<p>The cylinder liners’ surface is really important in an engine because it corresponds with piston rings to a tribologic system indispensable to know for reasons of wear, of oil consumption and engine’s life time. For these reasons, it is important to measure and characterize these surfaces.</p><p>The first part of the project is the observation of the impact of the number of strokes of the plateau honing on the surface of the cylinder liners. It is interesting to observe the impact of the variation of the number of strokes of the plateau honing on the peaks, plateaus and valleys of the surface.</p><p>The second part of the project is the simulation of the oil flow on the surface to observe the links between the roughness parameters and the oil flow and the shear stress.</p><p>The results are interesting, we will observe that the number of strokes of honing as a good impact on the quality of the surface.</p><p>In the second part of the project, the results show a correlation between the machining parameters and the roughness and functional parameters.</p><p>It could be interesting to mix the two parts of the project to see the correlation among machining, roughness and functional parameters for the samples made in the first of the project.</p>

The cylinder liners’ surface is really important in an engine because it corresponds with piston rings to a tribologic system indispensable to know for reasons of wear, of oil consumption and engine’s life time. For these reasons, it is important to measure and characterize these surfaces. The first part of the project is the observation of the impact of the number of strokes of the plateau honing on the surface of the cylinder liners. It is interesting to observe the impact of the variation of the number of strokes of the plateau honing on the peaks, plateaus and valleys of the surface. The second part of the project is the simulation of the oil flow on the surface to observe the links between the roughness parameters and the oil flow and the shear stress. The results are interesting, we will observe that the number of strokes of honing as a good impact on the quality of the surface. In the second part of the project, the results show a correlation between the machining parameters and the roughness and functional parameters. It could be interesting to mix the two parts of the project to see the correlation among machining, roughness and functional parameters for the samples made in the first of the project.

In recent times a number of workers have pointed out the importance of microcrack formation to the machining process and to surface integrity requirements of machined components. Microcracks have been identified within the shear zone and their presence used to explain some aspects of the chip formation process. It is clear that microcracks represent a major feature in the shear zone in machining, particularily when the workpiece is a two-phase material. The presence of microcracks in the machined surface was reported some fifteen years ago and confirmed recently. A preliminary study carried out on a number of materials machined under various cutting conditions has indicated that microcracks are produced in machined surfaces as a result of machining. However, to the present time there has been no systematic study of the formation of microcracks in the machined surface, and their extent, dimensions, and the conditions under which they are produced are completely unknown. In so far as microcracks may affect the fatigue, corrosion and other properties of the machined surface, it is important that a method of quantifying microcrack formation should be found. A feasibility study has been carried out which has led to the use of the transmission electron microscope as a tool to quantify microcrack formation in the machined surface. A technique based on transmission electron microscopy is described in the present thesis along with its application. Two new parameters, the microcrack area ratio "Ma" and the microcrack density "Md" are introduced and defined. The extent of microcrack formation in the machined surface is studied as a result of varying: (i)- cutting speed, (ii)- undeformed chip thickness, (iii)- rake angle, (iv)- workpiece hardness. The results are discussed and conclusions drawn. Finally, a number of suggestions for future work are formulated which mark the start of a whole new area of research in surface microcracking.

Este trabalho avalia a influência do método e qualidade do esmerilhamento de tarugos na qualidade superficial de barras redondas de aço laminadas. Foi avaliada a rejeição de barras laminadas para três condições diferentes de acabamento superficial de tarugo – não esmerilhado, esmerilhado total simples, e esmerilhamento total duplo. Constatou-se que o esmerilhamento superficial de tarugos melhora a qualidade superficial de barras laminadas e, para os aços testados, o esmerilhamento total simples ofereceu melhor custo beneficio entre rendimento metálico e rejeição de barras por defeito superficial. Também se constatou que a profundidade de remoção da camada superficial do tarugo no esmerilhamento não é proporcional à redução de defeitos no produto laminado, sendo a aproximação da camada colunar uma variável com provável influência em tal resultado, assim como a presença de defeitos internos subsuperficiais, que tendem a aflorar com a redução da distância até a superfície da peça. / This work evaluates the influence of billet grinding method and quality in surface defects of hot rolling steel bars. It was evaluated bar rejection rates due to surface defects for three different billet surface conditions: without grinding, bright grinding of the entire surface and double bright grinding of the entire surface. The results show that the bright grinding of the entire surface with a single pass results in better cost benefit between yield loss and bar rejection rates. It was also observed that the grinding depth of the superficial layer of the billet is not proportional to the reduction of defects in the rolled product. This may occur in consequence of the reduction of the chill zone thickness, or even by the presence of sub superficial defects that can emerge to the surface with the reduction of the defect distance to the billet surface

