tool life and has an impact on the bore surface. Due to the complex nature of deep hole drilling, Sandvik Coromant wishes to get a better understanding of how their current deep hole drilling tools are balanced. The purpose of this study is to conduct a survey of a number of drills of Sandvik Coromant deep hole drill assortment. The main aim of this study is to calculate and measure the resultant radial force generated during a deep hole drilling operation. The forces are calculated with the aid of a calculation program and test-runs on a number of drills. This report presents the calculated magnitude and direction of the resultant radial force duringentrance, full intersection and at the exit of the workpiece. In addition to the measured values of theresultant radial force during entry and full intersection. Four different drill geometries are evaluated which of two are competitor drills. A deep hole drill geometry is re-modified in aspect to drill stability based on the outcome of the measured and calculated results. The results acquired from the performed calculation and measurements of the resultant showed that the resultant radial force acts in an angular direction that was outside the range between the support pads. This true for three of the four evaluated drill geometries. There were minor differences between the measured and calculated forces which enforce the reliability of the used calculation program. The modified drill geometry of a deep hole drill gave an indication of which geometry variables have impact on the resultant radial force magnitude and angular direction. The data presented in this report can be a base for future development of a deep hole drill toolgeometry in regard to the resultant radial force. Variables affecting the calculated results and theresultant radial force are presented and discussed. The study is concluded with suggestions of futurework based on the acquired data.

No description available.

Processos de torneamento, muitas vezes na condição de corte interrompido, estão presentes em diversas operações na manufatura de componentes mecânicos, seja quando uma geometria específica é necessária como função deste componente ou quando ela é resultante de uma etapa anterior no processo produtivo, como no caso de peças forjadas. Este trabalho apresenta uma metodologia para avaliação da severidade de perfis irregulares durante o processo de torneamento. Esta avaliação é realizada principalmente sob o enfoque de esforços de corte e vibração, utilizando para tanto um dinamômetro e um acelerômetro. São estudados dois casos de torneamento apresentando geometria irregular: barras de seção transversal quadrada e barras cilíndricas contendo rasgos de chaveta. O material utilizado em ambos os casos foi o aço SAE 52100. Os sinais de forças e vibração foram obtidos em diferentes etapas do torneamento, sendo cada etapa representada por uma taxa de contato diferente. As velocidades de corte utilizadas foram de 60 m/min e 120 m/min, com avanço constante e igual a 0,2 mm/volta e profundidade de corte de 1 mm. Para a medição dos esforços foi instrumentado um porta-ferramentas equipado com extensômetros. Neste porta-ferramentas foi fixada a pastilha de metal duro (TPUN 160304) utilizada nos ensaios, buscando-se assim a condição de corte ortogonal. Como análises secundárias foram realizadas medições de rugosidade nas peças e medição dos cavacos obtidos durante o processo, assim como fotografias das ferramentas utilizando microscopia óptica. Os resultados obtidos mostraram relações entre a taxa de contato e as forças médias e máximas, além de diferenças significativas nos valores de rugosidade em função da geometria da peça, permitindo assim validar a metodologia empregada para análise de torneamento em condições de corte interrompido. Portanto, é possível relacionar forças e vibrações à geometria do material por meio do aparato experimental desenvolvido. / Interrupted cutting conditions often occur in the manufacturing of many mechanical components during turning processes. For instance, if a specific geometry feature is required or even if the geometry of the work piece is a result of a previous process, like in forged parts. This work presents a method to evaluate the severity during the turning process of irregular shape work pieces. This evaluation was carried out mainly analyzing the cutting forces and vibration signals by using a dynamometer and an accelerometer, respectively. Two different irregular geometries were studied during turning: square section bar and cylindrical bar with longitudinal key beds. The samples were made of the SAE 52100 steel for both geometries. Forces and vibration signals were recorded during different turning steps; each turning step was indicated by a different contact ratio. The cutting speeds used in the tests were 60 m/min and 120 m/min, with 0.2 mm/turn of feed rate and 1 mm of cut depth. A strain gage instrumented tool-holder was used to measure the cutting forces. The cemented carbide tool (TPUN 160304) used in the tests was fixed in the tool-holder device and the turning tests were carried out near the orthogonal cutting conditions. Complementary analysis of surface quality, chips size and shape and optical microscopy photos of the tools after the tests were also conducted. The results showed a relationship between the contact ratio and the cutting forces (average and maximum), and significant differences in the surface quality (roughness) as a function of work piece geometry. These results allow validating the proposed methodology to evaluate interrupted cutting conditions in turning operations. Therefore, it is possible to relate the forces and vibrations signals to the geometry of the material by the use of the experimental apparatus developed.

