Traditional liquid coolants used in metal machining are known to contain chemical carcinogens that could present serious health risks for machine operators and have inherent waste disposal concerns on the environment. In lessening these adverse effects, the manufacturing industry continually seeks to develop machining techniques incorporating liquid-less (dry) methods or environmentally benign coolants. Air-jet cooling is widely regarded as a viable alternative for liquid coolants in machining processes. This thesis proposes a novel air jet cooling arrangement, and assesses its thermal effectiveness and operational compatibility for specific requirements in metal cutting operation. For tests, steel rods were machined on a standard lathe workbench at selected cutting depth, feed and speed. Type 1040 steel, which is commonly used in automobile industry, was chosen as work piece material. Instead of traditional liquid coolant, a specially designed compressed air jet is used to dissipate heat generation in the cutting zone at the tool tip. The tool tip is presented orthogonally to the work piece to maintain conformity with relevant established cutting tool theories. A special air jet configuration based on a Ranque-Hilsch vortex tube was designed and developed for cooling the cutting zone and tool tip. The tool tip temperatures were measured by installing thermocouples at strategic locations on the tool piece and recorded on a data-logger for a range of cutting depths, feeds and speeds. The cutting power was measured with a power meter attached to the electrical power supply to the lathe. For comparison purposes, tests were also conducted with conventional single-nozzle air jets in place of the vortex-tube jets, using traditional liquid coolant and without any cooling applied to the tool tip. / A thermal vision camera was also deployed for selected tests to ascertain the temperature characteristics at the tool tip. The data was analysed to establish the thermal characteristics at the tool tip with vortex tube air jet, conventional air jet and no air jet cooling. The measured temperatures and cutting data were used to make assessments on cooling efficiency of jets used and surface finish quality of work piece. Estimates of tool life were made from the cutting theory to determine the effectiveness of the cooling systems used in the machining process. It is found that the proposed vortex tube based air jet cooling arrangement provides a highly efficient heat removal mechanism for metal cutting and delivers thermal cooling performance very much comparable to traditional liquid coolants without the inherent chemical exposure risks to machine operators and harmful impact on the environment. With the proposed air jet cooling, the tool life is very much unchanged and the surface finish quality of work piece shows no significant change while savings will realise though lesser dependency on liquid coolant requiring careful disposal and associated costs.

Thesis (MEng)--University of Stellenbosch, 2003. / ENGLISH ABSTRACT: The purpose of this project is to find a means to evaluate a number of machines to optimise a process chain. Firstly seven machine types were identified to be included in the study. These machine types include: broach machines, EDM machines, GNG lathes, engine lathes, drilling machines, milling machines and grinders. The information requirements for these machines in terms of attributes for three areas were identified. Functionality, economical and reliability and availability attributes were identified. These attributes were subsequently incorporated into a MS-Access database to provide a database of machine information. Several methods for comparing machines were studied and the decision then fell on one existing method to be used for machine evaluation. A new method was developed to use for evaluating machines. The existing method is the Analytic Hierarchy Process, whereas the new method developed, is called the Quotient Exponential Method. These methods were implemented in the MS-Access database to enable the user to evaluate machines by means of both methods. The results indicate that these methods provide the correct answers according to test values used. It should be noted that the decision methods should, however, only serve as an aid towards an answer and do not necessarily provide the final answer. The AHP process is very time-consuming for this project because of the large number of criteria evaluated. / AFRIKAANSE OPSOMMING: Die doel van hierdie projek is om "n manier te vind om masjiene te evalueer om sodoende "n proses-ketting te optimeer. Eerstens is besluit op die soorte masjiene wat ingesluit gaan word in die projek. Sewe soorte masjiene is gekies en sluit in: RNB draaibanke, masjiendraaibanke, boormasjiene, skuurders, elektriese ontladings masjiene, veelvuldige punt snymasjiene en rubeitelmasj iene. Die inligting-vereistes van die sewe masjiene, in terme van hul attribute vir drie areas, is vervolgens geïdentifiseer. Hierdie drie areas is funksionaliteit, koste, asook beskikbaarheid en betroubaarheid. Hierdie attribute word in "n MS-Access databasis gebruik om "n databasis van masjien-inligting te skep. Verskeie metodes vir die vergelyking en evaluasie van masjiene is bestudeer en daar is op een bestaande metode besluit vir die evaluering van "n aantal masjiene. Daarbenewens is ook "n nuwe metode ontwikkel vir die evaluering van masjiene. Die bestaande metode is die Analitiese Hiërargiese Proses, terwyl die nuwe metode die Kwosiënt Eksponensiële Metode genoem word. Altwee hierdie metodes is in MS-Access geïmplemeteer om die gebruiker in staat te stelom masjiene met albei metodes te vergelyk. Die resultate verkry toon aan dat die korrekte resultaat verkry word volgens die toetsdata wat ingevoer is ten opsigte van die twee metodes. Dit moet in gedagte gehou word dat hierdie metodes egter slegs as "n hulpmiddel tot besluitneming gebruik behoort te word en nie noodwendig die finale antwoord lewer nie. AHP is baie tydsaam gevind, aangesien die masjiene in die projek baie attribute bevat het.

