La réhabilitation des fonctions dentaires grâce à la pose de prothèses obtenues par CFAO est l’un des enjeux majeur de la dentisterie restauratrice moderne. La qualité de ces prothèses peut être évaluée grâce à la rugosité, correspondant à une composante de l’intégrité de surface (IS), prépondérante en dentisterie. Les travaux de thèse ont pour but l’évaluation et la quantification de l’influence des caractéristiques liées à différents outils usinant la pièce, des matériaux employés ainsi que les paramètres associés au procédé d’usinage sur la rugosité résiduelle. Grâce aux résultats obtenus lors de ces travaux il est montré une influence assez limitée de la vitesse d’avance sur la rugosité, alors que celles liées à la taille de la micro-géométrie de l’outil, à l’orientation outil/prothèse et aux biomatériaux sont plus significatives. Il est aussi démontré l’importance de l’utilisation d’un jeu de paramètres de rugosité, de façon à obtenir un maximum d’informations relatives à la topologie de la surface. Ceci a conduit à la définition d’indicateurs de performance du processus d'usinage pour l’évaluation multi-physique et multi-indicateurs de l’IS. La validation de la démarche par un cas d’application montre qu’une décomposition topologique de la couronne est nécessaire afin de mieux respecter le cahier des charges prothétique et fournir une aide précieuse au praticien ou technicien de laboratoire. Pour un meilleur respect du cahier des charges initial, chaque région topologique peut ainsi : être usinée grâce à des stratégies d’usinage différentes, être évaluée par un jeu de paramètres de rugosité qui lui est propre et subir un post-traitement de polissage, si nécessaire. / The rehabilitation of dental function following the fitting of prostheses obtained by CAD/CAM is one of the major challenges of modern restorative dentistry. The quality of these prostheses can be assessed using roughness, corresponding to a major surface integrity (SI) component in dentistry. This thesis work aims to evaluate and quantify the influence of the characteristics associated with various milling tools, the materials used, and the parameters associated with the milling process on the residual roughness. The achieved results obtained during this work show a rather limited influence of the feedrate on the roughness, whereas those related to the size of the tool micro-geometry, the tool/prosthesis inclination, and the biomaterials are more significant. The importance of using a roughness parameters set in order to obtain a maximum of information relating to the surface topology is also demonstrated. This in turn leads to the definition of machining process performance indicators for the multi-physical and multi-indicator SI evaluation. The validation of the approach through a case study shows that a topological decomposition of the crown is necessary in order to better respect the prosthetic specifications and to provide valuable assistance to the practitioner or the laboratory technician. Each topological region can thus be machined using different machining strategies, be evaluated by a set of its own roughness parameters set, and undergo a post-processing polishing treatment, if necessary.

Two aerospace superalloys, Inconel 718 and IMI 318, were machined with different grades of PVD (KC730 and KC732) and CVD (KC950) coated tools in order to evaluate their performance under various cutting conditions and to further investigate the effect of the machining conditions on surface finish and surface integrity of the work materials. A self-propelled rotary tool was also developed and used for machining under the finishing conditions. Tool wear, component forces and surface roughness were recorded and analysed during the machining trials. Study of the surface integrity involved physical as well as metallographic examination and analysis of the machined surfaces. The results of the machining trials show that the multi-layer (TiN/TiCN/TiN) PVD coated KC732 tools gave the best overall performance when machining both Inconel 718 and IMI 318, especially at lower feed conditions. Flank wear, excessive chipping, flaking of tool materials close to the cutting edge or on the rake face were the dominant failure modes when machining with the PVD coated tools while flank wear and notching were dominant when cutting with the CVD coated tools. These failure modes are associated with attrition, abrasion, diffusion and plastic deformation wear mechanisms acting individually or in combination during machining. The statistical regression analysis of the tool life data shows that wear of the PVD and CVD coated tools used for machining Inconel 718 was mainly affected by cutting speeds employed while cutting speed and feed rate exhibited similar influence on tool performance when machining IMI 318 with PVD coated tools. Tool life equations for each of the three coated grades when machining both superalloys under the cutting conditions investigated were derived. Severe plastic deformation and hardening of the machined surfaces occurred after machining both materials due to a combined action of increased component forces, thus increased stresses, and high temperature. Softening of the top surface layer when machining IMI 318 can be attributed to overaging of the titanium as a result of highly localised surface heating during machining. Tearing of the machined surfaces occurred when machining IMI 318 with the PVD coated tools, particularly with KC732 tools as a result of irregular flank wear and excessive chipping of KC732 tools. The self-propelled rotary tool (SPRT) incorporating K68 straight grade carbide exhibited superior wear-resistance when machining IMI 318 due to the absence of thermally related wear mechanisms caused by reduced temperature and the use of the entire edge of a round insert during rotary cutting. The minimal subsurface alterations (such as plastic deformation and hardness) when machining Inconel 718 and IMI 318 with the SPRT can also be attributed to lower cutting temperature with rotary action.

