O objetivo no presente trabalho foi avaliar a fidelidade dimensional de troqueis de gesso tipo IV (Vel-Mix®), obtidos a partir de moldes de um único elastômero (Impregum® F), utilizando-se duas diferentes técnicas de moldagem (com casquete ou com moldeira de estoque). A fidelidade de cada troquel obtido foi avaliada através de uma coroa-padrão, a qual encaixava-se com alta precisão ao troquelpadrão, o qual era a estrutura original a ser moldada. Assim foram compostos os 4 seguintes grupos, com o aquecimento do molde não tendo sido efetuado apenas no primeiro deles: 1- do casquete de resina, sem contato com a porção cervical do troquel-padrão (Cstsa); 2- do casquete, também sem o referido contato (Cstca) ; 3- novamente do casquete, agora com contato (Cctca) e 4-. da moldeira de estoque perfurada (Mca). Com base nos resultados encontrados nas condições estabelecidas, após o respectivo tratamento estatístico, foi possível concluir que: 1 - o pior desempenho ocorreu com a moldeira perfurada, com um desajuste médio da ordem de 397, 70 micrometros; 2 - o casquete com toque e com aquecimento (desajuste médio de 85,37 micrometros) apresentou desempenho semelhante ao do casquete sem toque e sem aquecimento (desajuste médio de 102,38 micrometros) e 3 - o melhor desempenho ocorreu com o casquete sem toque e com aquecimento, com um desajuste médio de 0, 03 micrometros. / The aim in this study was to evaluate the dimensional accuracy of dies made with a type IV stone (Vel-Mix®) dies, obtained from moulds of a sole elastomer (Impregum® F), by employing 2 different moulding techniques, with a shell or with a perforated stock tray. Stone dies accuracy was measured by means of a standard crown which could be accurately fitted to the standard die, the original structure to be moulded. In this way, the following 4 groups were stablished, with the mould heating not being done only in the first of them: 1- with the acrylic resin shell cervically not contacting the standard die; 2- with the refered shell but without that contact; 3- once more with the shell, again with that contact and 3- with the stock tray. Under the stablished conditions, after statistical treatment of results, the following conclusions could be drawn: 1- worst performance was presented by the stock tray, with a 397,70 µm mean inaccuracy; 2- the shell performance with cervical contact and heated (85,37 µm mean inaccuracy) was similar to that of it without contact and without heating (102,38 µm mean inaccuracy) and 3- better performance was presented by shell without contact and with heating, with a 0,03 µm mean inaccuracy.

"Spray cooling has been important to control die temperature in forging processes for years. One area that has had little research is how thermal stresses in a metal are related to flow characteristics of the spray. Wyman-Gordon Corporation at its North Grafton MA facility uses spray cooling to cool their die after a forging process. The current system used is found to cause cracking along the surface of the impression in the die. The purpose of this project is to compare the nozzle system used by Wyman-Gordon to selected commercially available spray nozzles, and determine if there is a better spray cooling system than the one currently used. First the flow parameters, of Sauter mean diameter, particle velocity, and volumetric spray flux were experimentally found using a laser PDA system for four water driven nozzles, including the Wyman-Gordon nozzle, and one air-atomizing nozzle. The water atomizing nozzles were tested using pressures from 30 psi to 150 psi. For the air-atomizing nozzle, the water pressure was set at 60 psi and the air pressure was varied from 30 to 150 psi. Three nozzles were chosen, the Wyman-Gordon nozzle, the smaller orifice water atomizing nozzle, the air-atomizing nozzle, and an air stream, to conduct an inverse heat conduction experiment. Using the temperature gradients created by the cooling effects of each nozzle, the heat flux and induced thermal stresses were determined. The results showed the Wyman-Gordon nozzle was causing higher thermal stresses than the air/water and water nozzles. However, the air-atomizing nozzle and air stream, due to the high temperatures that the dies are subjected to, did not cool the die quick enough to be practical. The smaller orifice water atomizing nozzle proved to be the nozzle that would cool the surface of the dies within a practical time, and induce allowable thermal stresses, sufficiently enough below the yield strength of the die material. These results, although collected specifically to study the cooling of dies at Wyman-Gordon, could be generalized to include the cooling of any test piece with a high surface temperature. "

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1980. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING. / Bibliography: leaf 89. / by Bruce Alan Olsen. / M.S.