Thesis (MEng)--Stellenbosch University, 2015. / ENGLISH ABSTRACT: Efficient face milling of titanium alloys provides a global challenge. Difficult-to-cut super alloys such as Ti-6Al-4V is considered the “workhorse” material for aerospace components. During the machining of aerospace components, 80% – 90% of the material is removed. This requirement drives the innovation for machines and tooling to become more efficient, while driving down costs. In South Africa, this requirement is no different. Due to the historic practice of exporting valuable minerals such as Ilmenite, leucoxene and rutile, South Africa does not enjoy many of financial benefits of producing value added titanium alloy products. The Titanium Centre of Competence (TiCoC) is aimed at creating a South African titanium manufacturing industry by the year 2020. More specifically, the roughing of Ti-6Al-4V aerospace components has been identified as an area for improvement. The thermal conductivity of Ti-6Al-4V is significantly lower than that of other “workhorse” metals such as steel or aluminium. Therefore, heat rapidly builds up in the tool tip during high speed machining resulting in shortened tool life and increased machining costs. Hence the ongoing developments in the field of cooling methods for high speed machining. The latest development in high pressure cooling (HPC) is split tools that deliver coolant into the cutting interface via flat nozzles in the rake face of the insert. Although it has been released recently and limited to a single supplier, this cooling method is commercially available, yet little is known about its performance or application conditions. The operational characteristics of split tools are studied by answering set research questions. A dynamometer was used to measure the tangential cutting forces during 11 cutting experiments that follow a three-factor factorial design at two levels and with three centre points. A second-order model for predicting the tangential cutting force during face milling of Ti-6Al-4V with split tools was fit to the data at 95% confidence level. A predictive cutting force model was developed in terms of the cutting parameters: (1) Axial depth of cut (ADOC), (2) feed per tooth and, (3) cutting speed. The effect of cutting parameters on cutting force including their interactions are investigated. Data for chip evacuation, surface finish and tool wear are examined and discussed. Practical work was done at a selected industry partner to determine: (1) impact of an analytical approach to perform process development for aerospace component roughing, (2) determine the feasibility of implementing split tools to an existing process. A substantial time saving in the roughing time of the selected aerospace component was achieved through analytical improvement methods. Furthermore it was found that the split tools were not a suitable replacement for current tooling. It was established that certain critical operational requirements of the split tools are not met by the existing milling machine at the industry partner. / AFRIKAANSE OPSOMMING: Doeltreffende masjinering van titaan allooie bied `n wêreldwye uitdaging. Moeilik-om-te-sny super allooie soos Ti-6Al-4V word as die “werksesel” materiaal vir lugvaart komponente beskou. Gedurende die masjinering van lugvaart komponente word 80% - 90% van die materiaal verwyder. Dit is hiérdie behoefte wat die innovering van masjien -en snygereedskap dryf om dit meer doeltreffend en finansieël vatbaar te maak. Die Suid Arikaanse behoefte vir doeltreffende snygereedskap vir Ti-6Al-4V masjinering stem ooreen met hierdie internationale behoefte. Die geskiedkundige Suid Afrikaanse praktyk om onverwerkte, waardevolle minerale soos Ilmeniet, rutiel en leucoxene uit te voer, kniehalter die land se kans om winste uit verwerkte titaan allooi produkte te geniet. Die “Titanium Centre of Competence” (TiCoC) se mikpunt is om `n Suid Afrikaanse titaanproduk vervaardigingsmark op die been te bring teen 2020. Stellenbosch Universiteit se funksie, binne hierdie strategiese raamwerk, fokus op hoë spoed masjinering van Ti-6Al-4V lugvaart komponente. Die hitte geleidingsvermoë van Ti-6Al-4V is noemenswaardig laer as die van ander “werksesel” materiale soos byvoorbeeld staal of alumium. Om hierdie rede word hitte in die freesbeitelpunt gedurende hoë spoed masjinering opgeberg. Dit verkort gereedskap leeftyd en verhoog masjinerings kostes. Daarvandaan deurlopende ontwikkelinge in verkoelingsmetodes vir hoë spoed masjinering. Die mees onlangse ontwikkeling in hoë druk verkoeling is “split tools” wat koelmiddel na die snyoppervlak deur middel van langwerpige gleufies in die hark gesig van die beitelpunt lewer. Hierdie tegnologie is op die mark beskikbaar, maar slegs deur `n enkele verskaffer. Daar is ook geen akademiese publikasies wat oor Ti-6Al-4V masjinering met “split tools” handel nie. Die verrigtings vermoë en toepassings gebied vir die gereedskap is steeds onbekend. 