A flexão da ferramenta, em operações de fresamento de topo, é responsável por interferir negativamente na qualidade superficial da peça a ser usinada e, muitas vezes, pela quebra prematura da mesma. O presente trabalho tem como objetivo estudar experimentalmente os efeitos da flexão de fresas de topo com 0,8 mm de diâmetro no processo de microfresamento. Os ensaios experimentais foram realizados com o intuito de identificar quais parâmetros de corte apresentam maior influência na flexão da ferramenta. Os parâmetros de corte escolhidos para estudo foram: velocidade de corte, velocidade de avanço, profundidade de usinagem e penetração de trabalho. Os ensaios investigam, além das faixas de parâmetros recomendados pelo fabricante da ferramenta, uma condição 25% acima e outra 25% abaixo para todos os parâmetros estudados. O monitoramento de forças de corte foi realizado em todos os ensaios. As forças obtidas se mostraram diretamente relacionadas com a área de secção de corte, conforme teoria básica. Para fins comparativos, a força máxima obtida experimentalmente foi aplicada na simulação com elementos finitos (FEM - Finite Element Method) da ferramenta e indicou um comportamento similar ao de uma viga engastada. A análise microscópica do aspecto superficial da usinagem mostrou que menores avanços por dente resultam em um melhor acabamento confirmando resultados do processo convencional. O conhecimento do efeito dos parâmetros de corte no processo de microfresamento tem o intuito de oferecer informações às empresas do setor no sentido de melhorar o planejamento e processo de fabricação. / The tool deflection, in end milling operations, is responsible to intervene negatively on the workpiece surface quality and can also cause a premature tool failure (breakage).The present work aims at studying experimentally the effects of tool deflection when end milling with 0,8 mm diameter in microoperations. The experimental tests had intended to identify which parameters of milling show more influence in tool deflection. The chosen milling parameters for the study were: cutting speed, feed rate, depth of cut and step over. The tests aim to investigate, beside the recommended parameters from tool manufacturer, a 25% higher and 25% lower conditions. The force acquisition was made in all tests. The measured forces shown that they are directly related to the uncut chip cross section, in accordance with theory. For comparative purpose, the maximum experimental force value was applied in the finite elements method (FEM) simulation of the tool and indicates a similar behavior of an encastré beam. The microscopic analysis of the superficial aspect of the milling showed that smaller feed per tooth results in better finishing, as observed in the conventional process. The knowledge of the effect of the cutting parameters in the micromilling process has the intention of offering information for industries to improve the planning and process of manufacturing.

O estudo trata da medição da força de usinagem a verde de corpos de provas cerâmicos e sua correlação com as propriedades mecânicas após a sinterização. A usinagem a verde é empregada em compactos brutos para conferir formatos sem extremo compromisso com precisão dimensional ou para obter uma pré-forma antes da usinagem de acabamento após sinterização; é extensivamente empregada na usinagem de cerâmicas avançadas. Durante o processo de usinagem a verde os esforços de corte determinam a introdução de defeitos críticos na superfície e são geralmente estes defeitos que governam as propriedades mecânicas das cerâmicas após a sinterização. O trabalho objetiva a elaboração e montagem de um sistema de aquisição de dados das forças de usinagem, e procura identificar o limite de agressividade de corte na manutenção da integridade do corpo de prova com produção econômica. As medidas de torque de usinagem e velocidade periférica do rebolo podem representar um modelo para predizer a associação das forças de usinagem. Corpos de prova cilíndricos foram conformados a 100 e 200 MPa, tratados termicamente após a prensagem e usinados com diferentes parâmetros de corte, sinterizados e ensaiados quanto à resistência mecânica através de compressão e flexão a quatro pontos. Os resultados mostraram a importância do tratamento térmico antes da usinagem acima da temperatura de transição vítrea do ligante para peças prensadas a 100 e 200 MPa. Peças prensadas a 200 MPa e tratadas termicamente foram usinadas sem danos a taxas de remoção de 10.000 \'MM POT.3\'/min com potencia consumida de 1700 W. Com o emprego de um cabeçote com mancais aerostáticos de alta potência e baixo ruído não se detectou a introdução progressiva de defeitos críticos na superfície devido à ação do rebolo, porém se identificou um limite de velocidade de 400 mm/min em função da profundidade de corte que excedeu a resistência mecânica dos corpos de prova comprimidos a 100 MPa, levando a ruptura. A correlação entre potência consumida e taxa de remoção, forneceu informações muito importantes para o projeto de uma máquina de usinagem á verde de produtos cerâmicos em alumina. / The present study deals with the measurement forces of green machining ceramics and their correlation with the mechanical properties after sintering. The green machining is employed in crude compacts either to check raw formats without compromising the extreme dimensional accuracy or to obtain a preform prior to finish machining after sintering, extensively used in the machining of advanced ceramics. During the process of the green machining, cutting forces determine the introduction of the critical defects in the surface, which generally govern the mechanical properties after the sintering of ceramics. The study aims at the development and installation of a system of machining forces data acquisition and also the identification of the limit of cutting aggression to maintain the integrity of the ceramics with economic production. The torque measurements of machining and grinding wheel peripheral speed can represent a model to predict the association of the machining forces. Cylindrical bodies were conformed at 100 and 200 MPa, heat-treated after pressing and machined with different cutting parameters, sintered and tested concerning strength by compression and bending at four points. The results showed the importance of the heat treatment before machining above the glass transition temperature of the binder for the parts pressed at 100 and 200 MPa. Parts pressed at 200 MPa and heat-treated were machined without damage at 10.000 \'MM POT.3\'/min removal rates with power consumption of 1700 W. With the use of a spindle with aerostatic bearings for high power and low noise the gradual introduction of critical defects into the surface was not detected due to the action of the wheel. However a speed limit was identified in function of the depth of the cut, which exceeded the strength of the ceramics compressed at 100 MPa, leading to rupture. The correlation between power consumption and rate of removal provided very important information for the design of a green machining of ceramic products in alumina.