Na Odontologia, ao se confeccionar peças restauradoras dentárias, pela técnica indireta, o processo mais rotineiramente empregado utiliza um modelo de gesso, obtido a partir de um molde de elastômero, tomado de um dente preparado. Vários fatores podem influenciar na boa precisão de ajustes destas peças como o escoamento do material de vazamento dentro da moldagem, a compatibilidade do material de vazamento com o da moldagem, o tempo de presa, a estabilidade dimensional, a resistência mecânica do material quando da separação moldagem/modelo, a resistência a abrasão e a fidelidade de reprodução de detalhes. Materiais foram introduzidos na odontologia para utilização na confecção de troquéis no intuito de minimizar as desvantagens do gesso, como baixa resistência a abrasão e ligeira expansão de presa. Dentre eles os troquéis metalizados e as resinas epóxicas, que tem vantagens em relação às propriedades mecânicas, porém o primeiro exige técnica demorada e de alto custo e o segundo apresenta contração. O presente trabalho se propõe a testar uma nova composição de poliéster insaturado com estireno adicionado ao carbonato de cálcio em diferentes proporções (10, 20, 30, 40, 50, 60 e 70%) e compará-la ao gesso tipo IV e a resina epoxídica com óxido de alumínio, através de ensaios mecânicos, de abrasão e de alteração dimensional, para avaliar a possibilidade de sua utilização como material de confecção de troquéis para a construção de restaurações indiretas. Para caracterização dos materiais foram feitas análises de espectrometria no infravermelho, Calorimetria de varredura diferencial, termogravimétrica e Microscopia eletrônica de varredura. O compósito a base de poliéster insaturado com 50% de carbonato de cálcio se mostrou viável para utilização como material para troquel. Quando comparado aos materiais de controle mostrou propriedades mecânicas próximas as da resina epoxídica e bem superiores ao gesso, resistência a abrasão superior ao gesso e inferior a resina epoxídica e alteração dimensional próxima a resina epoxídica e maior ao gesso. Sendo a formulação do poliéster/carbonato de cálcio apenas constituída de polímero, catalisador e carga, é possível melhorar a formulação modificando a carga e/ou acrescentando aditivos visando minimizar a contração de polimerização. / In dentistry, the most commonly used procedure to manufacture indirect dental restorations uses a cast of type IV stone. This cast is made from an elastomeric impression of a prepared tooth. Many factors may influence the accuracy of adaptation of these restorations, such as the flow of the pouring material into the mold, the compatibility between the pouring and the impression materials, the setting time, the dimensional stability, the mechanical strength of the material during the mold / cast separation, the abrasion resistance and fidelity to reproduce details. Materials were introduced for preparing dies in order to minimize the disadvantages of the stone, such as its low resistance to abrasion and slight expansion of setting. These materials include metal-plated dies and epoxy resins, which have advantages concerning mechanical properties. However, the first one has a time-consuming technique and requires high costs while the second material shows shrinkage. This study tested a new composition of unsaturated polyester with styrene added to calcium carbonate in different proportions (10, 20, 30, 40, 50, 60 and 70%) and compared it to the type IV stone and to the epoxy resin with aluminum oxide. This comparison was made by mechanical, abrasion and dimensional changes tests in order to evaluate the possibility of using it as material for dies in the process of construction of indirect restorations. The materials were characterized using the analysis of the infrared spectrometry, differential scanning calorimetry, thermogravimetric and scanning electron microscopy. The composite based on unsaturated polyester with 50% calcium carbonate (P5) was considered viable as material for dies. When it was compared to the control materials the following results were found: a) the mechanical properties of P5 are similar to those ones of the epoxy resin and well above the stone ones; b) the abrasion resistance of this new material is lower in relation to the epoxy resin, but higher than the stone one; c) the values for dimensional changes were similar to the epoxy resin ones and superior to those ones found in stone. As the formulation of polyester / calcium carbonate only consists of a polymer, a catalyst and filler particles, it is possible to improve its composition by modifying the filler particles and / or adding additives to minimize the shrinkage of polymerization.

