This thesis presents a detailed analysis of the plane rake faced drill design, its grinding method and grinding wheel geometry. A fundamental geometrical analysis has then been carried out on the major cutting edges of the modified drills according to the national and international standards. It has been shown that this new drill design results in a significant increase in the normal rake angle at lips as well as point relieving at the chisel edge region. Geometrical models for the various drill point features have been established which uniquely define the drill point features of the modified drill design. A comprehensive experimental investigation has been carried out to study the drilling performance of the modified drills, when drilling a high tensile steel, ASSAB 4340, with TiN coated high speed steel drills over a wide range of drilling conditions. Comparing to the drilling performance with conventional twist drills under the corresponding conditions, it has been found that the modified drills can reduce the thrust force by as much as 46.9% with the average of 23.8%; the reduction of drilling torque is also significant at an average of 13.2% and the maximum of 24.9%. Similarly, the new drill design shows great superiorities over the conventional drills in terms of drill-life. In the drill-life tests, a few conventional drills were broken, but all plane rake faced drills performed very well. In order to estimate the cutting performance in process planning on a mathematical and quantitative basis when drilling with the modified drills, predictive cutting force models have been developed based on the unified-generalized mechanics of cutting approach. The models have been assessed qualitatively and quantitatively and showed good agreements with the experimental thrust, torque and power. Empirical-type force equations have also been developed to provide simple alternatives for practical applications.

This thesis presents a detailed analysis of the plane rake faced drill design, its grinding method and grinding wheel geometry. A fundamental geometrical analysis has then been carried out on the major cutting edges of the modified drills according to the national and international standards. It has been shown that this new drill design results in a significant increase in the normal rake angle at lips as well as point relieving at the chisel edge region. Geometrical models for the various drill point features have been established which uniquely define the drill point features of the modified drill design. A comprehensive experimental investigation has been carried out to study the drilling performance of the modified drills, when drilling a high tensile steel, ASSAB 4340, with TiN coated high speed steel drills over a wide range of drilling conditions. Comparing to the drilling performance with conventional twist drills under the corresponding conditions, it has been found that the modified drills can reduce the thrust force by as much as 46.9% with the average of 23.8%; the reduction of drilling torque is also significant at an average of 13.2% and the maximum of 24.9%. Similarly, the new drill design shows great superiorities over the conventional drills in terms of drill-life. In the drill-life tests, a few conventional drills were broken, but all plane rake faced drills performed very well. In order to estimate the cutting performance in process planning on a mathematical and quantitative basis when drilling with the modified drills, predictive cutting force models have been developed based on the unified-generalized mechanics of cutting approach. The models have been assessed qualitatively and quantitatively and showed good agreements with the experimental thrust, torque and power. Empirical-type force equations have also been developed to provide simple alternatives for practical applications.

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / The growing demand for energy that causes the increased traffic of agricultural machinery, larger and more robust, acts negatively on soil compaction, directly and indirectly affecting crop productivity, as many changes in soil physical attributes. As a potential technique to solve this problem has the chiseling, which promotes the disruption of these compacted layers, without causing the inversion of the soil, keeps the plant residues deposited on the surface, improves infiltration, the structure and porosity of the soil and thus facilitates erosion control. However this operation has a high demand for traction. Seeking a more efficient operation of scarification, ie, better utilization of energy, developed and evaluated a tool to break ground in layers simultaneously. For this purpose it was necessary to construct a Structure-Port Mobile Tools capable of performing experimental procedures resulting from the planned treatments. As a mobile source of power was used a Massey Ferguson tractor model MF 275 with 53 kW. The experiment was conducted in the Municipality of Capon Beautiful South, Rio Grande do Sul, in a clayey soil. As a general objective, we sought to answer the following questions: (i) is there any significant difference between chiseling in a single layer or more than one layer, considering the average horizontal force on the drawbar, the specific resistance and the average hourly fuel consumption as criteria for each level of speed? (Ii) how the deepening affects the average horizontal force in the drawbar? And (iii) acts as the advance on the soil area mobilized? Configurations were tested with chiseling of the soil in one, two and three layers, with variations in longitudinal distances between the tips of the