Thesis (MScEng)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: In this study, tool forces from rock cutting tests were numerically simulated through a discrete element method (DEM) in association with PFC3D™. Tribological interactions such as contact, shearing, fracturing, friction and wear were presented during these cutting simulations. Particle assemblies, representing Paarl granite and Sandstone-2, were created in PFC3D™ through a material-genesis procedure. The macro-properties of these particle assemblies, namely Young’s modulus, Poisson’s ratio, uniaxial and triaxial compressive strength and Brazilian tensile strength, were calibrated by modelling the uniaxial and triaxial compressive strength test and the Brazilian tensile strength test. The calibration was done through adjustment of the micro-properties of the assembly, namely the stiffness and strength parameters of the particles and bonds. The influence of particle size on the calibration was also investigated. These assemblies were used in the rock cutting tests. Results suggested that DEM can reproduce the damage formation during calibration tests successfully. From the results obtained from the calibration tests, it was also concluded that particle size is not a free parameter but influences the macro-properties greatly. Different rock cutting tools were simulated, namely point-attack (conical) picks, chisel-shaped tools and button-shaped tools. The numerical cutting tools were treated as rigid walls to simplify the simulation and the tool forces were not influenced by wear. In each simulation the cutting tools advanced at a constant velocity. The tool forces acting on the cutting tool, in three orthogonal directions, were recorded during the numerical simulations and the peak cutting forces were predicted by theoretical equations. The damage to the Paarl granite and Sandstone-2 assemblies was revealed as broken bonds, which merge into microscopic fractures. The mean peak cutting forces of sharp cutting tools obtained from numerical, theoretical and experimental models (from the literature) were compared. Finally the influence of factors, including wear on the tool and depth of cut, on the value of tool forces was also investigated. The results from the rock cutting tests revealed that the correlation between the numerical and the experimental models as well as the theoretical and experimental models was not strong when using sharp point-attack and chisel-shaped picks. It was concluded that the influence of wear plays a substantial part in the cutting process and it has to be included during the numerical simulation for the results to be accurate and verifiable. This study also found that there is a non-linear increase in tool forces with an increase in depth of cut, since the contact area increases. At larger cutting depths, chip formation also generally increased and therefore damage to the sample as well as wear on the cutting tool will be minimized at shallow cutting depths. Overall this study concludes that DEM are capable of simulating calibration methods and rock cutting processes with different cutting tools and producing results which are verifiable with experimental data. Therefore numerical prediction of tool forces will allow the design of efficient cutting systems and the operational parameters as well as the performance prediction of excavation machines. / AFRIKAANSE OPSOMMING: In hierdie studie is die kragte wat tydens rotssny-toetse op die sny gereedskap inwerk, numeries gesimuleer met behulp van ‘n diskrete element metode (DEM) in samewerking met PFC3D™. Tribologiese interaksies soos kontak, skeer, breking, wrywing en slytasie is gedurende hiersie snytoetse voorgestel. Partikel versamelings, wat Paarl graniet en Sandsteen-2 verteenwoordig, is in PFC3D™ geskep deur middel van ‘n materiaal-skeppings prosedure. Die makro-eienskappe van die partikel versamelings, naamlik Young se modulus, Poisson se verhouding, eenassige en drie-assige druksterkte en Brasiliaanse treksterkte, is gekalibreer deur modellering van die eenassige en drie-assige druksterkte toets en die Brasiliaanse treksterkte toets. Die kalibrasie is gedoen deur aanpassing van die mikro-eienskappe, naamlik die styfheid en die sterkte parameters van die partikels en bindings. Die invloed van partikelgrootte is ook ondersoek. Daarna is hierdie versamelings