Este trabalho apresenta resultados de testes com processo de usinagem para diferentes ferramentas de torneamento. Foram realizados ensaios para avaliar a diferença de comportamento quantoa esforçosde cortee acabamentosuperficialem operaçãode torneamento para um mesmo tipo de ferramenta, com variação na superfície de saída, sendo uma com quebra cavaco com outra de superfície de saída lisa. O material usinado foi aço ao carbono 1045 recozido, testado para duas diferentes velocidades, variando-se também a profundidade de corte e avanço para cada ensaio. Os testes foram executados em um torno mecânico convencional, onde as variáveis do processo foram coletadas com um sistema de aquisição de dados, através de um dinamômetro piezoelétrico para avaliação das forças de corte e um rugosímetro portátil para medida da rugas idade superficial. Observou-se nos resultados, uma forte diminuição dos esforços quando aplicada a ferramenta sinuosa com quebra-cavaco, bem como melhoria nas características do cavaco. Em relação à rugas idade superficial houve uma pequena melhora quando utilizada a ferramenta com superfície de saída lisa, situação decorrente das condições de remoção do cavaco. / This wark presents the results af machiningpracess tests with different turning tools. Tests were done to evaluate behaviors differenceson cutting efforts and surface finishing in turning operations to a same type of tool, with a variation on rake face, where one had a chipbreaker groove and the other are flat. The machining material was 1045 annealed carbon steel, tested to two different cutting speeds, changing also the depth of cut and the feed rate for each case. The tests were done in a conventionallathe, where the process variances were collected by a data acquisition system, through a piezoelectric dynamometer to evaluate the cut efforts and a portable rugosimeter to measure the surface roughness. The results show a strong reduction of the efforts when grooved tools with chip-breaker were applied as well an improvement on the chip characteristics. In relation to the surface roughness, it was observed a slight improvement when the tlat tool was used, because ofthe conditions of chip remova!.