'n Dinamometer is gebruik om die tangensiale snykragte tydens 11 sny eksperimente te meet. Die eksperiment ontwerp is faktoriaal van aard en bevat drie faktore en drie middelpunte oor twee vlakke. `n Kwadratiese model is geskik om die data op 95% vertroue vlak voor te stel en voorspellings mee te maak. Die voorspellingsmodel is ontwikkel in terme van: (1) Diepte van snit, (2) voertempo, en (3) Snyspoed. Die invloed van die drie parameters op die tangentiale snykrag, asook invloed met mekaar word ondersoek. Verdere data in verband met materiaal verwydering, oppervlak afwerking en beitel slytasie word ook bespreek. Praktiese werk is met behulp van `n bedryfsvennoot gedoen om vas te stel: (1) die impak van 'n analitiese benadering en ontwikkelings proses op die uitrof van lugvaart komponente, (2) en om die lewensvatbaarheid van implementering van “split tools“ aan 'n bestaande proses te bepaal. `n Noemenswaardige besparing is sodoende behaal. Dit is verder bevind dat “split tools” nie `n geskikte plaasvervanger vir die huidige snygereedskap is nie. Die rede daarvoor is gedeeltelik omdat die huidige freesmasjien by die bedryfsvennoot nie aan die kritiese operasionele vereistes van die gereedskap vervaardiger voldoen nie.

O tempo de ciclo da usinagem por hidroerosão aumenta após longos períodos de uso do fluido erosivo sem renovação de partículas, o que caracteriza uma redução da eficiência do processo. Esta redução pode ser avaliada por alterações das fases sólida e líquida que compõem o fluido erosivo. Neste trabalho os indicadores de eficiência do processo foram obtidos para um período de 150 horas de usinagem para arredondamento da seção de entrada de canais internos de bicos injetores, sem renovação de partículas. Para este intervalo foram determinadas as distribuições de tamanho das partículas de B4C, concentrações volumétricas de sólidos, viscosidades e densidades do fluido. As partículas foram também caracterizadas quanto à geometria utilizando um programa computacional desenvolvido no Matlab. Após 150 horas de uso o processo teve sua eficiência reduzida em 20%, sendo a redução atribuída à redução de 28% da concentração volumétrica de sólidos, ao aumento de particulado fino presente no fluido erosivo e redução de 50% da viscosidade do fluido. As interações hidrodinâmicas entre partículas e fluido foram caracterizadas pelo momento de equilíbrio, parâmetro utilizado para caracterizar o nível de acoplamento entre partícula e fluido e a eficiência do impacto. No final do período avaliado houve redução de aproximadamente 30% do volume de partículas com alto acoplamento com o fluido, com impacto negativo para a eficiência do processo. O período de 70 horas em que a redução da eficiência do processo não ultrapassou 5% pode ser utilizado como referência para tempo máximo de produção sem adição de abrasivos. / The hydroerosive grinding cycle time increases after long-term use of erosive media without particle reload, thus characterizing the reduction of process efficiency. Modifications on solid and liquid phases contribute for this reduction. In this work the process efficiency indicators were obtained from a 150 hours production period without particle reload. The production consists of diesel injection nozzles inlet rounding by hydroerosive grinding. For this period the B4C particle size distribution, solid volume fraction, fluid viscosity and density were obtained. Particle shape factors were obtained by a computational routine using Matlab. After 150 hours the process efficiency was reduced by 20% and this reduction can be attributed to 28% decrease of solid volume fraction, to fine particles increase and to the 50% reduction in fluid viscosity. The hydrodynamic interactions between particles and fluid were characterized by the particle momentum equilibrium number. This parameter is used to classify the particle-fluid coupling, thus the impact efficiency. At the end of the monitored period the volume of particles classified as high coupling was reduced by approximately 30% and this represents negative impact for the process efficiency. The efficiency loss did not exceed 5% for the first 70 hour of production, and then this value could be used as reference for the maximum run period without particle reload.

