This work deals with operating production costs in machining process and further optimalization. In the first chapter, individual costs items which are related to machining process are specified. These cost items are quantified and total production costs are acquired. Optimalization of operation production costs are described for criterion of minimal production costs and criterion of maximal productivity are described in next chapter. Practical part of this work is focused to apply each individual criterion in practical example. There is CD with programs attached to this work. The goal is to find optimal combination of cutting speed, sufficient life time of cutting tool and suitable cutting technology so that chosen criterion can be acceptable.

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.

In this master thesis, performed at Sandvik Coromant Västberga (Stockholm), a comprehensive study has been made to investigate the wear on textured alumina (Inveio™) coated cutting tools when turning low-alloy steels. Specifically, wear studies have been made on tools’ rake faces when turning two separate batches of SS2541, after an initial turning time of 4 min. A particular focus has been given to elucidate what particular role the inclusions might have for the wear of the alumina coating onthe tools. Evaluation of tool wear has been made by employing several different analytical techniques, such as LOM, SEM, Wyko, Auger-spectrometry (AES), EPMA and XRD. The results shows that the arisen wear marks on both tested tool types may be divided into three separate and highly distinguishable wear zones, denoted here in thiswork as “wear bands”. Largest amount of wear tended to occur initially at the topmost part of the 3rd wear band. This was true for both tested tool types. This area demonstrated a characteristic 'lamellar' wear pattern, composed of narrow andstructured ridges. All the tools tested demonstrated the adhesion of workpiece materials of various composition that formed into smeared layers in these formed ridges. Depth-profiling Auger-spectrometry revealed that a significant amount of calcium was present in the machined alumina coating layers. This suggests that a reaction between the calcium-containing inclusions found in the steel and the aluminacoating layer had occurred during the performed turning tests.These results arecontradictory to the general belief that alumina is chemical inert during machiningand has previously, to the authors knowledge, not yet been published. Based on the results from this thesis and from a literature review concerning thebehavior of α-alumina during deformation, a new theoretical wear model has been developed. In this model, it is emphasised that the sliding of hard inclusions from the steel may activate pyramidal slip systems in the textured alumina coating. This causes a nano-crystallisation and/or amorphisation in the topmost part of the coating, which facilitates the further wear of these coated tools. / I detta examensarbete, som har utförts vid Sandvik Coromant i Västberga (Stockholm), har en omfattande studie gjorts i syfte att undersöka slitaget på texturerad aluminiumoxid-belagda skärverktyg (Inveio™) vid svarvningen av låglegerade stålsorter. Förslitningsstudier har framförallt gjorts på verktygens spånsidor vid svarvningen av två separata batcher av stålsorten SS2541 efter en inledande ingreppstid på 4 min. Ett särskilt fokus har även ägnats åt att belysa vilken roll stålets inneslutningar kan ha för slitaget av aluminiumoxidbeläggningen. Utvärderingen av verktygsslitaget har gjorts med hjälp av flera olika analytiska tekniker, däribland LOM, SEM, Wyko, Auger-spektrometri (AES), EPMA samt XRD. Resultaten från detta examensarbete visar på att det uppkomna slitaget på de verktyg som har testats kan uppdelas till tre separata och mycket distinkta ”slitagezoner”. Dessa zoner har för detta arbete benämnts som ”nötningsband”. Störst förslitning framträdde initialt i den översta delen av det 3:e nötningsbandet på de testade skärverktygen. Detta område uppvisade ett karaktäristiskt ”lamell”-liknande utseende, bestående av smala och strukturerade åsar och skåror. Vidare uppvisade samtliga undersökta verktyg på förekomsten av påsmetat arbetsmaterial av varierande sammansättning i dessa bildade åsar. När de slitna verktygen undersöktes med djuprofilerande Auger-spektrometri påvisades det att en signifikant mängd kalcium fanns inuti aluminiumoxidbeläggningen. Detta tyder på att en reaktion mellan de kalciuminnehållande inneslutningarna (som finns inuti stålet) och aluminiumoxidbeläggningen har reagerat med varandra under bearbetningsförloppet. Dessa resultat är motsägande till den allmänna uppfattningen om att aluminiumoxid är kemiskt inert vid bearbetningen av stål. Därutöver har dessa resultat även, till författarens kännedom, aldrig tidigare publicerats. Baserat på de resultat som har erhållits från detta examensarbete, och från en omfattande litteraturstudie gällande deformationen av α-aluminiumoxid, har en ny teoretisk förslitningsmodell utarbetats. I denna modell betonas det särskilt att glidningen av hårda inneslutningar från stålet kan aktivera s.k. pyramidala glidsystem i den texturerade aluminiumoxidbeläggningen. Detta orsaker en nano-kristallisering och/eller amorfisering av den översta delen av aluminiumoxidbeläggningen.  Denna omvandling tros kunna underlätta den fortsatta förslitningen av dessa belagda skärverktyg.