Particleboard (PB) is a widely used panel material because of its physical properties and low cost. Unfortunately, cutting can degrade its surface creating rejects and increasing manufacturing costs. A major challenge is PB’s internal variability. Different particle and glue bond strength combinations can sometimes create high quality surfaces in one area and defects such as edge chipping in nearby areas. This research examines methods of improving surface quality by examining PB characteristics and their interactions with the cutting tool. It also develops an analytical model and software tool that allows the effects of these factors to be simulated, thereby giving practical guidance and reducing the need for costly experiments. When PB is cut and the glue bond strength is weaker than the particle strength, particles are pulled out, leading to surface defects. When instead the glue bond strength is stronger than the particle strength, particles are smoothly cut, leading to a high quality surface. PB is modeled as a matrix of particles each with stochastically assigned material and glue bond strengths. The PB model is layered allowing particles to be misaligned. Voids are modeled as missing particles. PB cutting is modeled in three zones. In the finished material and tool tip zones, particles are compressed elastically and then crushed at constant stress. After failure, chip formation occurs in the chip formation zone. At large rake angles, the chip is modeled as a transversely loaded beam that can fail by cleavage at its base or tensile failure on its surface. At small rake angles, the chip is modeled as the resultant force acting on the plane from the tool tip through to the panel surface. Experimental and simulation results show that cutting forces increase with depth of cut, glue content and particle strength. They decrease with rake angle. Glue bond strength can be increased to the equivalent particle strength through the selection of particle geometry and the subsequent increased glue bond efficiency, which increases the cut surface quality without the need for additional glue. Minimizing the size and frequency of voids and using larger rake angles can also increase surface quality.

Particleboard (PB) is a widely used panel material because of its physical properties and low cost. Unfortunately, cutting can degrade its surface creating rejects and increasing manufacturing costs. A major challenge is PB’s internal variability. Different particle and glue bond strength combinations can sometimes create high quality surfaces in one area and defects such as edge chipping in nearby areas. This research examines methods of improving surface quality by examining PB characteristics and their interactions with the cutting tool. It also develops an analytical model and software tool that allows the effects of these factors to be simulated, thereby giving practical guidance and reducing the need for costly experiments. When PB is cut and the glue bond strength is weaker than the particle strength, particles are pulled out, leading to surface defects. When instead the glue bond strength is stronger than the particle strength, particles are smoothly cut, leading to a high quality surface. PB is modeled as a matrix of particles each with stochastically assigned material and glue bond strengths. The PB model is layered allowing particles to be misaligned. Voids are modeled as missing particles. PB cutting is modeled in three zones. In the finished material and tool tip zones, particles are compressed elastically and then crushed at constant stress. After failure, chip formation occurs in the chip formation zone. At large rake angles, the chip is modeled as a transversely loaded beam that can fail by cleavage at its base or tensile failure on its surface. At small rake angles, the chip is modeled as the resultant force acting on the plane from the tool tip through to the panel surface. Experimental and simulation results show that cutting forces increase with depth of cut, glue content and particle strength. They decrease with rake angle. Glue bond strength can be increased to the equivalent particle strength through the selection of particle geometry and the subsequent increased glue bond efficiency, which increases the cut surface quality without the need for additional glue. Minimizing the size and frequency of voids and using larger rake angles can also increase surface quality.