The addition of lead to the copper alloys increase the machinability of thework material (without reference here to environmental factors) and reduces the overall production cost of the components at different stages, despite copper being expensive, which makes a challenging task to replace lead. Since lead is dangerous to human health. Many materials are considered to replace lead in brass and silicon is one of the alternative. This thesis characterizes the lead and the lead free brass's surfacemetallurgy for a certain cutting data. The study includes identification of alteredmaterial zones (AMZ) defined by the plastic deformation, hardness alterationsand grain distributions.The study results include the analysis of deformed subsurface region andcomparison exemplifying differences between the two materials under twodifferent studies. / Lead free brass

Machining operations are widely used to produce parts with different shapes and complicated profiles. As a machining operation, broaching is commonly used for the machining of a broad range of complex internal and external profiles either circular or non-circular such as holes, keyways, guide ways, and slots on turbine discs having fir-tree shape. Broaching is performed by pushing or pulling a tapered tool through the workpiece to remove the unwanted material and produce the required profile. Broaching is also acknowledged because of its high productivity and attainable surface quality in comparison to the other machining processes. The objective of this thesis is to simulate the broaching operation and use the results to present a methodology for optimum design of the broaching tools. In the course of the presented thesis, a new B-spline based geometric model is developed for broaching cutting edges followed by model validation using 3D ACIS modeller. To study the mechanics of cutting and generated cutting forces during broaching operation, an energy based force model is presented which can predict the cutting forces based on the power spent in the cutting system. An experimental investigation is conducted in order to confirm the estimated forces. The integrity of the broached surface is also investigated by focusing on surface roughness, subsurface microhardness, and subsurface microstructure as three major parameters of surface integrity. An optimization procedure for broaching tools design is presented in this thesis. A mathematical representation of broaching tooth geometry is also presented which is used to simulate the tooth as a cantilevered beam subjected to a distributed load. The beam is solved considering the given design constraints to achieve optimum geometric parameters for maximum durability and performance. / UOIT

Since grinding is often the last process of a manufactured part, caution has to be taken in order to ensure the integrity of the surface. The role of grinding induced residual stresses can be important in fatigue or wear resistance. In most cases we cannot evaluate accurately and easily their distribution. On this purpose, many scientists are working on the modeling of grinding and its effects on a many points. The main aim of this work is to analyse of residual stresses influenced by grinding parameters.

The aim of this thesis is to design, implement and evaluate an experiment that verifies the influence the size effect on selected parameters of the surface integrity. For the experiment were used highly productive reaming head MT3 made by HAM-FINAL. Evaluation of the surface integrity was done in terms of the characteristics of the surface roughness, geometric tolerances and changes in microstructure. Furthermore, the influence of the depth of chips evaluated for changes in the feed force, cutting torque and changes in specific cutting energy. The theoretical part deals with the description of the size effect, characteristic reaming, surface integrity, preparation of material and identification of highly productive MT3 reaming head.