Les composites utilisés dans l'industrie aéronautique sont hétérogènes. Ils sont composés d'une matrice polymère souple et ductile et d'un renfort dur et fragile. Les différentes phases ainsi que l'anisotropie du matériau peuvent rendre l'usinage de ces matières, difficile. Deux problèmes majeurs peuvent être rencontrés lors de l'usinage : garder l'intégrité de la matière usinée et réduire l'usure de l'outil de coupe. Les niveaux de qualité demandés dans le secteur aéronautique imposent une coupe sans défaut, ces derniers pouvant entrainer une altération ultérieure de la pièce. Les principaux défauts rencontrés sont : le délaminage des plis, la surchauffe de la résine, les plis non coupés francs ou l'écaillage. / Aeronautic composites are inhomogeneous and most often consist in two distinctly phases. The reinforcement fibres are relatively hard and brittle whereas the matrix is soft and ductile. The anisotropy causes some severe challenges when machining composites. People in the field often experience a trade-off between two main problems ; on one hand, keeping the composite parts integrity and quality, and on the other hand, reducing the wear of the cutting tools. The quality level required in aeronautic applications imposes a high quality cut of machined parts. Common defects that may occur during machining of these materials are delamination, overheat of the resin, uncut fibres, and fibre pull-out.

L’étude présentée dans ce mémoire se focalise sur l’usinage de moules en matériaux composites, en considérant les problèmes d’état de surface et de gamme d’usinage. Les pièces de structure aéronautiques peuvent être obtenues par les procédés de fabrication de la famille LCM (Liquid Composite Molding). Ce procédé impose une température de fonctionnement élevée qui conduit à une dilatation du moule néfaste à la qualité de la pièce injectée. Pour remédier à ce problème, il est nécessaire de réaliser l’outillage dans un matériau à faible dilatation ou se comportant comme le matériau injecté. Pour cela, un matériau composite (Hextool™) est proposé en remplacement des moules métalliques conventionnels. L’étape d’usinage de forme est indispensable car elle donne les dimensions finales de l’outillage et conditionne le temps de polissage manuel nécessaire pour atteindre la rugosité arithmétique visée. Ce travail propose deux voies d’amélioration à travers l’étude micro-géométrique de l’opération de finition par outil coupant puis par outil abrasif. La première voie met en évidence l’existence d’une valeur minimale de rugosité accessible lors d’un usinage avec un outil coupant. L’analyse de ce phénomène permet de proposer une valeur de prise de passe radiale optimisant le ratio rugosité du moule / temps d’usinage. La deuxième conduit à la définition d’un outil abrasif utilisable sur un centre d’usinage. La faisabilité d’une telle opération et les capacités de cette technologie innovante sont discutées. Enfin, le choix des outils, des stratégies d’usinage et de la machine outil sont discutés et aboutissent à la proposition d’une gamme de référence pour l’usinage d’ébauche et de finition de moules en matériaux composites. / Presented research works deal with the milling of mold in composites materials, considering surface roughness and plan of procedure. Aeronautical structure parts could be produced by LCM (Liquid Composite Molding) processes. These processes induce high operating temperature for mold which is harmful for the dimensional quality of manufactured parts. In order to solve this problem, material with low heat elongation or with the same behavior as injected resin should be used for the mold. Thus, a composite material (Hextool ™) is proposed to replace conventional metallic molds. The milling operation produces the final dimensions of the tool and determines the time of manual polishing operation to reach the required arithmetic roughness. This work offers two ways of improvement through the study of micro-geometric surface finishing operation by cutting tool and then abrasive tool. The first way highlights the appearance of a minimum reachable value of roughness during machining with a cutting tool. The analysis of this phenomenon ensures to give an optimal value of radial depth of cut. Indeed, in this case, the best ratio surface quality / machining time is achieved. The second ensures to define an abrasive tool usable on a CNC machine tool. The feasibility of this operation and capabilities of this innovative technology are discussed. Finally, the choice of tools, machining strategy and machine tool are discussed and lead to the proposal of a reference process planning for composite molds roughing and finishing.