in die rotssny-toetse gebruik. Resultate het daarop gedui dat DEM die kraakvorming gedurende kalibrasie toetse suksesvol kan reproduseer. Vanuit die kalibrasie is ook gevind dat die partikelgrootte nie ‘n vrye parameter is nie, maar die makro-eienskappe grotendeels beïnvloed. Verskillende rotssny gereedskap is gesimuleer, naamlik koniese, beitel-vormige en knopie-vormige instrumente. Die numeriese sny gereedskap is gesimuleer as rigiede mure om simulasies te vereenvoudig en die gereedskap-kragte is dus nie deur slytasie beïnvloed nie. Tydens elke simulasie is die sny gereedskap vorentoe beweeg teen ‘n konstante snelheid. Die gereedskap-kragte, in drie ortogonale rigtings, is aangeteken gedurende die numeriese simulasies en die piek snykragte is ook voorspel deur teoretiese vergelykings. Die skade aan die Paarl graniet en Sandsteen-2 versamelings, is voorgestel as gebreekte bindings, wat saamsmelt tot mikroskopiese frakture. Die gemiddelde piek snykragte van skerp sny gereedskap van numeriese, teoretiese en eksperimentele modelle (uit die literatuur) is vergelyk. Ten slotte is die invloed wat faktore, onder andere die slytasie van gereedskap en die snydiepte, op die grootte van die kragte het ondersoek. Die resultate van die rotssny-toetse het aan die lig gebring dat die korrelasie tussen die numeriese en eksperimentale modelle sowel as die teoretiese en eksperimentele modelle nie sterk is tydens die gebruik van skerp koniese en beitel-vormige instrumente nie. Die gevolgtrekking is gemaak dat die invloed van slytasie van sny gereedskap ‘n wesenlike rol speel in die snyproses en dat dit in die numeriese simulasie ingesluit moet word sodat die resultate akkuraat en virifieerbaar is. Hierdie studie het ook gevind dat daar ‘n nie-lineêre toename in die gereedskap-kragte is met ‘n toename in snydiepte aangesien die kontak-area toeneem met ‘n toename in die snydiepte. By groter snydieptes, het die formasie van afsplinterings verhoog en dus sal skade aan die partikel versamelings en die slytasie van die gereedskap geminimeer word by vlakker snydieptes. Algeheel het die studie tot die gevolgtrekking gekom dat DEM in staat is om kalibrasie metodes en rotssny-toetse met verskillende sny gereedskap te simuleer asook om resultate te produseer wat verifieerbaar is met eksperimentele data. Numeriese voorspellings van die gereedskap-kragte sal dus toelaat om doeltreffende sny prosesse en operasionele parameters te ontwerp sowel as om die werkverrigting van uitgrawings masjiene te voorspel.

This Diploma Theses focuses on the assessment of two pick-up balers which compress crop into compact bales. The balers are made and delivered by different manufacturers with a variable bale chamber and cutting mode at the moment of haylage, hay and straw harvesting. Specifically, the given assessment compared John Deere 960 Baler and Kuhn VB 2160 Baler while considering the following parameters: quality of cutting, bale density, haylage, capacity and performance, economic analysis and recommendation for their use in agriculture. John Deere 960 Baler achieved better results in the majority of performed tests. The values of bale density were the following: 666.25 kg.m-3 (haylage), 221.39 kg.m-3 (hay), 176.62 kg.m-3 (straw). The assessment of haylage quality was excellent. The given baler (JD 960) also excelled at harvesting capacities: 20.89 t.h-1 (haylage), 15.61 t.h-1 (hay) and 12.54 t.h-1 (straw). Baling costs per 1 kilogram of forage revealed the following figures: 0.036 CZK (haylage), 0.079 CZK (hay) and 0.101 CZK (straw). Costs assessment for practical use of both balers per operating year indicates that the JD 960 Baler´s use is more cost effective by 1,320 CZK per 100 hectares (haylage), by 2,690 CZK (hay) and by 6,000 CZK (straw) in comparison with Kuhn VB 2160 Baler. As a consequence, the use and operation of John Deere 960 Baler can be recommended to large-sized companies with a sufficient amount of financial resources which can be invested in purchase of the given machinery. The baler is suitable for large areas with the demanding seasonal harvesting. On the other hand, Kuhn VB 2160 Baler did not show such an impressive result as JD 960 Baler. However, its use and operation is recommended to small or medium-sized agricultural companies which can appreciate the baler´s performance especially during hay and straw harvesting.