Made available in DSpace on 2014-06-11T19:27:13Z (GMT). No. of bitstreams: 0 Previous issue date: 2010-02-26Bitstream added on 2014-06-13T19:55:30Z : No. of bitstreams: 1 rigatti_amy_me_ilha.pdf: 2241422 bytes, checksum: 8c8e195352a6068cd9086572b3723f9f (MD5) / Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq) / Este trabalho apresenta um estudo sobre a influência das condições de fresamento na força de usinagem e na energia específica de corte. Foram ensaiados dois tipos de materiais que sofreram diferentes formas de tratamentos térmicos. O aço CL 23 (Eaton Ltda) foi normalizado, resfriado ao forno e resfriado ao ar, e o aço COS AR 60 (Usiminas S/A) foi empregado na condição “como recebido” e tratado termomecanicamente, onde a microestrutura foi refinada a 1,7 m. Para o primeiro material, empregou-se 3 condições de usinagem, com parâmetros de corte fixos e distintos entre si, e para o segundo material, foram utilizadas 8 condições, em que todos os parâmetros variaram visando à aplicação da Análise de Variância (ANOVA). Os ensaios de fresamento de topo concordante a seco foram conduzidos em um centro de usinagem CNC de 11 kW de potência e rotação do eixo-árvore de 7.500 rpm. Empregou-se ferramenta de diâmetro 25 mm com dois insertos de metal duro revestidos com TiN e TiNAl. A força de usinagem foi obtida utilizando-se um dinamômetro piezelétrico de 3 componentes e sistema de aquisição, cujos sinais foram pós-processados para o cálculo da força de usinagem máxima, força de usinagem RMS e energia específica de corte. Os resultados apontam para uma influência da condição de usinagem sobre a força de usinagem e energia específica de corte. A condição com alta velocidade de corte (HSC - High-Speed Cutting) apresentou menores forças de usinagem e maiores energias específicas de corte. A usinagem assumida como convencional, apresentou maiores níveis de força de usinagem e energia específica menores. A força de usinagem se mostrou estatisticamente dependente da profundidade de usinagem e a energia específica do avanço da ferramenta. A velocidade de corte influiu de forma significativa na força de usinagem e na energia específica de corte... / This research deals with the influence of milling conditions on machining force and specific cutting energy. Two kind of workpiece materials thermally treated were used on tests. CL23 carbon steel (Eaton Ltda) was normalized, furnace cooled and air cooled and COS AR 60 carbon steel (Usiminas S/A) was employed in “as received” and refined grains (1.7 m) conditions. For the first material, three machining conditions were applied with constant and different cutting parameters. For the second steel, eight machining conditions were implemented where all cutting parameters varied aiming at application of Variance Analysis (ANOVA). The machining tests were carried out by using dry end milling under down milling strategy in a CNC machining center with 11 kW power and 7,500 rpm spindle speed. A 25 mm diameter endmill with two inserts (TiN and TiNAl coatings) was used. The machining force was measured by means of 3-components piezoelectric dynamometer and acquisition system, whose signals were post-processed in order to calculate the maximum machining force, RMS machining force and specific cutting energy. The results show the cutting condition influences on all researched variables. High-speed cutting (HSC) decreased the machining force and increased the specific cutting energy. The milling named conventional condition elevated the machining force and diminished the specific cutting energy. The depth of cut was statistically influent on machining force and the feed per tooth was determinant for specific cutting energy. The cutting speed influenced significantly on machining force and specific cutting energy. Microstructural condition of workpiece material demonstrated to be important over studied variables only when hardness values were different significantly. The results of specific cutting energy from this work present good correlation with those obtained from theoretical models proposed by Taylor, Kienzle, ASME, AWF and Sandvik

