The development of glass substrates for use as an alternative to printed circuit boards (PCBs) attracts significant industrial attention, because of the potential for low cost but high performance interconnects and optical connection. Electroless plating is currently used to deposit conductive tracks on glass substrates and the quality of copper / glass adhesion is a key functional issue. Without adequate adhesive strength the copper plating will prematurely fail. Existing studies have covered the relationship between surface roughness and adhesion performance, but few of them have considered the detail of surface topography in any depth. This research is specifically considering the mechanical contribution of the glass surface texture to the copper / glass adhesive bond, and attempting to isolate new ISO 25178 areal surface texture parameters that can describe these surfaces. Excimer laser machining has been developed and used to create a range of micro pattern structured surfaces on CMG glass substrates. Excimer mask dimensions and laser operation parameters have been varied and optimized according to surface topography and adhesion performance of the samples. Non-contact surface measurement equipment (Zygo NewView 5000 coherence scanning interferometry) has been utilized to measure and parameterize (ISO 25178) the surface texture of the glass substrates before electroless copper metallization. Copper adhesion quality has been tested using quantitative scratch testing techniques, providing an identification of the critical load of failure for different plated substrates. This research is establishing the statistical quality of correlation between the critical load values and the associated areal parameters. In this thesis, the optimal laser processing parameter settings for CMG glass substrate machining and the topographic images of structured surfaces for achieving strong copper / glass plating adhesion are identified. The experimental relationships between critical load and areal surface parameters, as well as the discussions of a theoretical approach are presented. It is more significant to consider Sq, Sdq, Sdr, Sxp, Vv, Vmc and Vvc to describe glass substrate surface topography and the recommended data value ranges for each parameter have been identified to predict copper / plating adhesion performance.

It has been reported that minimum quantity lubrication (MQL) provides better tool life compared to flood cooling under some drilling conditions. In this study, I evaluate the performance of uncoated HSS twist drill when machining AISI 1018 steel using a newly developed lubricant designed for MQL (EQO-Kut 718 by QualiChem Inc.). A randomized factorial design was used in the experiment. The results show that a tool life of 1110 holes with a corresponding flank wear of 0.058 mm was realized.

During the traditional manufacturing route, there are large amount of titanium alloys wasted in the form of machining chips. The conventional recycling methods require high energy consumption and capital cost. Equal channel angular pressing (ECAP), one of the severe plastic deformation techniques, has been developed to recycle the metallic machining chips. The purpose of the PhD work is to realize the ECAP recycling of titanium alloys, in particular Ti-6Al-4V and Ti-15V-3Cr-3Al-3Sn, and investigate the effects of processing parameters on the resultant relative density, microstructure evolution, texture development and microhardness homogeneity. The microstructures of Ti-6Al-4V and Ti-15V-3Cr-3Al-3Sn machining chips obtained from conventional turning (CT) and ultrasonically assisted turning (UAT) were initially investigated. It was found that ultrafine grains were formed in the primary and secondary shear zones. For Ti-6Al-4V chips, the β phase in the shear zones was refined into nano-sized equiaxed grains and aligned up to form banded structures. For Ti-15V-3Cr-3Al-3Sn chips, the nano-crystalline grains were enveloped in the shear zones and have clear boundaries to the surrounding matrix. It was observed that in terms of microstructure, there is no significant difference between CT and UAT chips. Recycling of Ti-6Al-4V machining chips was carried out at moderate temperatures with various back-pressures. For single-pass samples, the relative density was increased with the applied back-pressure and operating temperature. It was found that after multiple passes, near fully dense recycled Ti-6Al-4V can be fabricated. The microstructure observations showed that the nano-sized equiaxed and elongated grains co-existed with relatively coarser lamellar structures which were initially refined after the first pass. In the subsequent passes, the fraction of equiaxed nano-grains increased with the number of passes. The original β phase banded structures were fragmented into individual nano-sized grains randomly distributed within α matrix. The chip boundaries were eliminated and nano-crystalline microstructure region was observed at the chip/chip interface after multiple passes. In the sample processed at 550 °C, < a →+c → > type dislocations were observed and oxide layer at chip/chip interface was detected. The texture evolution was investigated using electron backscatter diffraction. It was found that the recycled samples performed a strong basal texture along the normal to ECAP inclination direction after the first pass. After multiple passes, in addition to the normal to inclination direction, the recycled Ti-6Al-4V exhibits a basal texture towards the transverse direction. Microhardness mapping showed that the average hardness and degree of homogeneity were increased with number of passes, while the imposed back-pressure had little effect on the average value and homogeneity. Recycling of Ti-15V-3Cr-3Al-3Sn machining chips was implemented using similar ECAP conditions. The effects of processing parameters, such as back-pressure, operating temperature and number of passes, on the relative density were similar to those for Ti-6Al-4V. Microstructural characterization showed that equiaxed instead of needle shaped α precipitates formed in the β matrix due to the high dislocation density and sub-grain boundaries introduced during ECAP. In terms of microhardness, the maximum hardness was obtained at the specimen pressed at 450 °C. It was found that the applied back-pressure and number of passes enabled to improve the homogeneity, but had little effect on the average hardness.