Este trabalho avalia a influência do método e qualidade do esmerilhamento de tarugos na qualidade superficial de barras redondas de aço laminadas. Foi avaliada a rejeição de barras laminadas para três condições diferentes de acabamento superficial de tarugo – não esmerilhado, esmerilhado total simples, e esmerilhamento total duplo. Constatou-se que o esmerilhamento superficial de tarugos melhora a qualidade superficial de barras laminadas e, para os aços testados, o esmerilhamento total simples ofereceu melhor custo beneficio entre rendimento metálico e rejeição de barras por defeito superficial. Também se constatou que a profundidade de remoção da camada superficial do tarugo no esmerilhamento não é proporcional à redução de defeitos no produto laminado, sendo a aproximação da camada colunar uma variável com provável influência em tal resultado, assim como a presença de defeitos internos subsuperficiais, que tendem a aflorar com a redução da distância até a superfície da peça. / This work evaluates the influence of billet grinding method and quality in surface defects of hot rolling steel bars. It was evaluated bar rejection rates due to surface defects for three different billet surface conditions: without grinding, bright grinding of the entire surface and double bright grinding of the entire surface. The results show that the bright grinding of the entire surface with a single pass results in better cost benefit between yield loss and bar rejection rates. It was also observed that the grinding depth of the superficial layer of the billet is not proportional to the reduction of defects in the rolled product. This may occur in consequence of the reduction of the chill zone thickness, or even by the presence of sub superficial defects that can emerge to the surface with the reduction of the defect distance to the billet surface

Orientador: Marcos Tadeu Tiburcio Gonçalves / Banca: Ricardo Marques Barreiros / Banca: Marcos Valério Ribeiro / Banca: João Batista Turrioni / Banca: Eduardo Mauro do Nascimento / Resumo: O presente trabalho teve como objetivo principal, verificar o desempenho de juntas coladas de peças de Eucalyptus sp., submetidos à esforços de cisalhamento e à tração normal, em função da qualidade superficial dos planos da madeira colados e das superfícies usinadas em relação à posição dos anéis de crescimento da madeira, empregando-se dois adesivos de diferentes fabricantes, à base de Poli Acetato de Vinila (cola PVA). Os adesivos foram denominados por C1 e C2, sendo que o primeiro apresentava certa resistência à umidade enquanto que o segundo não. Na usinagem das superfícies da linha de colagem dos corpos de prova, foram empregadas as velocidades nominais de avanço „„ " para o processo de fresamento: 6,0 m/min; 11,0 m/min e 15,0 m/min, correspondendo, respectivamente aos avanços por dente "fz" da ferramenta de corte: 0,86 mm; 1,57 mm e 2,14 mm. Os corpos de prova confeccionados foram preparados para composições com linha de cola em diferentes planos em relação aos anéis de crescimento da madeira. Tais composições de planos resultaram nos seguintes conjuntos de superfícies coladas: R-R; R-T; T-T e RT-RT, sendo os mesmos submetidos a ensaios normatizados pela Norma ABNT - NBR 7190 para testes de resistência à ruptura na lâmina de cola por esforços de cisalhamento e por tração normal. Pôde-se inferir um melhor desempenho para uso do adesivo denominado por "C1" e melhor superfície de adesão para a velocidade de avanço intermediária de 11,0 m/min. Quanto aos diferentes planos de corte, os resultados sugerem que na média o plano T-T possui maior resistência ao cisalhamento e tração normal. No entanto, estudos futuros envolvendo a correlação entre a composição dos planos e a resistência mecânica, são necessários para conhecer a correlação entre estas importantes variáveis envolvidas no processo de usinagem da madeira. / Abstract: The present work aimed to check the Eucalyptus sp bonded joints parts performance, submitted to shear stress and tensile strength, depending on the surface quality of wood glued plans and the position relation of wood growth rings machined surfaces, using two different manufacturers adhesives, based on Poly Vinyl Acetate (PVA glue). The adhesives were named by C1 and C2, where the first one showed some resistance to moisture while the second one does not. In order to make the bonding line surface machining for the specimens, it was employed three nominal feed speeds called, „„ ", for the milling process: 6,0 m/min, 11,0 m/min and 15,0 m / min, corresponding respectively to the tooth advances "fz" cutting tool: 0,86 mm, 1,57 mm and 2,14 mm. The specimens were made for different compositions in the glue line at different relations on growth rings of wood levels. Such plans compositions resulted in the following glued surfaces sets: R-R, R-T, T-T and RT-RT, and subjected to the same standardized tests by ABNT - NBR 7190, for testing the strength for blade glue, it was chosen two tests: shear strain and tensile strength. It might be inferred for a better performance had obtained for the adhesive called "C1" and a better surface adhesion for intermediate feed speed of 11.0 m / min. The results suggest to different cutting plans on average, the TT plane had a higher resistance to shear and tensile strength. However, future studies involving the correlation between the composition and mechanical strength of the plans are required to know the correlation between these important variables involved in the wood machining. / Doutor