Made available in DSpace on 2014-06-11T19:24:38Z (GMT). No. of bitstreams: 0 Previous issue date: 2008-02-09Bitstream added on 2014-06-13T19:52:11Z : No. of bitstreams: 1 santos_ajm_me_botfca.pdf: 1014705 bytes, checksum: a380df7d0c36dd92557eb57e9d7c7468 (MD5) / Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq) / A qualidade e eficiência no corte da palha realizado pelos mecanismos de corte das semeadoras-adubadoras são elementos determinantes no processo de semeadura, em função da ocorrência de “embuchamentos” e de paradas, no afastamento da palhada ou mesmo no conhecido efeito do “envelopamento” da semente que ocasiona a deposição sobre a palha enterrada pelo mecanismo. Dessa forma, o objetivo deste trabalho foi avaliar o desempenho de diferentes mecanismos de corte de palha de uma semeadora-adubadora de maneira individualizada em diferentes quantidades de cobertura vegetal adicionadas artificialmente em um solo de textura argilosa. Para a realização do trabalho foi utilizado um dinamômetro (anel ortogonal), projetado, construído e calibrado numa célula de carga padrão. O experimento foi conduzido na Fazenda Experimental Lageado, pertencente à Faculdade de Ciências Agronômicas – Unesp de Botucatu. O delineamento experimental utilizado foi em parcelas subdivididas com quatro repetições, sendo as parcelas principais constituídas de cinco quantidades de palhada de aveia preta, adicionadas artificialmente ao solo em área conduzida em plantio direto e as subparcelas de três mecanismos de abertura de sulco, sendo estes: disco liso (DL), disco corrugado (DC) e disco ondulado (DO). O disco ondulado proporcionou maior resistência ao rolamento, reduzindo a velocidade do conjunto (trator e equipamento). A mobilização do solo avaliada nos diferentes tratamentos principais (quantidade de palhada) e secundários (configuração de discos) apresentou diferenças de volume de solo mobilizado, as maiores quantidades de palhada proporcionaram maior taxa de cobertura do solo e consequentemente menor evaporação de água aumentando a área mobilizada. Os discos estriados e ondulados apresentam comportamento semelhante em relação às forças laterais, horizontal, momento... / The quality and efficiency in straw cutting are determinants in the sowing process, according to the occurrence of tamp and stops, the magnitude of the straw removal or even the known effects of the seed envelopment where the cutting mechanism can not cut the remaining straw. Thus, the objective of this study was to evaluate the performance of different mechanisms for straw cutting of a seeder individualized in different amounts of crop coverage artificially added in a clay soil. It was used a dynamometer (orthogonal ring), designed, built and calibrated in a standard load cell to carry out the work . The experiment was conducted at Unesp – Sao Paulo State University in the Experimental Farm Lageado, belonging to the College of Agricultural Sciences - Unesp, Botucatu. The experimental design was split plot with four replications, with main plots consisting of five quantities of black oat straw, artificially added to the soil in area with no-tillage system and subplots of three opening furrows mechanisms, which are: plane disk (PD), corrugated disk (CD) and wavy disk (WD). The wavy disk provided greater rolling resistance, reducing the speed of the set (tractor and equipment). The evaluation of the soil in the different main treatments (amount of straw) and secondary treatments (setting disks), showed differences in the volume. The largest quantities of straw provided higher rate of soil cover and consequently less water evaporation by increasing the mobilized area. The striated and wavy disks showed similar behavior with respect to lateral and, horizontal forces and longitudinal time and horizontal force in function of the mobilized area. In the settings of the studied disks, it was found that the plane disk needed less load to greater penetrate into the soil, due to the values found in the vertical force in the component of reaction, demonstrating higher efficiency... (Complete abstract click electronic access below)