Doctor of Philosophy / Department of Industrial & Manufacturing Systems Engineering / Zhijian Pei / High-performance materials, such as silicon, aerospace stainless steels, titanium alloys, and carbon fiber reinforced plastic (CFRP) composites, have a variety of engineering applications. However, they usually have poor machinability and are classified as hard-to-machine materials. Drilling is one of the important machining processes for these materials. Industries are always under tremendous pressure to meet the ever-increasing demand for lower cost and better quality of the products made from these high-performance materials. Rotary ultrasonic machining (RUM) is a non-traditional machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining. It is a relatively low-cost, environment-benign process that easily fits in the infrastructure of the traditional machining environment. Other advantages of this process include high hole accuracy, superior surface finish, high material removal rate, low tool pressure, and low tool wear rate. The goal of this research is to provide new knowledge of machining these high performance materials with RUM for further improvement in the machined hole quality and decrease in the machining cost. A thorough research in this dissertation has been conducted by experimental, numerical, and theoretical investigations on output variables, including cutting force, torque, surface roughness, tool wear, cutting temperature, material removal rate, edge chipping (for silicon), power consumption (for CFRP), delamination (for CFRP), and feasible regions (for dry machining of CFRP). In this dissertation, an introduction of workpiece materials and RUM are discussed first. After that, two literature reviews on silicon drilling and dry drilling are presented. Then, design of experiment and finite element analysis on edge chipping in RUM of silicon, experimental investigations and finite element analysis on RUM of aerospace stainless steels, an ultrasonic vibration amplitude measurement method and a cutting temperature measurement method for RUM using titanium alloys as workpiece, experimental and theoretical investigations on RUM of CFRP composites, and experimental studies on CFRP/Ti stacks are presented, respectively. Finally, conclusions and contributions on RUM drilling are discussed.

OBJECTIVE: The purpose of this in vitro study was to evaluate the cutting performance and accuracy of CAD/CAM diamond burs in different chemo-mechanical conditions when machining yttria-stabilized zirconia (YTZ), lithium-disilicate, feldspathic porcelain, and double network hybrid ceramic material. The study also examined bur wear mechanisms. MATERIALS AND METHODS: Two experiments were performed. Experiment 1: 45 samples of each material were milled, and four criteria were tested: milling time; surface roughness; change in bur weight after machining, and total cement space. Experiment 2: Four different coolant liquids were used while machining 15 samples of lithium-disilicate, feldspathic porcelain, and double network hybrid ceramic material. The four criteria in Experiment 1, plus marginal adaptation, were measured. Burs and ceramic materials used were examined with SEM before and after machining. RESULTS: Experiment 1: All burs milled 15 crowns of each material successfully, with a general increase in milling time and decrease in weight. Four wear patterns were identified: grit cracks, micro-fractures, dislodgement, and matrix abrasion. Sequential milling time increased for all of the ceramic materials. Surface roughness (Ra) decreased in general for all materials used in the study except YTZ, which showed an increase in Ra by the end of the machining series. Experiment 2: Additives used in this study had no significant effect on IPS e.max CAD milling efficiency or Ra. Boric acid reduced Vita MarkII machining time significantly and Ra. CONCLUSIONS: The cutting rate of diamond burs differed when machining different ceramic materials. In sequential machining, every consecutive milling demonstrated lower cutting efficacy. The surface roughness of consecutive machined samples differed. Some cooling liquids affected the quality of the machined surface. The bur wear mechanism was the same when different ceramic materials were machined, and their microstructure affected their machinability. / 2019-09-26T00:00:00Z