Made available in DSpace on 2014-06-11T19:27:13Z (GMT). No. of bitstreams: 0 Previous issue date: 2005-01-28Bitstream added on 2014-06-13T18:31:04Z : No. of bitstreams: 1 doria_mat_me_ilha.pdf: 1141481 bytes, checksum: 2ce4bee4fea125f50133c730f3b951db (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Realizou-se um estudo da influência da rigidez estática do sistema Máquina-Ferramenta / Ferramenta de Corte / Dispositivo de Fixação / Peças (MFDP), na formação dos erros dimensionais e geométricos no processo de torneamento. Foi determinado a deflexão do sistema através de valores obtidos experimentalmente com a aplicação de forças estáticas em cinco pontos da peça de diâmetro 17 e 35 mm e comprimento 240 mm. Foi calculado a flexibilidade do carro porta ferramenta, da placa e do porta ferramenta, e a deflexão em todos os pontos de aplicação da força que variou de 49.05 N à 981 N. Usinou-se essas peças e estimou-se a força de corte atuante nas mesmas. Efetuou-se um comparativo entre os valores prático, teórico e usinado, com a peça fixa entre a placa e o ponto. Constatou-se que a rigidez do sistema, em especial a da peça tem grande influência na formação de erros das peças torneadas, e que com a equação que foi utilizada para os cálculos é possível prever os erros dimensionais e de forma de uma peça torneada. / This study aimed to verify the influence of the Machine-Tool/ Cutting Tool/ Fixing Device and Parts rigidness on the causing of geographic and dimension errors in the process of tilting. It was determined the defluxion of the system through experimental values obtained by applying statistic forces in 5 points of the part. The shape has 17 and 35mm diameter and 240mm of length. It was calculated the flexibility of the tilting component tool, plate and the modifying tool, and the defluxion in all points of the applying forces varied from 49,05 N to 981981 N. The e was an estimative of the cutting power of these parts, and a comparison was made between practical, theoretical and factored values with the part fixed between place and point. It concluded that the rigidness of the system, in special in the part, has a great influence in the causing of errors of the tilted parts. The equation used for the calculation is possible for predicting dimensional errors and the shape of a tilted part.

Made available in DSpace on 2014-06-11T19:28:34Z (GMT). No. of bitstreams: 0 Previous issue date: 2006-01-31Bitstream added on 2014-06-13T20:58:34Z : No. of bitstreams: 1 pimentel_mf_me_guara.pdf: 1070534 bytes, checksum: 041ac691a65005dd8019ca974206734b (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Nos componentes mecânicos em aço, a operação de usinagem pode representar mais de 50% do custo de produção. Por isso, tem-se procurado, com o desenvolvimento tecnológico, obter materiais que respondam adequadamente à solicitação de boa usinabilidade. No caso dos aços para construção mecânica, dentre os fatores que influenciam a usinabilidade, tem-se como principal fator a microestrutura do material, que por sua vez é definida pela composição química, tratamento térmico e o tipo, forma e distribuição das inclusões. No presente trabalho, o principal objetivo é avaliar a influência da composição química e da microestrutura, basicamente o tipo, a morfologia e a distribuição das inclusões, na usinabilidade do aço de corte fácil baixo-carbono com adição de chumbo. Para caracterização do material, foram realizadas análises químicas e executaram-se ensaios metalográficos. As análises químicas foram realizadas em amostras retiradas do lingotamento e em amostras retiradas do material laminado. Os ensaios metalográficos foram realizados para avaliar os principais tipos de microconstituintes e de inclusões presentes no aço estudado, por meio de microscopia óptica e eletrônica de varredura. Nos ensaios de usinabilidade, foi utilizada ferramente de corte de metal duro, sendo a usinabilidade avaliada pelo desgaste de flanco da ferramenta. Os resultados mostram que a maior usinabilidade foi obtida nas regiões dos corpos de prova com os maiores teores de carbono, enxofre e chumbo. Nestas regiões, também se verificou a maior quantidade de inclusões de sulfeto de manganês globulares e homogeneamente e distribuídas. / For mechanical steel components, the machinability could represent more than 50% of the production cost. Consequently, it's very important to develop steels with good performance in this kind of process. Microstructure is the main point, when it is analyzed all the factors that affect machinability. The microstructure can be defined by composition, heat treatment and inclusions type, shape and distribution. The present report has the target of evaluate how the chemical composition and microstructure influence the machinability of the leaded resulfurized low-carbon steel (leaded free-cutting steel). The material evaluation was based on chemical analysis and metallography of ladle and rolled samples. Metallography was used to iedentify the steel constituents and evaluate inclusions (type, shape and distribution). In machinability tests, the machinability was evaluated by flank wear of cutting tool. The results indicated that the machinability was easier in the test specimen regions with high contents of carbon, sulfur and lead. In these regions, it was verified high amount of globular manganese sulfide inclusions with homogeneous distribution.