spikes. The chiseling treatments in two concurrent 0,15 meters layers and longitudinal distance between the tip ends of 0,30 and 0,40 meters, with one in 0,10 meter of deepening and 0,30 meters advancing presented as the most promising. It was concluded at the end of this work, considering all the tested configurations, there are combinations of deepening, advancing and speed, which proved more efficient than chiseling a single layer. / A crescente demanda de energia que ocasiona o aumento do tráfego de máquinas agrícolas, maiores e mais robustas, atua negativamente na compactação do solo, afetando direta e indiretamente a produtividade das culturas, pois modifica diversos atributos físicos do solo. Como técnica potencial para solucionar este problema tem-se a escarificação, que promove o rompimento dessas camadas compactadas, sem ocasionar a inversão do solo, mantém os resíduos vegetais depositados na superfície, melhora a infiltração, a estrutura e a porosidade do solo e facilita assim o controle da erosão. Contudo esta operação apresenta elevada demanda de tração. Visando uma operação de escarificação mais eficiente, ou seja, com maior aproveitamento de energia, desenvolveu-se e avaliou-se uma ferramenta para o rompimento do solo em camadas, de forma simultânea. Para tanto foi necessária a construção de uma Estrutura Porta-Ferramentas Móvel, capaz de executar os procedimentos experimentais decorrentes dos tratamentos planejados. Como fonte móvel de potência foi utilizado um trator marca Massey Ferguson, Modelo MF 275 com 72 CV (53 kW) de potência. O experimento foi conduzido no Município de Capão Bonito do Sul, Rio Grande do Sul, em um solo de textura muito argilosa. Como objetivo geral, buscou-se responder às seguintes perguntas: (i) existe alguma diferença significativa entre a escarificação em única camada ou em mais de uma camada, considerando a força horizontal média na barra de tração, a resistência específica e o consumo horário médio de combustível como critérios, para cada nível de velocidade? ; (ii) de que forma influi o aprofundamento (espessura das camadas) na força horizontal média na barra de tração? ; e (iii) como atua o avanço (distância longitudinal entre as ponteiras das hastes), sobre a área de solo mobilizada? Foram testadas configurações com escarificação do solo em uma, duas e três camadas, com variações nas distâncias longitudinais entre as pontas das ponteiras. Os tratamentos com escarificação em duas camadas simultâneas de quinze centímetros e distância longitudinal entre as pontas das ponteiras tanto de trinta quanto de quarenta centímetros, juntamente com aquele com aprofundamento de dez e avanço de trinta centímetros apresentaram-se como mais promissores. Concluiu-se ao final deste trabalho, considerando todas as configurações testadas, que existem combinações de aprofundamento, avanço e velocidade, que revelaram-se mais eficientes que a escarificação em camada única.

Orientador: Marco Lúcio Bittencourt / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-24T09:08:40Z (GMT). No. of bitstreams: 1 LimaeSilva_RafaelAugustode_M.pdf: 10555723 bytes, checksum: 1d037ebafbabc24e214c06ad76c5f54a (MD5) Previous issue date: 2013 / Resumo: O trabalho descreve o projeto mecânico convencional de uma biela automotiva de motor de combustão interna e apresenta uma metodologia alternativa baseada em métodos de otimização estrutural com o objetivo de reduzir a massa do componente. Para tal, é feita a descrição de todos os parâmetros de projeto assim como a definição de critérios de projeto. Em virtude da criticidade da aplicação selecionada, motor de ciclo Diesel utilizado em caminhões de trabalho pesado com picos de pressão de combustão de até 240 bar, a biela foi projetada sem bucha utilizando-se extensivamente os métodos numéricos. O Método dos Elementos Finitos foi aplicado para cálculo de tensões, deslocamentos, pressões de contato, flambagem, fadiga e para a síntese modal de componentes utilizados na análise dinâmica de multicorpos com mancais elasto-hidrodinâmicos. Dois modelos de fadiga dos materiais foram estudados: o modelo americano baseado no diagrama de Goodman e tensões principais e o modelo alemão baseado no diagrama de Haigh e efeito do gradiente de tensões multiaxiais; dos quais concluiu-se que o modelo americano é suficiente para o projeto da biela ao passo que o modelo alemão traz oportunidades adicionais de redução de massa. A otimização topológica, otimização de forma e análise de sensibilidade permitiram a obtenção de uma biela 210g (3\%) mais leve e com melhor desempenho dos mancais hidrodinâmicos. Finalmente, concluiu-se que o Método da Otimização Topológica apresenta oportunidades interessantes aos projetistas na fase de conceituação de produtos como alternativa aos desenhos convencionais, no entanto, demanda esforço adicional para o atendimento de todos os critérios de projeto do componente / Abstract: The present work consists of the conventional mechanical design description of an internal combustion engine connecting rod and also the proposal of an alternative methodology based on optimization methods with the objective of reducing the component mass. Therefore, it is performed a detailed view of all design parameters as well as the definition of design criteria. Because of the critical application selected, Diesel engine of heavy duty truck with combustion pressure reaching up to 240bar, the connecting rod was designed without bushing and with extensive use of numerical methods. The Finite Element Method was applied to assess stresses, displacements, contact pressures, buckling, fatigue and to perform the Component Modal Synthesis for