O estudo das forças de corte em usinagem tem várias aplicações, tais como definir a melhor geometria da ferramenta e sua interação com a peça. Este trabalho apresenta os resultados de simulações do processo de torneamento utilizando o método dos elementos finitos no corte ortogonal em aço AISI 4340 usando insertos de metal duro, comparando-os com resultados experimentais. As simulações foram realizadas no programa comercial Abaqus/Explicit TM considerando os efeitos térmicos do processo oriundos tanto da deformação do material quanto dos atritos nas interface peça-ferramenta-cavaco. As variáveis do processo estudadas foram a velocidade de corte e o avanço. Os resultados da força de corte simulada mostraram-se bem próximos daqueles obtidos experimentalmente, com erro médio em torno de 5%, enquanto que os da força de avanço apresentaram erro médio de cerca de 27%. / Cutting force is a very important parameter, which can be used to determine tool geometry and its interaction with the workpiece. This work presents some orthogonal cutting simulations using Abaqus/Explicit TM finite element methods code with carbide tool on an AISI 4340 hardened steel workpiece. Comparison with experimental results are also carried out. The simulation considers the thermal effect caused by material deforming and friction between tool, workpiece and chips. The main parameters changed during the simulations are the cutting speed and the feed rate. As results, the simulated cutting forces showed an error around 5% and the simulated feed forces about 27% when compared to the experimental values.

Vários fatores, tais como custos, qualidade, flexibilidade e tempo de resposta, levam a vantagens competitivas. Nas indústrias do ramo metal mecânico, os fatores custos e qualidade estão intimamente ligados ao surgimento de novos materiais de difícil usinagem (cujos comportamentos ainda são desconhecidos), e como conseqüência o surgimento de novos e caros materiais de ferramentas juntamente com as exigências de alta produção, lotes variados, faixas de tolerâncias cada vez mais estreitas e baixos custos de produção, o que têm extrapolado os limites e habilidades de operadores de máquinas. Quanto aos fatores flexibilidade e tempo de resposta, as indústrias têm apontado uma grande necessidade de informações confiáveis sobre desempenho da produção e informações sobre parâmetros tecnológicos das máquinas-ferramenta. Sistemas de apontamentos manuais mostram-se deficientes, quanto à confiabilidade, velocidade de atualização, detecção de não conformidades e outros fatores prejudiciais à produção, além de gerarem redundância de trabalho na coleta e alimentação de bancos de dados. O sistema proposto contribui para a satisfação dessas necessidades, utilizando-se de tecnologias de comunicação e de aquisição de dados, que propicia o monitoramento e supervisão de processos de torneamento. Permite o monitoramento da qualidade dimensional e indiretamente do desgaste de ferramentas, e ainda o compartilhamento de informações de chão de fábrica, em tempo real, para qualquer localidade via intranet e/ou internet, auxiliando na integração do sistema de manufatura. / Several factors, such as costs, quality, flexibility and response time, influence the competitive advantages. In the metal working industries, the factors cost and quality are closely linked to the appearance of new materials difficult to machine (whose behaviors are still ignored). As a consequence, the appearance of new and expensive tool materials, together with the demands for high production, varied batches, range of tolerances more and more narrow and low production costs, what have been extrapolating the limits and abilities of operator’s machine. With regards to the factors flexibility and response time, industries have been pointing to a need for reliable information about production performance and about machine-tools technological parameters. Systems of manual appointments are subject to lack of reliability, up date, detection of non conformities and other factors affecting negatively the production system. Additionally, they can generate work redundancy in the acquisition and database feeding. The proposed system contributes to achieve that need using communication and data acquisition technologies, that allows the monitoring and supervision of turning processes. It allows the monitoring of the dimensional quality and indirectly tools wear, as well as sharing shop floor information, in real time, with any place through intranet and/or Internet, aiding the integration of the manufacturing system.