Orientador: Carlos Antonio Gamero / Banca: Saulo Philipe Sebastião Guerra / Banca: Antonio Gabriel Filho / Resumo: A qualidade e eficiência no corte da palha realizado pelos mecanismos de corte das semeadoras-adubadoras são elementos determinantes no processo de semeadura, em função da ocorrência de "embuchamentos" e de paradas, no afastamento da palhada ou mesmo no conhecido efeito do "envelopamento" da semente que ocasiona a deposição sobre a palha enterrada pelo mecanismo. Dessa forma, o objetivo deste trabalho foi avaliar o desempenho de diferentes mecanismos de corte de palha de uma semeadora-adubadora de maneira individualizada em diferentes quantidades de cobertura vegetal adicionadas artificialmente em um solo de textura argilosa. Para a realização do trabalho foi utilizado um dinamômetro (anel ortogonal), projetado, construído e calibrado numa célula de carga padrão. O experimento foi conduzido na Fazenda Experimental Lageado, pertencente à Faculdade de Ciências Agronômicas - Unesp de Botucatu. O delineamento experimental utilizado foi em parcelas subdivididas com quatro repetições, sendo as parcelas principais constituídas de cinco quantidades de palhada de aveia preta, adicionadas artificialmente ao solo em área conduzida em plantio direto e as subparcelas de três mecanismos de abertura de sulco, sendo estes: disco liso (DL), disco corrugado (DC) e disco ondulado (DO). O disco ondulado proporcionou maior resistência ao rolamento, reduzindo a velocidade do conjunto (trator e equipamento). A mobilização do solo avaliada nos diferentes tratamentos principais (quantidade de palhada) e secundários (configuração de discos) apresentou diferenças de volume de solo mobilizado, as maiores quantidades de palhada proporcionaram maior taxa de cobertura do solo e consequentemente menor evaporação de água aumentando a área mobilizada. Os discos estriados e ondulados apresentam comportamento semelhante em relação às forças laterais, horizontal, momento... (resumo completo, clicar acesso eletrônico abaixo) / Abstract: The quality and efficiency in straw cutting are determinants in the sowing process, according to the occurrence of "tamp" and stops, the magnitude of the straw removal or even the known effects of the seed "envelopment" where the cutting mechanism can not cut the remaining straw. Thus, the objective of this study was to evaluate the performance of different mechanisms for straw cutting of a seeder individualized in different amounts of crop coverage artificially added in a clay soil. It was used a dynamometer (orthogonal ring), designed, built and calibrated in a standard load cell to carry out the work . The experiment was conducted at Unesp - Sao Paulo State University in the Experimental Farm Lageado, belonging to the College of Agricultural Sciences - Unesp, Botucatu. The experimental design was split plot with four replications, with main plots consisting of five quantities of black oat straw, artificially added to the soil in area with no-tillage system and subplots of three opening furrows mechanisms, which are: plane disk (PD), corrugated disk (CD) and wavy disk (WD). The wavy disk provided greater rolling resistance, reducing the speed of the set (tractor and equipment). The evaluation of the soil in the different main treatments (amount of straw) and secondary treatments (setting disks), showed differences in the volume. The largest quantities of straw provided higher rate of soil cover and consequently less water evaporation by increasing the mobilized area. The striated and wavy disks showed similar behavior with respect to lateral and, horizontal forces and longitudinal time and horizontal force in function of the mobilized area. In the settings of the studied disks, it was found that the plane disk needed less load to greater penetrate into the soil, due to the values found in the vertical force in the component of reaction, demonstrating higher efficiency... (Complete abstract click electronic access below) / Mestre