This thesis deals with design for manufacturing technology single part on machine FS, which is the connecting part. Work deals with the material of this component, therefore, cast iron with lamellar graphite, the properties of this material, primarily focusing on the machinability. Due to the shape and dimensions of the workpiece is also described problems cutting of box parts, the most common operations used in their manufacture, including cutting tools and materials. These findings are then applied in terms of the company TOS Kuřim - OS a.s. An analysis of current manufacturing technology and design is made for its amendment. In conclusion with the technical-economic evaluation.

Die Dissertation befasst sich mit der Optimierung des Schneidprozesses bei der Gesteinsgewinnung und der Erarbeitung eines Modells zur Prognose der relevanten Arbeitsgrößen unter Berücksichtigung der Abnutzung der Schneidwerkzeuge. Die Untersuchungen wurden mit Rundschaftmeißeln unterschiedlicher Verschleißzustände durchgeführt. Gegenstand der Untersuchungen waren die von den Schneidparametern abhängigen Größen wie Schneidkräfte, spezifische Energie, Staubmengenanteil und Stückigkeit des gewonnenen Gesteins. Es wurden die Auswirkungen des Meißelverschleißes auf die optimalen Schneidparameter festgestellt, denen beim Einsatz einer Gewinnungsmaschine oder bereits in der Konstruktionsphase des Gewinnungsorgans Rechnung getragen werden sollten.

Start-up företaget Wood Tube har utvecklat en ny typ av miljövänlig byggregel gjord av papper. Pappersreglar är en ny produkt som ännu inte finns på marknaden, men som kan komma att innebära stora fördelar för byggindustrin och snickare i fråga om pris, miljövänlighet och förbättrad arbetsmiljö. Det tänkta användningsområdet är att ersätta plåtreglar som ram i icke-bärande innerväggar, men det finns även stor potential i andra applikationer, såsom i möbler. Pappersreglarna tillverkas i standardlängder och ska kapas på plats ute på det aktuella bygget, i dagsläget genom sågning.  Detta projekt går ut på att utveckla ett specialanpassat kapningsverktyg som ska möjliggöra en enkel och smidig kapning av dessa reglar, i syfte att göra lösningen mer attraktiv för potentiella kunder. Inom detta projekt har enklare tester utförts som indikerar att klippning är den metod med störst möjlighet till måluppfyllelse. En kravspecifikation har tagits fram och innefattar bland annat att verktyget ska drivas utan el, vara portabelt, ej avge sågspån, motstå korrosion och kunna klippa pappersreglar av olika dimensioner.   Ett klippande sax-koncept väljs efter nyttjande av systematiska metoder för konceptgenerering och urval. Mycket inspiration till verktyget hämtas från konkurrentanalys av en grensax med kugg-utväxling av märket Fiskars. Egna tester har utförts för att ta reda på pappersreglarnas klippbarhet och kapningsverktygets tänkta lastfall. Konstruktionsarbetet utförs med Brain-Aided-Design (BAD), Pen-Aided-Design (PAD) och Computer-Aided-Design (CAD), och inkluderar även riskanalyser (FMEA) samt hållfasthetsberäkningar. Slutligen har ett specialiserat kapningsverktyg utvecklats för att snabbt och enkelt kunna klippa miljövänliga pappersreglar från Wood Tube. / Wood Tube is a start-up company with a new invention, environmental-friendly building bars made out of paper. The product is not yet available on the market, but these bars are likely to be a lot cheaper and easier to use for carpenters when building drywall, where the bars will replace the commonly used plate metal bars for framing. These bars are manufactured in standard lengths and are supposed to be cut on site to fit the local application. As of now they are sawn with a hand saw.  This project is about developing a new specialized cutting-tool for easy and fast cutting of the Wood Tube paper bars, with the idea that a customised tool will make the paper bars even more attractive to carpenters and other potential customers.  Tests indicate that cutting with shear-blades is the cutting method with the highest probability to meet the product requirements, which include requirements such as the tool being manually powered, highly portable, does not produce sawdust, is resistant to corrosion and being able to cut paper bars of different dimensions. Using systematic methods for generating concepts and the final selection, this results in a handheld scissors-concept, similar to a lopper. A lot of inspiration for the tool has come from the benchmarking of a lopper with gears  from the brand Fiskars. Tests have been performed to determine the cuttability of the paper bars, as well as to predict the loads which will be exerted on the cutting tool. The cutting tool is designed using the methods Brain-Aided-Design (BAD), Pen-Aided-Design (PAD) and Computer-Aided-Design (CAD), along with calculations for tool-strength and risk-analysis (FMEA).  The end result are blueprints for a tool which has been specifically developed for cutting paper bars from Wood Tube.