The Masters thesis is focused on surface integrity at reaming with high productive reaming head MT3 made by HAM-FINAL. Theoretical part of thesis aims at analyse of the most frequently evalueted surface integrity parametrs and its possible influence on functional performance of machined components. Next theoretical parts are aimed at reaming process, reaming tools characteristics, detailed reaming head MT3 characteristics and its aplication in company Sauer Danfoss. The aim of experimetal part of thesis is surface integrity of holes reamed MT3 during its tool life evalation.

Al 7050-T7451 alloy with good combinations of strength, stress corrosion cracking resistance and toughness, is used broadly in the aerospace/aviation industry for fatigue-critical airframe structural components. However, it is also considered as a highly anisotropic alloy as the crack growth behavior along the short transverse direction is very different from the one in the long transverse direction, due to the inhomogeneous microstructure with the elongated grains distributed in the work material used in the sheet/plate applications. Further processes on these materials are needed to improve its mechanical and material properties and broaden its applications. The material with ultra-fine or nano grains exhibits improved wear and corrosion resistance, higher hardness and better fatigue life, compared to the one with coarse grains. In recent times, the development of novel processing technologies has gained great attention in the research community to enhance the properties of the materials employed in the aerospace, biomedical, precision instrument, automotive, nuclear/power industries. These novel processing technologies modify the microstructure of this alloy and improve the properties. The aim of this dissertation is to investigate the effects of cryogenic processes, including friction stir processing (FSP), machining and burnishing, on Al 7050-T7451 alloy to solve the inhomogeneity issue and improve its surface integrity. FSP is applied to modify the microstructure of Al 7050-T7451 alloy for achieving more homogeneous structure with near ultra-fine grains (UFG) which were less than 2 µm, particularly in cryogenic FSP with liquid nitrogen as the coolant. Approximately 10% increase could be observed from the hardness measurement from the samples processed by cryogenic FSP, in contrast to dry FSP. Also, the texture change from Al (200) to Al (111) could be achieved in all the samples processed by dry and cryogenic FSP. Cryogenic machining and burnishing processes were also applied to enhance the surface integrity of the manufactured components with near-UFG structure. The highest cutting temperature was reduced by up to 44.7% due to the rapid cooling effect of liquid nitrogen in cryogenic machining, compared with dry machining. Nano grains were produced in the refined layers induced by cryogenic burnishing. And, up to 35.4% hardness increase was obtained within the layer depth of 200 µm in the cryogenically-burnished surface. A numerical finite element method (FEM) model was developed for predicting the process performance in burnishing. Less than 10% difference between the experimental and predicted burnishing forces was achieved in the simulation of cryogenic burnishing, and reasonable predictions were also achieved for temperatures, severe plastic deformation (SPD) layers.

The functional performance of joint implants is largely determined by the surface layer properties in contact. Wear/debris-induced osteolysis and aseptic loosening has been identified as the major cause of failure of metal-on-metal joint implants. A crucial requirement for the long-term stability of the artificial joint is to minimize the release of debris particles. Severe plastic deformation (SPD) processes have been used to modify the surface integrity properties by generating ultrafine, or even nano-sized grains and grain size gradients in the surface region of many materials. These fine grained materials often exhibit enhanced surface integrity properties and improved functional performance (wear resistance, corrosion resistance, fatigue life, etc.) compared with their conventional coarse grained counterparts. The aim of the present work is to investigate the effect of a SPD process, cryogenic burnishing, on the surface integrity modifications of a Co-Cr-Mo alloy, and the resulting wear performance of this alloy due to the burnishing-induced surface integrity properties. A systematic experimental study was conducted to investigate the influence of different burnishing parameters on distribution of grain size, phase structure and residual stresses of the processed material. The wear performance of the processed Co-Cr-Mo alloy was tested via pin-on-disk wear tests. The results from this work show that the cryogenic burnishing can significant improve the surface integrity of the Co-Cr-Mo alloy which would finally lead to advanced wear performance due to refined microstructure, high hardness, compressive residual stresses and favorable phase structure on the surface layer. A finite element model (FEM) was developed for predicting the grain size changes during burnishing of Co-Cr-Mo alloy under both dry and cryogenic conditions. A new material model was used for incorporating flow stress softening and associated grain size refinement caused by the dynamic recrystallization (DRX). The new material model was implemented in a commercial FEM software as a customized user subroutine. Good agreement between predictions and experimental observations was achieved. Encouraging trends are revealed with great potential for application in industry.

