O monitoramento de emulsões utilizadas na indústria metalmecânica compõe uma importante atividade para o controle da qualidade das peças trabalhadas, proporcionando também o aumento da vida útil de ferramentas e maquinários utilizados neste setor através da lubrificação e refrigeração da região de corte. Em grande parte dos casos, estas emulsões são preparadas pela diluição de um fluido de corte em meio aquoso, constituindo assim um conjunto de gotículas estabilizadas em um meio contínuo devido à presença de compostos emulsificantes, estando constantemente sujeitas a ciclos de aquecimento e resfriamento durante os processos de usinagem. Apesar do acompanhamento deste material ser realizado através de análises periódicas usuais, não há um método eficiente estabelecido para verificar sua qualidade em tempo real e em linha de processo. Neste contexto, torna-se possível aplicar técnicas relacionadas à espectroscopia UV-Vis para se obterem informações sobre a estabilidade destes sistemas, correlacionando intensidades de espalhamento de luz com as dimensões das gotas presentes no meio. Dessa forma, tornou-se possível o estudo da desestabilização térmica de emulsões de um fluido de corte comercial, a qual mostrou-se, através do acompanhamento do cálculo do expoente do comprimento de onda, dependente do tempo de exposição ao aquecimento e de sua temperatura média temporal, não sendo influenciada pela perda de meio contínuo por processos evaporativos ou sua posterior reposição. Também se verificou que parâmetros típicos do processo de preparo de emulsões, como a temperatura do meio dispersante e o tempo de repouso do fluido de corte sobre a superfície do mesmo, apresentam fundamental importância para a definição do tamanho médio de gota inicial destes sistemas, o que forneceu evidência da possibilidade de se relacionar a área sob espectros de extinção de luz com tamanhos médios de gota. / The monitoring of emulsions used in the metal-mechanical industry comprise an important activity to the quality control of the products manufectured, also providing an increase in the working life of the tools and machinery employed in this sector through the lubrication and refrigeration of the cutting zone. In the majority of cases, these emulsions are prepared diluting a metalworking fluid in an aqueous media, constituting a collection of particles stabilized by emulsifiers and undergoing heating and cooling cycles during metalworking processes. Currently, monitoring routines are based on regular analyses of samples taken from the process fluid, and an effective in-line method is not available to monitor emulsion quality in real time. In this context, it is possible to apply techniques related to UV-Vis spectrocopy in order to obtain information concerning the stability of those systems, correlating light scattering intensities to the droplet dimensions. In this study, it was possible to investigate the thermal destabilisation of a commercial metalworking fluid emulsion, which showed, through the evaluation of the wavelength exponent, to be dependant on the exposure time to heating and its time-averaged temperature. It was also noted that the loss of continuous phase by evaporation and its reposition do not affect the emulsion stability. Moreover, it was observed that important emulsion preparation parameters, such as continuous phase temperature and the time span between the addition of the metalworking fluid on the water surface and the stirring, have fundamental roles in defining the initial average droplet size, which made possible to correlate the area under the light extinction spectra with average droplet sizes.

Monitoring of emulsion properties is important in many applications, like in foods and pharmaceutical products, or in emulsion polymerization processes, since aged and broken emulsions perform worse and may affect product quality. In machining processes, special types of emulsions called metalworking fluids (MWF) are widely used, because of its combined characteristics of cooling and lubrication, increasing the productivity, enabling the use of higher cutting speeds, decreasing the amount of power consumed and increasing tool life. Even though emulsion quality monitoring is a key issue in manufacturing processes, traditional methods are far from accurate and generally fail in providing the tools for determining the optimal useful life of these emulsions, with high impact in costs. The present study is dedicated to the application of a spectroscopic sensor to monitor MWF emulsion destabilization, which is related to changes in its droplet size distribution. Rapeseed oil emulsions, artificially aged MWF and MWF in machining application were evaluated, using optical measurements and multivariate calibration by neural networks, for developing a new method for emulsion destabilization monitoring. The technique has shown good accuracy in rebuilding the droplet size distribution of emulsions for monomodal and bimodal distributions and different proportions of each droplet population, from the spectroscopic measurements, indicating the viability of this method for monitoring such emulsions. This study is part of a joint project between the University of São Paulo and the University of Bremen, within the BRAGECRIM program (Brazilian German Cooperative Research Initiative in Manufacturing) and is financially supported by FAPESP, CAPES, FINEP and CNPq (Brazil), and DFG (Germany). / Sem resumo em português.