Dans l’industrie, les fabricants tendent à limiter la lubrification conventionnelle lors de l’usinage et s’orientent de plus en plus vers la microlubrification (MQL : Minimum Quantity Lubrication) pour des raisons économiques, écologiques et pour respecter la santé des opérateurs. Une très faible quantité de lubrifiant de faible pression nécessite une conception optimale des canaux internes de l’outil afin de limiter les pertes de charges et avoir les avantages de la microlubrification. Premièrement, une revue bibliographique introduit l’étude en présentant les avantages qu’induit le passage à la microlubrification. Par la suite, quelques conceptions d’outils avec une lubrification interne qui vise la face de coupe ou la face de dépouille de la plaquette sont passées en revue. / In machining industry, manufacturers tend to limit conventional lubrication and are moving increasingly towards Minimum Quantity Lubrication (MQL) for economic and ecological reasons, and with a view to safeguarding operator health and safety. A very small amount of lubricant at low pressure requires optimized design of the tools internal channels in order to minimize pressure drops and gain benefit from MQL. First, a literature review introduces the study by presenting the benefits induced by switching to MQL. Thereafter, some tool designs with internal lubrication for rake face or flank face lubrication are presented.

Application of clean and ultraclean steels have shown to provide favourable mechanical properties for bearings and transmission components, specifically regarding fatigue performance, compared to conventional steel grades. Clean steels are characterized by containing a very low level of non-metallic inclusions. While this characteristic is beneficial for the fatigue strength, inclusions in steels have shown to be favorable for the machinability and therefore challenges during machining of clean steels can arise. In this thesis the machinability and tool wear mechanisms of ultraclean steel have been evaluated during longitudinal turning. The aim of the study was to determine how steel cleanness and inclusions impact different machinability aspects. This was achieved by performing a comparative study of three steel grades with different level of cleanness and inclusions characteristics. Four machining experiments were executed investigating the chip breakability, cutting force, tool life and cutting tool coating degradation. The machined inserts were then analysed using light optical microscopy, secondary electron microscopy and electron probe microanalysis. The result revealed that the ultraclean steel grade has the overall worst machinability with the lowest chip breakability, highest cutting forces, and lowest tool life for the investigated steels. Additionally, it was found that the inserts that machined the ultraclean steel and the calcium treated steel was exposed to severe crater wear. However, the coating degradation causing the crater wear differs between the two grades. For the ultraclean steel the wear rate of the entire chemical vapor deposition coating is high. In contrast, for the calcium treated steel only the top alumina layer degrades rapidly and the underlying titanium carbonitride layer have a low wear rate. / Användning av rena och ultrarena stål har visat sig ge gynnsamma mekaniska egenskaper för kullager och transmissionskomponenter, speciellt gällande utmattningsprestanda, jämfört med konventionella stålsorter. Rena stål kännetecknas av att de innehåller en mycket låg nivå av icke-metalliska inneslutningar. Denna egenskap är fördelaktig för utmattningshållfastheten, men däremot har inneslutningar i stål visat sig vara gynnsamma för bearbetbarheten och därför kan utmaningar uppstå vid bearbetning av rena stål. I detta arbete har bearbetbarheten och verktygsslitagemekanismerna för ultrarent stål utvärderats under längsgående svarvning. Syftet med studien var att fastställa hur stålets renhet och inneslutningar påverkar olika bearbetningsaspekter. Detta uppnåddes genom att utföra en jämförande studie av tre stålsorter med olika renhetsgrad samt inneslutningar. Fyra bearbetningsexperiment utfördes för att undersöka spånbrytbarheten, skärkraften, verktygets livslängd och nerbrytningen av skärverktygets beläggning. De bearbetade skären analyserades sedan med användning av ljusoptisk mikroskopi, svepelektronmikroskopi och elektronprobmikroanalys. Resultatet visade att den ultrarena stålsorten har den totalt sett sämsta bearbetbarheten med lägst spånbrytbarhet, högsta skärkrafter och lägsta verktygslivslängd av de undersökta stålen. Dessutom upptäcktes att skären som bearbetade det ultrarena stålet och det kalciumbehandlade stålet utsattes för kraftigt kraterslitage. Nedbrytningen av verktygs beläggningen som orsakar kraternötningen skiljer sig dock mellan de två stålkvaliteterna. För det ultrarena stålet är slitagehastigheten för hela beläggningen hög. För det kalciumbehandlade stålet bryts däremot endast det övre aluminiumoxidskiktet ned snabbt och det underliggande titankarbonitridskiktet har en låg nötningshastighet.