Ces travaux de thèse s'inscrivent dans le cadre du projet européen ACCENT qui fait suite au projet européen ManHIRP (2001-2005). Ces travaux ont pour objectifs principaux de développer une méthodologie expérimentale permettant d'établir une fenêtre de conditions de coupe garantissant une intégrité matière acceptable de la pièce en Ti-6Al-4V usinée, en s'appuyant sur la mesure des signaux des moyens de surveillance en cours d'usinage.Une attention particulière s'est portée sur l'identification et la classification des anomalies géométriques et de celles produites sur la surface usinée en fonction de la vitesse de coupe et de l'avance. Parallèlement aux investigations sur les anomalies géométriques et de surface, une étude du mode d'endommagement de l'outil en carbure cémenté WC-Co non revêtu et de celle de l'évolution des signaux de surveillance ont conduit à une bien meilleure compréhension des phénomènes liés à la coupe.Les anomalies générées en sous-couche de la surface usinée, telles que les couches à grains déformés et les « couches blanches » ont été étudiées par l'intermédiaire d'analyses métallurgiques fines comme la microsonde de Castaing et par des observations et des analyses au microscope électronique à transmission (MET). Des mesures de microdureté et de contraintes résiduelles ont complété ces analyses chimiques et microstructurales. Aussi, la connaissance de l'état métallurgique et mécanique de ces anomalies a permis de déduire leur genèse et les mécanismes de déformation et de transformations métallurgiques (phases et taille de grains) qui ont opéré en sous-couche du Ti-6Al-4V. Le suivi par la technique de l'analyse d'images des paramètres microstructuraux attachés aux grains globulaires alpha a conduit à mieux comprendre l'écoulement de la matière selon les directions de coupe et d'avance ainsi que les mécanismes de dissolution de ces phases globulaires alpha lorsque l'effet thermique prend le pas sur l'effet mécanique pendant l'usinage. A l'issue de ces caractérisations métallurgiques, des corrélations ont été entreprises entre les anomalies générées et les signaux des moyens de surveillance. Celles-ci s'appuient principalement sur les efforts radiaux dont l'évolution singulière au cours du temps indique l'apparition de défauts. L'amplitude de cet effort radial se corrèle avec la profondeur de la couche de Ti-6Al-4V affectée thermomécaniquement. / The scientific works presented in this thesis is taken place within the framework of an European project ACCENT which is the continuity of the ManHIRP European project (2001-2005). The main aim of these studies is the development of an experimental approach allowing of the determination of an acceptable surface integrity within the validity domain according to the cutting parameters by using the recorded monitoring signals during turning operation. The identification and the classification of the geometrical anomalies generated on the machined surface versus the cutting speed and feed rate were especially investigated. At the same time, damage on uncoated cemented carbide and evolution on process monitoring signals have conducted to a better understanding of cutting phenomena. The anomalies generated within the machined sub-surface such as the highly worked layers and “white layers” were studied with fine metallurgical analysis like the use of Castaing microprobe and transmission electron microscopy (TEM). In addition, micro-hardness and residual stresses measurements have completed the previous analysis. The knowledge of the metallurgical and mechanical states within the sub-layer have enabled to deduce the causes of their formation and to define the deformation mechanisms and the metallurgical transformations (phases and grains size) which have occurred during the machining operation. The tracking of the microstructural features related to globular alpha grains by the investigations of the images analysis have led to a better understanding of material flow according to the cutting and feed directions. Also, the dissolution phenomena of globular alpha grains occurring when the thermal loading becomes preponderant before the mechanical one has been highlighted. After these metallurgical analyses, correlations between the surface integrity and the process monitoring signals have been found. The singular evolution of the radial force signal indicates the anomalies appearance. Its amplitude is linked with the depth of the thermo-mechanically affected sub-layer of the machined surface.