Aluminum alloys are having more attention due to their high specific stiffness and processing advantages. 7075 aluminum alloy is a wrought composition aluminum alloy in the Al-Zn-Mg-Cu series. Due to the significant addition of these alloying elements, 7075 has higher strength compared to all other aluminum alloys and effective precipitation hardenability characteristic. On the other hand, aluminum alloys have some drawbacks, which hinder the widespread application of them. One of the most commonly encountered defects in aluminum alloys is the hydrogen porosity. Additionally, in case of 7075, another problem is the lack of fluidity. Magnesium addition is thought to be effective in compensating this deficiency. Accordingly, in this study, die cast 7075 aluminum alloy samples with hydrogen porosity and additional magnesium content were investigated. The aim was to determine the relationship between hydrogen content and hydrogen porosity, and the effects of hydrogen porosity, additional magnesium and T6 heat treatment on ultimate tensile and flexural strength properties of pressure die cast 7075 aluminum alloy. 7075 aluminum alloy returns were supplied from a local pressure die casting company. After spectral analysis, pressure die casting was conducted at two stages. In the first stage, 7075 aluminum alloy with an increase in magnesium concentration was melted and secondly 7075 aluminum alloy was cast directly without any alloying addition. While making those castings, hydrogen content was measured continuously before each casting operation. As a final operation T6 heat treatment is carried out for certain samples. Finally, in order to accomplish our aim, mechanical and microstructural examination tests were conducted.

In this study, a novel incremental ring rolling process used in production of rings with various cross sections is examined. A basic type of this process is investigated numerically, using commercial finite element programs / MSC Superform, MSC Marc. The user defined subroutines are also utilized for flexibility in modeling. The aim of modeling is to determine the material flow for geometrical analysis, strain/stress distribution for tool force analysis and residual stresses, in a cost effective way. The process has instabilities and requires large number of incremental stages to complete a full finite element simulation. The full models are reliable but costly hence the numerical studies are focused on reliable simplified models with lower computation time. Different approaches are developed: three-dimensional segment model, improved segment model, velocity coupling model. The results of these models are compared with experimentally verified full models. Numerical parameters such as mesh type, step size, convergence ratio are examined. After verification of the model different applications to of the process is developed and physical parameters affecting the process are discussed / such as the tool path .

In the present study, the applicability of the hybrid plasma arc welding, in which a keyhole is responsible of deep penetration and a filler wire electrode supplies a high deposition rate, was examined. The microstructural evolutions in grade 2205 duplex stainless steel plates joined by keyhole and melt-in techniques were investigated. The specimens obtained from welded plates having thickness of 8 mm were examined via optical and scanning electron microscopy. Metallographic investigations were supported by X-ray diffraction and energy dispersed spectra analyses by characterizing the phases formed after welding. Impact toughness properties, hardness profiles, and crack propagation behavior of welding zones were quantitatively and qualitatively compared for mechanical characterization. Fracture characteristics were determined via scanning electron microscopy examinations. It was observed that single-pass HPA weldment seemed to be free of secondary austenite precipitation in acicular form, which is inevitable in multi-pass conventional arc welding methods. Besides &delta / -ferrite was successfully kept under 70%, which is presented as a limit to not to deteriorate the mechanical properties of DSS. High linear welding speed and high power density supplied by HPAW presented narrower weld metal and heat affected zone with not only lower hardness but also higher impact toughness energies. Synergic effect of the keyhole formed by a plasma arc and the metal transfer supplied by gas metal arc gave reasonable dilution in the weld metal. Furthermore, fatigue crack growth tests revealed that crack propagation rates in HPAW joints were comparable to GMAW joints.

Developing process plans and part programs rapidly and correctly for CNC machine tools plays a vital role in manufacturing. This study is concerned with the development of a web-enabled virtual design and manufacturing application system for rotational parts. The object oriented methodology is used in the application development. Windows Distributed interNet Application (DNA) architecture which describes a framework of building software technologies in an integrated web and client-server model of computing, is employed in the system. The entire system was modeled with Unified Modeling Language (UML), which is an industry-standard visual modeling notation to express software development architectures. Feature-based design approach, being a practical way of linking the design with manufacturing, is implemented in the rotational part design. Users have to be registered in order to use the system. With the supplied web site, users can easily register to system. After registration, the user obtains a password and a unique username. Upon the user authentication, the user session starts. A typical user session involves new or past project selection, material selection, part sketching, blank size definition and cutting parameters determination. After all the steps are completed, process plan and part-program, which are required to manufacture the part on Denford Mirac CNC Turning Machine are generated and displayed on the web site and then saved to the database. The application enables the users to see past projects and to generate new process plan and part programs for different cutting parameters. The process plan, part program and the 2D wire frame drawing of the corresponding part are demonstrated on the web site for the chosen projects.