Made available in DSpace on 2014-06-11T19:28:35Z (GMT). No. of bitstreams: 0 Previous issue date: 2004-01Bitstream added on 2014-06-13T20:48:20Z : No. of bitstreams: 1 ferreira_l_me_guara.pdf: 2176881 bytes, checksum: 8f2778a638b354767b4b063574bf7559 (MD5) / Universidade Estadual Paulista (UNESP) / A bomba de pistões axiais tipo swashplate é uma máquina relativamente nova nas aplicações industriais. Uma pesquisa para se obter informações de funcionamento dessa máquina revelou que pouco existe na literatura especializada, a menos de um trabalho de tese de doutorado apresentado na UNESP em 1993. Este trabalho desenvolve procedimento para o projeto de máquinas de pistões axiais e segue uma metodologia para se obter o desenho de conjunto, os detalhes, os ajustes e montagem desta máquina. Em seguida foi feito um estudo para proceder às etapas de usinagem desta máquina, utilizando máquinas convencionais e máquinas de controle numérico. O trabalho visa também fazer com que esta máquina funcione bombeando óleo. O objetivo é garantir com que o mecanismo funcione perfeitamente e não a pressões elevadas. / The swashplate piston pump is relatively new in industrial applications. A literature research for obtaining the operation principles of such machines, revealed that little is published in the specialized literature but a work presented as a thesis research at UNESP in 1993. This work presents a procedure for the design of axial piston machines and a methodology in order for one to obtain the cutaway view, the detailed drawings, the fit process and how to assemble this machine. After a long discussion, a detailed process was accomplished in order to develop the machining phases, making use of conventional machines and CNC ones. The present work also declare how this machine will be running along the tests: a way that only the pumping action is required. At this point only the well running and not the pressure value is important.

Orientador: Manoel Cléber de Sampaio Alves / Banca: Ivaldo de Domênico Valarelli / Banca: Marcos Tadeu Tiburcio Gonçalves / Resumo: Alternativas para otimizar os processos de fabricação por usinagem têm sido buscadas com o objetivo de diminuir custos, aumentar produtividade e diminuir problemas ambientais. Entre essas alternativas destacam-se a procura pela usinagem a seco, o desenvolvimento e aprimoramento de materiais para ferramentas de corte e de recobrimento da mesma e a usinagem de aços endurecidos com o intuito de eliminar o processo de retificação. Com base nisto, neste trabalho foi analisado o fresamento frontal, do tipo abertura de canal, do aço SAE 4340 na forma recozida e na forma endurecida (temperado e revenido), utilizando ferramenta de metal duro com recobrimento de TiAlN e TiN na condição à seco. Este aço é comumente utilizado em componentes mecânicos, solicitados à esforços dinâmicos, na indústria automobilística e aeroespacial. O objetivo deste trabalho foi avaliar a viabilidade da usinagem a seco deste aço na forma endurecida, através da análise do comportamento da qualidade superficial, da potência consumida, da vibração, da emissão acústica, do desgaste das ferramentas e das formas e tipos de cavacos produzidos nas diferentes condições de usinagem. Esta pesquisa foi realizada em um Centro de Usinagem CNC, variando-se os parâmetros velocidade de corte e avanço. Os ensaios foram realizados em duas etapas, no qual, na primeira etapa as amostras do material, nas duas formas mencionada (recozido e endurecido), foram usinadas com Vc de 200 e 300 m/min e avanço de 0,1 e 0,04 mm/dente. Na se... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: Alternatives to optimize machining processes have been sought with the aim of reducing costs, increasing productivity and reducing environmental problems. Among those options, it is highlighted the demand for dry machining, the development and improvement of materials for cutting and covering the same tools and the machining of hardened steels in order to eliminate the grinding process. On this basis, this paper analyzed the steel face milling, of channel opening type, SAE 4340 in annealed form and in hardened form (quenched and tempered) using carbide tool with coating TiAlN and TiN in the dry condition. This steel is commonly used in mechanical