Nos últimos anos, avanços consideráveis foram alcançados no estudo da usinabilidade de materiais frágeis tais como cristais semicondutores, vidros ópticos, cerâmicas, etc. em função da demanda por processos mais rápidos de fabricação de superfícies com formas complexas para aplicações nos campos da óptica e eletrônica. A ductilidade apresentada por monocristais de silício durante a usinagem tem sido explicada através das Teorias de Mecânica de Fratura. Recentemente, algumas teorias novas foram apresentadas para justificar esta ductilidade. Foi proposto que a ductilidade de monocristais semicondutores seria provavelmente o resultado final de uma transformação de fase induzida por pressão/tensão durante o corte. Neste trabalho, a diferença entre os modos dúctil e frágil no Torneamento com Ferramenta de Ponta Única de superfícies de silício monocristalino foram investigadas através da técnica de espalhamento Raman. Nas condições que proporcionam o regime dúctil, existem sempre uma amorfização superficial nas amostras, denunciadas através da ativação de uma banda óptica Raman mais larga em 470 cm-1. Esta fase amorfa pode ser considerada resultante da transição de fase a qual o silício pode ter sofrido. Por outro lado, para as condições onde o modo frágil é predominante, somente um pico óptico agudo de fonon em 521.6 cm-1 está presente no espectro Raman. Baseado nas medições que determinados parâmetros de corte, tais como a profundidade de corte e a espessura crítica do cavaco, apresentaram este estudo propõe que o regime dúctil não deve possuir uma faixa definida e fixa de valores para os parâmetros críticos mas, ao invés disso, estes seriam dependentes da extensão da camada transformada induzida por pressão/tensão gerada pela interação entre a ponta/aresta da ferramenta de corte com a peça durante a usinagem. Esta proposta se baseia na comparação entre os valores obtidos e os medidos por outros autores que mostram que a extensão da fase amorfa observada após processos de deformação mecânica (p.e., indentação, riscamento, polimento, nanoretificação e torneamento com ferramenta de ponta única de diamante) encontram-se na mesma faixa de valores encontrados para os parâmetros críticos (100-200 nm). Finalmente, foi demonstrado, através de observações da topografia de ambos, cavacos e superfícies geradas, realizadas com MEV e MFA, que este tipo de análise pode oferecer explicações significativas sobre os mecanismos de remoção de material em ação durante a usinagem e também sobre o estado microscópicos da ferramenta de diamante. / In recent years, considerable progress has been made on the study of the machinability of fragile materials such as semiconductors crystals, optical glasses, ceramics, etc., because of the demand for faster fabrication processes of complex surface shapes for optoelectronic applications. The ductility presented by single crystal silicon during machining has been explained by fracture mechanics theories. Recently, some new theories have been presented in order to give another justify to this ductility. It was proposed that semiconductors single crystal ductility is likely the end result of a pressure/stress induced phase transformation during cutting. In this work, the difference between ductile and brittle mode single-point diamond turning on the surface of machined silicon samples were investigated using Raman scattering. In the ductile mode conditions of machining, there are always an amorphization of the surface samples, denounced by the activation of the broad Raman optical band at 470 cm-1. This amorphous phase can be considered resulted from the phase transiton which silicon might have suffered. Contrary to the findings, in the brittle mode conditions, only the sharp optical phonon peak at 521.6 cm-1 is present in Raman spectra. Based on the observation that certain cutting parameters such as cutting depth and critical chip thickness, e.g., the point where ductile-to-brittle transition occurs, somehow presents values in the same range (100-200 nm) that the amorphous phase layer depth extension after mechanical deformation. (p.e., indentation, scratching, polishing, nanogrinding and single point diamond turning) observed in the literature, it is propposed that the ductile regime has not a definite range of values for the critical parameters but instead, it is dependent of the extension of the phase transformed layer induced by pressure/stress generated by the tool tip/edge interaction with workpiece during machining. Finally, it is shown that observation of topography and morphology of chip and the surface generated through SEM and AFM can offer very significant explanation of the material removal mechanisms in action during the current machining cut and diamond tool state.