O objetivo do trabalho foi fabricar ferramentas de corte para usinagem a partir de materiais em gradação funcional (Functionally Graded Materials FGM), fazendo uso da técnica de sinterização por plasma pulsado (Spark Plasma Sintering SPS), a qual permite taxa de aquecimento e resfriamento maior do que as técnicas tradicionais, menor temperatura e tempo de operação, melhor controle energético e alta repetibilidade. Os materiais utilizados foram pós cerâmicos a base de alumina (Al2O3-ZrO2 e Al2O3-TiC) e metal duro (WC-Co), de modo que dois insertos foram desenvolvidos, um de cerâmica branca (Al2O3-ZrO2) em gradação com metal duro e outro de cerâmica mista (Al2O3-TiC) em gradação com metal duro. A metodologia experimental levou em conta a aplicação de um modelo termomecânico para estimar a tensão residual térmica ao longo da espessura da ferramenta, estudo da influência dos parâmetros de sinterização por SPS (Temperatura e Pressão) sobre a qualidade do sinterizado (caracterização da propriedade física, densidade), com base nesses dados foi escolhida a melhor condição de operação para fabricar corpos de prova (CPs) para os ensaios mecânicos de resistência à flexão, dureza e tenacidade à fratura, além de insertos em FGM para os ensaios de usinagem em ferro fundido cinzento fazendo uso da operação de torneamento. Os resultados mostraram que o parâmetro de máquina que mais influenciou a densidade foi a Temperatura, os FGMs de AlTiC e AlZr obtiveram um aumento de 126 e 73% na resistência à flexão em relação às suas respectivas cerâmicas homogêneas, seguindo a sequência dos materiais, a dureza foi avaliada em 13,8 e 15,8 GPa, enquanto a tenacidade à fratura em 4,91 e 5,04 MPa.m1/2. Quanto aos ensaios de usinagem, as ferramentas de FGM AlZr apresentaram menor desgaste do que as de FGM AlTiC, as forças de corte foram influenciadas pelas variáveis Avanço e Velocidade de corte, finalmente, o Avanço foi a variável que mais influenciou os resultados de rugosidade. / The aim was fabricating cutting tools from functionally graded materials (FGM) by spark plasma sintering method (SPS), which allow heating and cooling rates higher than traditional methods, lower temperature and shorter time sintering, better energy control and high reproducibility. The materials used were ceramic powders based on alumina (Al2O3-ZrO2 and Al2O3-TiC) and cemented carbide (WC-Co), so that two inserts were developed, one of white ceramic (Al2O3-ZrO2) graded with cemented carbide and the other of mixed ceramic (Al2O3- TiC) graded with cemented carbide. The experimental methodology was developed from thermo-mechanical model application to estimate thermal residual stress along with tool thickness, study into the influence of SPS sintering parameters (Temperature and Pressure) over sintered quality (physical properties characterization, density), on the basis of these data, the best operating condition was chosen to fabricate workpieces for mechanical tests of flexural strength, hardness and fracture toughness, besides FGM inserts to machining tests in grey cast iron using turning operation. The results showed the machine parameter that mostly influenced density was Temperature; the AlTiC and AlZr FGMs got an increase of 126 and 73% in flexural strength in relation to their homogeneous ceramics. Following the materials sequence, the hardness was evaluated at 13.8 and 15.8 GPa, whereas the fracture toughness was 4.91 and 5.04 MPa.m1/2. For the machining tests, FGM AlZr cutting tools showed lower wear than FGM AlTiC ones; the cutting forces were influenced by Feed Rate and Cutting Speed. Finally, the Feed Rate was the variable that mostly influenced the roughness results.