components, ordered the dynamic forces in the automotive and aerospace industry. The aim of this study was to investigate the behavior of the surface quality, consumed power, vibration, acoustic emission, wear of tools and forms and types of chips produced in different machining conditions. This research was conducted in a CNC Machining Center, varying the parameters cutting speed and feed. The tests were carried out in two stages, in which, in the first step, samples of the material in the two forms mentioned (annealed and hardened) were machined with Vc of 200 and 300 m/min and advance of 0,1 and 0,04 mm/tooth. In the second step, the annealed material was tested with a Vc of 400 m/min and the cured material was tested with a Vc of 300 m/min, in both cases the tests were performed at both feed rates. In which, through the analysis ... (Complete abstract click electronic access below) / Mestre

Orientador: Luiz Eduardo de Angelo Sanchez / Banca: Carlos Alberto Fortulan / Banca: Gilberto de Magalhães Bento Gonçalves / Resumo: A usinagem de cerâmicas avançadas geralmente é feita com o objetivo de corrigir as deformações após a etapa de sinterização, conferir precisão dimensional e qualidade superficial. Para cumprir esta tarefa é utilizada, principalmente, a retificação com rebolo de diamante sob baixas taxas de remoção de material. O torneamento com ferramenta de diamante pode ser aplicado para a maioria das cerâmicas, mas esbarram em condições limites de remoção de material, como profundidade de corte nanamétricas, que se ultrapassadas mudam o regime de remoção de dúctil para frágil. Uma alternativa é a usinagem da peça no estado verde, a qual apresenta fácil usinagem com a diminuição da introdução de defeitos prejudiciais à resistência mecânica. Após a sinterização invariavelmente ocorrem distorções devido à distribuição heterogênea de gradientes de densidade que se localizam nas porções mais externas do compactado. Na tentativa de remover estes gradientes, o presente trabalho analisou a influência da remoção de sobrematerial no estado verde na distorção da peça após a sinterização. Corpos-de-prova de alumina, com 99,8% de pureza, foram torneados com sobremateriais de 1,0, 2,0 3,0, 4,0 e 5,0 mm por uma ferramenta de metal duro sob condições constantes de usinagem. Além da distorção, outras variáveis de saída foram analisadas, com desgaste de ferramenta, força de corte (Fc) e rugosidade média aritmética (Ra) do compactado em verde e sinterizado. Os resultados apontam uma redução da distorção da peça sinterizada de até 81,4% com o maior valor de remoção de sobrematerial em verde e a influência do desgaste da ferramenta na rugosidade da peça em verde e na correspondente peça sinterizada / Abstract: Advanced ceramics machining is generally done with the objective of correcting distortions in pieces after sintering. In order to comply with this task grinding with a diamond grinding wheel is mainly used with low material removal rates. Turning can be done diamong tool to most of the ceramics, but is runs into very narrow material removal limit conditions, as nanometric cutting depths, which if exceeded change the removal system from ductile to brittle. An alternative is machining the piece on the green state, which presents easy machining without the introduction of harmful defects to mechanical resitance. However, after sintering there are invariably distortions caused by the heterogeneous distribution of density gradients that are located in the most outlying portions of the compacted. In an attempt to remove these gradients, this study examined the influence of different allowance values removed and the corresponding distortion after sintering. Alumina speciments are used for this procedure, with 99,8% purity, from which allowances of 1.0,2.0,3.0,4.0, 5.0 mm are removed by turning with a cermented carbine tool under constant machining conditions. Besides distortion, other output variables were analyzed, such as tool wear, cutting force and surface roughness of the green ceramics and the sintered. The results presents a reduction of the distortion of the sintered piece of 81,4% with the greater allowance removal values and the influence of tool wear on the green machining surface roughness and on the corresponding sintered piece / Mestre