Made available in DSpace on 2016-12-08T16:59:56Z (GMT). No. of bitstreams: 1 118960.pdf: 1996026 bytes, checksum: 5e3b2b4fc7e3382e785386af002e6e8c (MD5) Previous issue date: 2014-08-07 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / The aim of this present study is to understand the inclusion of the working woman in the metalworking industry, in the section where mostly men used to work, called macharia , in Joinville city, in the 1970s and 1980s. However, to understand this topic, this study looked for having support in local historiography and other contributions that were required during its development. Documentary sources as reporting and collection of Oral History, under the responsibility of Arquivo Histórico de Joinville - AHJ (Historical Archives of Joinville city), we focused in this study, as well as the periodic Mail Tupy and other journalistic printed city that circulated in the period analyzed in this research, and these, also could be found in the AHJ. These papers help us to understand the images and discourses (Speeches) conveyed in a city dedicated to work. So, it defends itself as a consistent space for the benefits derived from productive activities. However, the growth of Joinville metalworking industry during that period would bring several and different situations, especially due to lack of manpower to the industry (especially in the Metallurgical Section). The shortage of workers led the business group in Joinville to establish a real rush for men and women workers together. Facing this scenario, I decided to understand the insertion of female presence in the metalworking sector, taking Tupy Industry Indústria de Fundição Tupy S.A - as a field for this discussion, because this company is considered one of the biggest factories in Brazil within that segment, and the first to hire women for productive lines in the early 1970s.The women s participation in this industry shows up as a major event of their professional empowerment, embracing in its wake, a number of subsequent social changes. / Este trabalho busca conhecer a inserção da mulher operária na indústria metalmecânica no setor da Macharia, em Joinville, nas décadas de 1970 e 1980. Para entender essa temática, a pesquisa buscou apoio na historiografia local e demais contribuições que se fizeram necessárias durante sua realização. Fontes documentais como relatórios e acervo de História Oral, sob responsabilidade do Arquivo Histórico de Joinville (AHJ), foram privilegiadas nesse estudo, bem como o periódico Correio da Tupy e demais impressos jornalísticos da cidade que circularam no período analisado nessa pesquisa, sendo esses, também, acondicionados no AHJ. Esses informativos ajudam a compreender as imagens e os discursos veiculados em uma cidade voltada ao trabalho. Logo, se defende esse local como um espaço consentâneo pelos benefícios oriundos das atividades produtivas. No entanto, o crescimento da indústria metalmecânica joinvilense, no referido período, traria situações adversas, especialmente por falta de mão de obra para a indústria (sobretudo no setor metalúrgico). O déficit de trabalhadores levou o grupo empresarial desse município a estabelecer uma verdadeira corrida em busca de operários e operárias. Diante desse cenário, busquei entender a inserção da presença feminina no setor metalmecânico, tomando a Indústria de Fundição Tupy S.A., como campo para essa discussão, pois essa empresa é considerada uma das maiores fábricas do país dentro desse segmento e a primeira a contratar mulheres para as linhas produtivas no início da década de 1970. A participação da mulher nesse setor industrial é percebida como um dos principais acontecimentos de sua emancipação profissional, abarcando, em seu bojo, uma série de mudanças sociais subsequentes.