multi-body dynamics simulation with elasto-hydrodynamic bearings. Two fatigue models were studied: the American model based on Goodman's diagram and principal stresses and the German model based on Haigh's diagram and multiaxial stress gradient effect; from which it was concluded that the American model is enough to design the connecting rod, while the German model presents additional weight reduction opportunities. The topology optimization, shape optimization and sensitivity analysis enabled a 210g (3\%) lighter connecting rod with improved bearings performance. Finally, it was concluded that the Topology Optimization Method presents good opportunities for the design engineers in the conceptual phases of product development with alternatives to the conventional designs. However, additional effort is necessary to fit the concept into all design criteria / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica

Indiana University-Purdue University Indianapolis (IUPUI) / This thesis concentrates on the study of hybrid gas journal bearings (bearings with externally pressurized mass addition). It differs from most work in that it goes back to “basics” to explore the hydrodynamic phenomena in the bearing gap. The thesis compares geometrically identical bearings with 2 configurations of external pressurization, porous liners where mass-addition compensation is varied by varying the liner’s permeability, and bushings with 2 rows of 6 feedholes where the mass-addition compensation is varied by the feedhole diameter. Experimentally, prototype bearings with mass-addition compensation that spans 2 orders of magnitude with differing clearances are built and their aerostatic properties and mass addition characteristics are thoroughly tested. The fundamental equations for compressible, laminar, Poiseuille flow are used to suggest how the mass flow “compensation” should be mathematically modeled. This is back-checked against the experimental mass flow measurements and is used to determine a mass-addition compensation parameter (called Kmeas) for each prototype bushing. In so doing, the methodology of modeling and measuring the mass addition in a hybrid gas bearing is re-examined and an innovative, practical, and simple method is found that makes it possible to make an “apples-to-apples” comparison between different configurations of external pressurization. This mass addition model is used in conjunction with the Reynolds equation to perform theory-based numerical analysis of virtual hybrid gas journal bearings (CFD experiments). The first CFD experiments performed use virtual bearings modeled to be identical to the experimental prototypes and replicate the experimental work. The results are compared and the CFD model is validated. The ontological significance of appropriate dimensionless similitude parameters is re-examined and a, previously lacking, complete set of similitude factors is found for hybrid bearings. A new practical method is developed to study in unprecedented detail the aerostatic component of the hybrid bearings. It is used to definitively compare the feedhole bearings to the porous liner bearings. The hydrostatic bearing efficiency (HBE) is defined and it is determined that the maximum achievable hydrostatic bearing efficiency (MAHBE) is determined solely by the bearing’s mass addition configuration. The MAHBE of the porous liner bearings is determined to be over 5 times that of the feedhole bearings. The method also presents a means to tune the Kmeas to the clearance to achieve the MAHBE as well as giving a complete mapping of the hitherto misunderstood complex shapes of aerostatic load versus radial deflection curves. This method also rediscovers the obscure phenomenon of static instability which is called in this thesis the “near surface effect” and appears to be the first work to present a practical method to predict the range of static instability and quantify its resultant stiffness fall-off. It determines that porous liner type bearings are not subject to the phenomenon which appears for feedhole type bearings when the clearance exceeds a critical value relative to its mass-addition compensation. The standing pressure waves of hydrostatic and hybrid bearings with the 2 configurations of external pressurization as well as a geometrically identical hydrodynamic bearing are studied in detail under the methodology of the “CFD microscope”. This method is used to characterize and identify the development, growth, and movement of the pressure wave extrema with increased hydrodynamic action (either increasing speed or increasing eccentricity). This method is also used to determine the “cause” of the “near surface effect”. A gedanken experiment is performed based on these results which indicates that a bearing with a “stronger aerostatic strength” component should be more stable than one with a low aerostatic strength component. Numerical instability “speed limits” are found that are also related to the hydrostatic strength of the bearing. The local conditions in the standing waves are characterized in terms of their local Mach number, Knudsen number, Reynolds number, and Taylor Number. It is concluded that low eccentricity bearing whirl can be attributed to the off load-line orientation of the bearing load force caused by the overlay of the hydrodynamic bearing standing wave onto the hydrostatic bearing wave of the hybrid bearing, whereas it is hypothesized that aperiodic and random self-excited vibration which occurs at high eccentricity, as reported in the literature, is probably due to shock waves, turbulence, near surface effect, and slip at local areas of the standing wave.