Manufacturing of dies has been presenting greater requirements of geometrical accuracy, dimensional precision and surface quality as well as decrease in costs and manufacturing times. Although proper cutting parameter values are utilized to obtain high geometrical accuracy and surface quality, there may exist geometrical discrepancy between the designed and the manufactured surface profile of the die cavities. In milling process / cutting speed, step over and feed are the main cutting parameters and these parameters affect geometrical accuracy and surface quality of the forging die cavities. In this study, effects of the cutting parameters on geometrical error have been examined on a representative die cavity profile. To remove undesired volume in the die cavities, available cutting strategies are investigated. Feed rate optimization is performed to maintain the constant metal removal rate along the trajectory of the milling cutter during rough cutting process. In the finish cutting process of the die cavities, Design of Experiment Method has been employed to find out the effects of the cutting parameters on the geometrical accuracy of the manufactured cavity profile. Prediction formula is derived to estimate the geometrical error value in terms of the values of the cutting parameters. Validity of the prediction formula has been tested by conducting verification experiments for the representative die geometry and die cavity geometry of a forging part used in industry. Good agreement between the predicted error values and the measured error values has been observed.

Thesis (M.S.)--Mississippi State University. Department of Mechanical Engineering. / Title from title screen. Includes bibliographical references.

published_or_final_version / Industrial and Manufacturing Systems Engineering / Master / Master of Philosophy

The actual industrial development linked to the financial situation over the world lead automotive and other companies to expand their production level to stay competitive. Changing an organization to raise its production or profit is not a one day journey, but requires some steps. Tools exist to develop the production level of manufacturing industry since more or less the fifties, and the continuous improvement is measured by some available and famous indicators around lean manufacturing mainly. Pressing equipment especially like a metal stamping press expressed through the following case study can be improved by respecting some fundamentals. Lean manufacturing aspects as 5 S’s and TPM (Total Productive Maintenance) for example are tools that can be applied to improve the production rate of a stamping press. To even better improve the OEE (Overall Equipment Effectiveness) of the same machine, a tool like SMED (Single Minute Exchange of Dies) reveals to be really powerful when improving the global output rate of the machine. The case study developed inside this present report aims to investigate all the possibilities to improve the OEE of pressing equipment facing theoretical aspects and reality issues. The tools involved are part of the content, but the way to support a company for the organizational change required to the success is another part of the content. Technical solutions are taking part of the outcome, and a strong link to change management is included. Correlation between both technical and managerial aspects is the main line followed to get the final results. An experimental and actual OEE is calculated, and improved following a rating according to the possible improvements. Those results are analyzed to provide a weighted feedback related to the whole research.

The motivation behind this study is the lack of specialized analysis regarding internal failure caused by the adiabatic shear hand (ASB) phenomenon in the cold-headed products. Its aim was to present an integrated workability study to improve and assist cold-heading (CH) multistage design procedures to replace the current design rules of thumb, as they are neither effective nor adequate in fulfilling the needs of the new developments in the rapidly expanding CH industry. / To achieve these goals, a comprehensive testing methodology and FE modeling, implemented within ABAQUS/Explicit, were established. This methodology includes an instrumented Drop Weight Compression Test (DWCT) tower equipped with a guided pocket die-set configuration capable of developing internal failure at different stages of ASBs and integrated metallographic inspection techniques. A validated FE model of the DWCT and guided pocket die-set configuration was a valuable tool in establishing the failure criteria and indicating the workability limits. / A detailed experimental and FE study for the ASB stages in the CH process was introduced to uncover the affect of different parameters controlling the failure mechanisms within the ASBs in the CH process. This study investigated the effect of the thermal, geometric and the material flow softening and hardening mechanisms affecting ASB evolution. Moreover, a detailed metallurgical and FE study of the internal ductile and Transformed Adiabatic Shear Band (TASB) failures caused by the ASB phenomenon in DWCT was conducted. / Three ductile failure criteria were introduced to predict the initiation and location of the internal ductile failure in the ASBs. One TASB failure criteria was introduced to predict the phase transformation to undesirable brittle martensite. These failure criteria were employed to establish integrated workability methodologies to indicate the objective workability limits. / Applying these workability methodologies on multistage CH FE models showed that these methodologies are an efficient tool to predict the damage levels and failure initiation locations within the cold-headed bolts. Moreover, these methodologies were successful in optimizing the die designs in order to reduce damage levels.

Thesis (Ph. D.)--Ohio State University, 2007. / Title from first page of PDF file. Includes bibliographical references (p. 265-278).