Este trabalho avalia a influência do método e qualidade do esmerilhamento de tarugos na qualidade superficial de barras redondas de aço laminadas. Foi avaliada a rejeição de barras laminadas para três condições diferentes de acabamento superficial de tarugo – não esmerilhado, esmerilhado total simples, e esmerilhamento total duplo. Constatou-se que o esmerilhamento superficial de tarugos melhora a qualidade superficial de barras laminadas e, para os aços testados, o esmerilhamento total simples ofereceu melhor custo beneficio entre rendimento metálico e rejeição de barras por defeito superficial. Também se constatou que a profundidade de remoção da camada superficial do tarugo no esmerilhamento não é proporcional à redução de defeitos no produto laminado, sendo a aproximação da camada colunar uma variável com provável influência em tal resultado, assim como a presença de defeitos internos subsuperficiais, que tendem a aflorar com a redução da distância até a superfície da peça. / This work evaluates the influence of billet grinding method and quality in surface defects of hot rolling steel bars. It was evaluated bar rejection rates due to surface defects for three different billet surface conditions: without grinding, bright grinding of the entire surface and double bright grinding of the entire surface. The results show that the bright grinding of the entire surface with a single pass results in better cost benefit between yield loss and bar rejection rates. It was also observed that the grinding depth of the superficial layer of the billet is not proportional to the reduction of defects in the rolled product. This may occur in consequence of the reduction of the chill zone thickness, or even by the presence of sub superficial defects that can emerge to the surface with the reduction of the defect distance to the billet surface

Particleboard (PB) is a widely used panel material because of its physical properties and low cost. Unfortunately, cutting can degrade its surface creating rejects and increasing manufacturing costs. A major challenge is PB’s internal variability. Different particle and glue bond strength combinations can sometimes create high quality surfaces in one area and defects such as edge chipping in nearby areas. This research examines methods of improving surface quality by examining PB characteristics and their interactions with the cutting tool. It also develops an analytical model and software tool that allows the effects of these factors to be simulated, thereby giving practical guidance and reducing the need for costly experiments. When PB is cut and the glue bond strength is weaker than the particle strength, particles are pulled out, leading to surface defects. When instead the glue bond strength is stronger than the particle strength, particles are smoothly cut, leading to a high quality surface. PB is modeled as a matrix of particles each with stochastically assigned material and glue bond strengths. The PB model is layered allowing particles to be misaligned. Voids are modeled as missing particles. PB cutting is modeled in three zones. In the finished material and tool tip zones, particles are compressed elastically and then crushed at constant stress. After failure, chip formation occurs in the chip formation zone. At large rake angles, the chip is modeled as a transversely loaded beam that can fail by cleavage at its base or tensile failure on its surface. At small rake angles, the chip is modeled as the resultant force acting on the plane from the tool tip through to the panel surface. Experimental and simulation results show that cutting forces increase with depth of cut, glue content and particle strength. They decrease with rake angle. Glue bond strength can be increased to the equivalent particle strength through the selection of particle geometry and the subsequent increased glue bond efficiency, which increases the cut surface quality without the need for additional glue. Minimizing the size and frequency of voids and using larger rake angles can also increase surface quality. / Applied Science, Faculty of / Mechanical Engineering, Department of / Graduate