In case of metalworking operations, the purpose of lubrication is served by a complex mixture of two or more phases, these mixtures are known as metalworking fluids (MWFs). For many decades oil-in-water emulsions have been used as metalworking fluids. The particular advantage of using oil-in-water emulsion in metalworking operations is that it combines the cooling property of water and the lubrication property of the oil. To explain the lubrication mechanism for oil-in-water emulsions as metalworking fluids a variety of models and theories has been proposed. To understand the lubrication mechanism, the role of each ingredient in the tribological process needs to be studied. In the present study a model for lubrication which determines force and proximity regimes of droplets based on the droplet size distribution is proposed. Dynamic light scattering (DLS) is used to characterize the emulsions. The small droplets are found to be the ones which enhance lubricity. DLVO (Derjaguin-Landau-Verwey-Overbeek) theory is used to validate the results. The concentration and type of surfactant is found to be the performance controlling parameter. A further analysis of the three interfacial energetics; oil/water, oil/substrate, water/substrate, is studied in the presence and absence of surfactants with the help of a Goniometer, Fourier transform infrared spectroscopy (FTIR), atomic force microscopy (AFM). Such energetics reflects the rate at which the excess surfactant molecules accumulate at the water/oil interface and desorb into the phases. The tribological response is recorded using AFM and the nanotribometer (NTR). Frictional response of the chemisorbed self-assembled monolayer of surfactant (sodium oleate) on the steel substrate reflects that a tribofilm helps in lubricating the contact under boundary lubrication by creating a low shear strength material. Water being the continuous phase in oil/water emulsion a thin water layer adjacent to steel substrate is always present. This thin layer on the solid substrate acts as a barrier to the lubricating oil droplets to reach the metal surface. The focus of the present work is also to investigate conditions which permit the disjoining of the water film to allow the oil to lubricate the metal substrate. AFM is used to study the interaction force between an oil droplet and the steel substrate through water. An oil encapsulated SiO2 colloidal probe used to simulate the oil droplet. The charge regulatory status of the substrates and interfaces are found to be critical in mapping the force characteristics when DLVO interaction is considered. The condition for activation of non-DLVO (hydration, hydrophobic, capillary) forces are also identified and found to be dependent on the physical states of surfaces. Disjoining of the thin film can be controlled by selecting surfactants based on interfacial energetics and attractive force characteristic can be achieved to facilitate lubrication.

Orientador: Sérgio Tonini Button / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-27T18:58:44Z (GMT). No. of bitstreams: 1 Batalha_MarioHenriqueFernandes_M.pdf: 5393156 bytes, checksum: a53f9730323b17df3ef4631f7f7de1e7 (MD5) Previous issue date: 2015 / Resumo: Este estudo teve como finalidade avaliar a estampabilidade de chapas de aço de ultra-alta resistência mecânica (da sigla inglesa UHSS), neste caso o aço DIN 27MnCrB5-2 (nº 1.7182), para a estampagem a quente com estiramento controlado. Esse processo é conhecido por associar a alta produtividade da estampagem com o tratamento térmico de têmpera durante a conformação, o que se torna vantajoso no caso de aços UHSS, já que simultaneamente, reduz os esforços durante a conformação, praticamente elimina o efeito de retorno elástico e permite gerar produtos com limite de resistência superior a 1.500 MPa. O objetivo principal de associar a redução de espessura à estampagem a quente é de gerar uma peça que atenda aos esforços aplicados e que não apresente variações bruscas de microestrutura devidas à variação local na têmpera ou pela união de chapas que seria uma alternativa para a obtenção de seções com espessuras diferentes. Além disso, também tem-se por objetivos elevar a complexidade geométrica, diminuir o peso do componente estrutural e reduzir o custo de produção. Nesse caso, buscou-se avaliar a capacidade do material de confeccionar peças com redução de espessura variável durante a conformação a quente, por meio da análise dos limites de conformabilidade, obtidos pelo ensaio Nakazima em um modelo real e outro virtual, no caso, utilizando o software Forge 2008 ® que é baseado no método de elementos finitos. Além disso, foi confeccionado um componente com variação de espessura em sua parede, a fim de exemplificar em um modelo real a aplicação das informações obtidas no ensaio Nakazima. Ao final da análise, foi possível determinar uma faixa de deformação verdadeira segura de trabalho, válida para os diferentes estados de tensão e deformação, e verificou-se uma coerência na previsão do modelo virtual previamente calibrado com os resultados experimentais / Abstract: This study aimed to evaluate the formability of ultra-high strength steel (UHSS), in this case the DIN 27MnCrB5-2 (No. 1.7182), for hot stamping with controlled stretching. The process is known by its high productivity in stamping with simultaneous heat treatment of quenching, which is advantageous in the case of UHSS steel, since it simultaneously reduces the loads during forming, practically eliminates the "springback" effect and generates products with ultimate tensile strength exceeding 1.500 MPa. The main purpose of associating the reduction of thickness with hot stamping, is to generate a continuous structure that support the loading, or in other words, without abrupt changes in microstructure due to local variation in quenching conditions or welding of blanks which is another alternative to obtain parts with different thickness along the product. Moreover, it allows high geometric complexity, reduce component weight and reduce the cost of production. In this context, it was evaluated the capacity of the material to produce parts with variable thickness reduction during forming, by analyzing the limits of formability obtained by Nakazima test in a real and virtual model with the software Forge 2008 ® which is based in the Finite Element Method. Furthermore, it was manufactured a component with varying thickness in its wall, in order to exemplify the application of the data obtained in the Nakazima tests. After the analysis, it was determined a range of safe deformation, valid for the different states of stress and strain, also it was noticed a consistency in predicting hot formability between the virtual calibrated model and experimental results / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

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