Este trabalho discute as alterações micro-estruturais superficiais nos aços usinados por torneamento duro. Uma estrutura não aceita metalurgicamente, chamada de Camada Branca (\"White Layer\" - WL), é freqüentemente encontrada na superfície torneada. A presença desta camada branca depende dos parâmetros do processo de corte, especialmente do desgaste da ferramenta e da velocidade do corte. A formação da camada branca foi investigada no presente trabalho na face plana inferior de um anel de rolamento fabricada com o aço DIN 100Cr6, usinada por torneamento duro no estado temperado e revenido (dureza 60HRC). A profundidade foi medida usando as técnicas padrões metalográficas. As propriedades mecânicas da camada superficial (módulo de rigidez, E, e microdureza Vickers, HV) foram estimadas pelo método de microidentação instrumentada em uma amostra isenta da camada branca e em duas outras amostras, com camadas brancas de diferentes espessuras (respectivamente 7 e 12 mm de espessura). De acordo com a literatura a profundidade da camada branca aumenta de acordo com o desgaste da aresta da ferramenta. Este por sua vez aumenta com a velocidade de corte, mas atinge a saturação. Em outras palavras, a profundidade de corte tem pouco efeito sobre a profundidade da camada branca; porém aumentando o avanço da ferramenta de corte ocorre o aparecimento da mesma. Os presentes resultados confirmam um efeito do avanço da ferramenta sobre a espessura da WL, tal que quanto menor o avanço, maior é a espessura, porém não confirmam o efeito do desgaste da ferramenta. A formação desta camada é discutida no contexto da sua influência sobre a rugosidade das peças. / This work deals with the microstructural changes in the surface of steels machined by hard turning. A non-acceptable microstructure, called White Layer - WL, is usually found in the hard turned surface. The presence of the white layer depends on hard turning parameters, especially on the wear of the machining tool and cutting speed. The formation of the white layer was investigated in the present work by hard turning the inferior face of a roller-bearing ring fabricated with DIN 100Cr6 steel quenched and tempered (60 HRC hardness). The depth of the WL was measured by standard metallographic procedures. The mechanical properties (stiffness modulus, E, and Vickers hardness) of the surface layer were measured by intrumented indentation in three samples: one with no WL, and two containing a WL of respectively 7 and 12 mm. According to the literature the depth of the WL increases with the wear of the machining tool. This increased with cutting speed, but reaches saturation. The presentresults confirm an effect of tool advance upon the depth of the WL, such that decreasing the advance leads to an increase in its depth, but an effect of tool wear could not be recognized. The formation of the WL is discussed in the context of its effect on surface roughness.

The 21st century demand for innovation is leading towards a revolution in the way products are perceived. This will have a major impact on manufacturing technologies as current product innovation is constrained by the available manufacturing processes, which function independently. One of the most significant developments is the emergence of hybrid manufacturing technologies integrating various individual manufacturing processes. Hybrid processes utilise the advantages of the independent processes whilst minimising their weaknesses as well as extending application areas. Despite the fact that the drawbacks of the individual processes have been significantly reduced, the application of state of the art hybrid technology has always been constrained by the capabilities of their constituent processes either from technical limitations or production costs. In particular, it is virtually impossible to machine complex parts due to limited cutting tool accessibility. By contrast, additive manufacturing (AM) techniques completely solve the tool accessibility issue, but this increased flexibility and automation is achieved by compromising on part accuracy and surface quality. Furthermore, the shape and size of raw materials have to be specific for each hybrid process. More importantly, process planning methods capable of effectively utilising manufacturing resources for hybrid processes are highly limited. In this research, a hybrid process, entitled iAtractive, combining additive, subtractive and inspection processes is proposed. An experimental methodology has been designed and implemented, by which a generative reactionary process planning algorithm (GRP2A) and feature-based decision-making logic (FDL) is developed. GRP2A enables a complex part to be accurately manufactured as one complete unit in the shortest production time possible. FDL provides a number of manufacturing strategies, allowing existing parts to be reused and transformed into final parts with additional features and functionalities. A series of case studies have been manufactured from zero and existing parts, demonstrating the efficacy of the iAtractive process and the developed GRP2A and FDL, which are based on a manual process. The major contribution to knowledge is the new vision for a hybrid process, which is not constrained by the capability of the individual processes and raw material in terms of shape and size. It has been demonstrated that the hybrid process together with GRP2A and FDL provides an effective solution to flexibly and accurately manufacture complex part geometries as well as remanufacture existing parts.