Nos últimos anos, avanços consideráveis foram alcançados no estudo da usinabilidade de materiais frágeis tais como cristais semicondutores, vidros ópticos, cerâmicas, etc. em função da demanda por processos mais rápidos de fabricação de superfícies com formas complexas para aplicações nos campos da óptica e eletrônica. A ductilidade apresentada por monocristais de silício durante a usinagem tem sido explicada através das Teorias de Mecânica de Fratura. Recentemente, algumas teorias novas foram apresentadas para justificar esta ductilidade. Foi proposto que a ductilidade de monocristais semicondutores seria provavelmente o resultado final de uma transformação de fase induzida por pressão/tensão durante o corte. Neste trabalho, a diferença entre os modos dúctil e frágil no Torneamento com Ferramenta de Ponta Única de superfícies de silício monocristalino foram investigadas através da técnica de espalhamento Raman. Nas condições que proporcionam o regime dúctil, existem sempre uma amorfização superficial nas amostras, denunciadas através da ativação de uma banda óptica Raman mais larga em 470 cm-1. Esta fase amorfa pode ser considerada resultante da transição de fase a qual o silício pode ter sofrido. Por outro lado, para as condições onde o modo frágil é predominante, somente um pico óptico agudo de fonon em 521.6 cm-1 está presente no espectro Raman. Baseado nas medições que determinados parâmetros de corte, tais como a profundidade de corte e a espessura crítica do cavaco, apresentaram este estudo propõe que o regime dúctil não deve possuir uma faixa definida e fixa de valores para os parâmetros críticos mas, ao invés disso, estes seriam dependentes da extensão da camada transformada induzida por pressão/tensão gerada pela interação entre a ponta/aresta da ferramenta de corte com a peça durante a usinagem. Esta proposta se baseia na comparação entre os valores obtidos e os medidos por outros autores que mostram que a extensão da fase amorfa observada após processos de deformação mecânica (p.e., indentação, riscamento, polimento, nanoretificação e torneamento com ferramenta de ponta única de diamante) encontram-se na mesma faixa de valores encontrados para os parâmetros críticos (100-200 nm). Finalmente, foi demonstrado, através de observações da topografia de ambos, cavacos e superfícies geradas, realizadas com MEV e MFA, que este tipo de análise pode oferecer explicações significativas sobre os mecanismos de remoção de material em ação durante a usinagem e também sobre o estado microscópicos da ferramenta de diamante. / In recent years, considerable progress has been made on the study of the machinability of fragile materials such as semiconductors crystals, optical glasses, ceramics, etc., because of the demand for faster fabrication processes of complex surface shapes for optoelectronic applications. The ductility presented by single crystal silicon during machining has been explained by fracture mechanics theories. Recently, some new theories have been presented in order to give another justify to this ductility. It was proposed that semiconductors single crystal ductility is likely the end result of a pressure/stress induced phase transformation during cutting. In this work, the difference between ductile and brittle mode single-point diamond turning on the surface of machined silicon samples were investigated using Raman scattering. In the ductile mode conditions of machining, there are always an amorphization of the surface samples, denounced by the activation of the broad Raman optical band at 470 cm-1. This amorphous phase can be considered resulted from the phase transiton which silicon might have suffered. Contrary to the findings, in the brittle mode conditions, only the sharp optical phonon peak at 521.6 cm-1 is present in Raman spectra. Based on the observation that certain cutting parameters such as cutting depth and critical chip thickness, e.g., the point where ductile-to-brittle transition occurs, somehow presents values in the same range (100-200 nm) that the amorphous phase layer depth extension after mechanical deformation. (p.e., indentation, scratching, polishing, nanogrinding and single point diamond turning) observed in the literature, it is propposed that the ductile regime has not a definite range of values for the critical parameters but instead, it is dependent of the extension of the phase transformed layer induced by pressure/stress generated by the tool tip/edge interaction with workpiece during machining. Finally, it is shown that observation of topography and morphology of chip and the surface generated through SEM and AFM can offer very significant explanation of the material removal mechanisms in action during the current machining cut and diamond tool state.

The main content of of this thesis is a construction design and analysis of a machine for cutting tires. The resulting solution emerges from the design options and the option that meets the best selection criteria is chosen. Then the thesis stops for a while at the choice of cutting technology and tries to exemine its suitability for cutting tires. In its other part there is an attempt to clarify the relevant parts of the machine, where the benefits of three-dimensional views is used. Basic design and check calculations are done in the selected machine parts.