Este trabalho apresenta resultados de testes com processo de usinagem para diferentes ferramentas de torneamento. Foram realizados ensaios para avaliar a diferença de comportamento quantoa esforçosde cortee acabamentosuperficialem operaçãode torneamento para um mesmo tipo de ferramenta, com variação na superfície de saída, sendo uma com quebra cavaco com outra de superfície de saída lisa. O material usinado foi aço ao carbono 1045 recozido, testado para duas diferentes velocidades, variando-se também a profundidade de corte e avanço para cada ensaio. Os testes foram executados em um torno mecânico convencional, onde as variáveis do processo foram coletadas com um sistema de aquisição de dados, através de um dinamômetro piezoelétrico para avaliação das forças de corte e um rugosímetro portátil para medida da rugas idade superficial. Observou-se nos resultados, uma forte diminuição dos esforços quando aplicada a ferramenta sinuosa com quebra-cavaco, bem como melhoria nas características do cavaco. Em relação à rugas idade superficial houve uma pequena melhora quando utilizada a ferramenta com superfície de saída lisa, situação decorrente das condições de remoção do cavaco. / This wark presents the results af machiningpracess tests with different turning tools. Tests were done to evaluate behaviors differenceson cutting efforts and surface finishing in turning operations to a same type of tool, with a variation on rake face, where one had a chipbreaker groove and the other are flat. The machining material was 1045 annealed carbon steel, tested to two different cutting speeds, changing also the depth of cut and the feed rate for each case. The tests were done in a conventionallathe, where the process variances were collected by a data acquisition system, through a piezoelectric dynamometer to evaluate the cut efforts and a portable rugosimeter to measure the surface roughness. The results show a strong reduction of the efforts when grooved tools with chip-breaker were applied as well an improvement on the chip characteristics. In relation to the surface roughness, it was observed a slight improvement when the tlat tool was used, because ofthe conditions of chip remova!.

Made available in DSpace on 2015-05-08T14:59:55Z (GMT). No. of bitstreams: 1 arquivototal.pdf: 8849589 bytes, checksum: 337394414de1a3c9ab9c071e9c18f59b (MD5) Previous issue date: 2014-02-04 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior - CAPES / The shape memory alloy, more specifically constituted of CuAlBe, have played an important role in the manufacture of electromechanical components, especially when worked requests from thermal and/or applied stresses. At first, this present research work, were obtained, by casting the gas, samples of alloys Cu-11.8%Al-0.60%Be; Cu-11.8%Al-0.55%Be; Cu-11.8%Al-0.55%Be-0.50%Nb-0.27%Ni (wt%). Sequentially, quenched to half of them, with the intention of doing them acquire the shape memory effect. In a third moment, said samples passed assays DSCs, aiming raise the temperature curves of phase transformation (austenite: Ai/Af and martensite: Mi/Mf). The main study, performed during machining by turning dry, using a piezoelectric dynamometer, were defined the cutting forces of samples tempered and not tempered. In compliance with the track methodology, were applied five replicates, with four levels of cutting speed for each of the samples tested. The signals from the dynamometer were processed in LabVIEW and further processed in by a program done on MatLAB. Secondary assays were also performed soon after machining by turning dry. In the first, by means of a K-type thermocouple, temperatures of machining were measured along the stride; on the second, by assay of circularity, it was verified if there was or no retention of the martensite in the samples of shape memory alloys. It was found that the percentage of beryllium and nickel present in the alloys investigated, as well as the introduction of niobium as a grain refiner were decisive for achieving the results / As ligas com memória de forma, mais especificamente as constituídas de CuAlBe, têm desempenhado um papel importante na fabricação de componentes eletromecânicos, sobretudo quando trabalhados a partir de solicitações térmicas e/ou tensões aplicadas. A princípio, neste presente trabalho de pesquisa, foram obtidas, por fundição a gás, amostras das ligas Cu-11,8%Al-0,60%Be; Cu-11,8%Al-0,55%Be; Cu-11,8%Al-0,55%Be-0,50%Nb-0,27%Ni (% em peso). Sequencialmente, temperou-se a metade delas, com o intuito de fazê-las adquirir o efeito memória de forma. Num terceiro momento, as referidas amostras passaram por ensaios de DSCs, visando levantar as curvas de temperatura de transformação de fases (da austenita: Ai/Af e da martensita: Mi/Mf). No ensaio principal, realizado durante a usinagem por torneamento a seco, por meio de um dinamômetro piezoelétrico, definiram-se as forças de corte das amostras temperadas e não temperadas. Dando cumprimento à trilha metodológica, foram aplicadas cinco réplicas, com quatro níveis de velocidade de corte para cada uma das amostras ensaiadas. Os sinais oriundos do dinamômetro foram processados no LabVIEW e posteriormente tratados por uma programação feita em MatLAB. Ensaios secundários também foram realizados logo após a usinagem por torneamento a seco. No primeiro, por meio de um termopar tipo K, foram medidas as temperaturas de usinagem ao longo da passada; no segundo, por ensaio de circularidade, foi verificado se ocorreu ou não a retenção da martensita nas amostras das ligas com memória de forma. Constatou-se que a percentagem de berílio e de níquel presente nas ligas investigadas, bem como a introdução do nióbio como refinador de grãos foram decisivos para o alcance dos resultados obtidos