Limitation of conventional machining equipment has become a growing concern over the past two decades due to the demands for greater machining accuracy in today’s manufacturing. The development of micro-machining has therefore attracted significant attention; it signifies the advancement of national economy as well as the level of accuracy manufacturing industry could achieve. While the connection between tool lifespan, cost of machining and throughput is well established, the factor of tool lifespan appears to have more significance since the miniaturization of tool could lead to further performance concerns such as its lack of strength and durability. On the other hand, raising feed rate and spindle rotation speed are the two common approaches for increasing manufacturing throughput. Such approaches tend to cause an increase in the thrust force subjecting the tool to greater stress, which is the main cause of tool wear and even tool failure. Through literature review and preliminary experiments, it was found that spot-drill is often done prior to micro-drilling since it prepares a pre-drill countersunk hole that helps the alignment of tool for subsequent micro-drilling. Although such pre-drill step does improve the micro-drilling operation, the fundamental issue of tool diameter difference still remains. Often the tool used for pre-drill has a bigger diameter than the one for micro-drilling although a significant difference is always something to be avoided. This is because the difference has to be picked up by the tool used for micro-drilling and is directly linked to the wear caused by increased thrust force. In this research the operation of micro-drilling is investigated via mathematical models. Such operation is further broken down into various steps and stages so more detailed description can be achieved. The findings are then further enhanced by simulation based on the 3D model of micro-drilling. Three materials were selected for this research: Al 6061T, Al/Cu metal alloy panel and Carbon fibre reinforced composites. Such a selection enables the study of individual characteristics of different materials and the variation in respective thrust forces. Finally, Conclusions present the summary of the main findings from micro-drilling process analysis based on research and investigation shown in earlier chapters. By combining actual measurements on micro-drilling and mathematic model this research hopefully would improve the understanding towards micro-drilling processes.

In recent years, there has been a substantial growth in the application of carbon fiber reinforced plastic (CFRP) composite materials in automobile and aerospace industries due to their superior properties such as lightweight, high strength, excellent corrosion resistance, and minimal fatigue concerns. The present study evaluates the drilling performance of woven carbon fiber reinforced plastics under both dry and cryogenic cooling conditions using uncoated solid carbide drill with a through-hole for coolant application. The effects of the cooling conditions and the cutting parameters on drilling performance in drilling CFRP were evaluated in terms of generated thrust force, torque, cutting edge radius, outer corner flank wear, hole quality (including surface roughness, diameter error, roundness, delamination, burr formation, sub-surface quality). Both cooling conditions and cutting parameters were found to influence the thrust force and torque at different levels. The thrust force and the torque are higher in cryogenic cooling under all cutting parameters. In most of the cases, cryogenic drilling gives better bore-hole quality with lower surface roughness, more accurate diameter, less burr generation, better sub-surface quality, etc. Also, the tool-wear rates measured in drilling shows that cryogenic drilling produces less tool-wear than dry drilling does.

Orientador: Marcos Valério Ribeiro / Resumo: A utilização de materiais compósitos em componentes do setor aeronáutico vem crescendo muito nos últimos anos. Isso se deve ao fato destes materiais apresentarem boas propriedades mecânicas, aliadas a sua baixa massa específica. Dentre estes, os laminados metal fibra, são uma classe de materiais que vem ganhando destaque. Contudo seu emprego na maioria dos casos, requer a confecção de furos, algo que é muito complexo e pode causar danos ao material. Portanto, o objetivo desta pesquisa foi estudar o processo de furação em cheio de um laminado de metal fibra de alumínio 2024-T3/epóxi/fibra de vidro apoiado no alumínio 7075, aplicando diferentes parâmetros de usinagem para avaliar a influência na qualidade dos furos e o desgaste das ferramentas, correlacionando com a potência consumida, vibração, força de avanço, variações dimensionais nos furos e alteração das propriedades mecânicas do material. Para tal, o material foi processado via moldagem por compressão a quente e caracterizado por meio dos ensaios de cisalhamento interlaminar (ILSS), cisalhamento por compressão (CST) e Lap shear. Posteriormente, foram realizados processos de furação utilizando 4000, 6000 e 8000 rpm, bem como avanços de 0,05; 0,1 e 0,2 mm/rot. Após a análise dos resultados, pode-se concluir que os parâmetros influenciaram nos dados de potência, vibração e força de avanço, bem como houve variação significativa nos diâmetros obtidos, sendo que o melhor resultado ocorreu para combinação de 6000 rpm com 0,05mm... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The use of composite materials in aeronautical components has been increased in the last years. This is due to these material presente good mechanical properties, allied with low specific mass. Among them, the fiber metal laminated (FML) are a class of materials that has been gaining prominence. However, its use in most cases requires the drilling of holes, which is very complex and can cause damage to the material. Therefore, the objective of this research was to study the conventional drilling process in aeronautical aluminum structures reinforced with fiber metal laminates. Applying different machining parameters, to evaluate the delamination and the wear tools, correlating with the power consumed, vibration, advance force, dimensional variations in the holes and variation of the mechanical properties on material. For this, the material was processed by hot compression molding and characterized by interlaminar shear stress (ILSS), compression shear test (CST) and Lap-shear. Afterwards, drilling processes were carried out using 4000, 6000 and 8000 rpm, as well as an advance of 0.05; 0.1 and 0.2 mm / rot. After the analysis of the results, it was possible to conclude that the parameters influenced the data of power, vibration and force of advance, as well as there was significant variation in the diameters obtained, being the best result occurred for a combination of 6000 rpm with 0,05mm / rot. It can also be stated that there is a tendency of shear strength of the Lap Shear... (Complete abstract click electronic access below) / Mestre

Le perçage vibratoire auto entretenu propose la rupture technologique nécessaire à une augmentation de la performance du perçage profond. Un porte outil spécifique a été conçu pour permettre les vibrations axiales, et se présente sous la forme d'un système masse ressort, dont les caractéristiques sont identifiés par l'utilisation de la théorie des lobes de stabilité. L'identification des caractéristiques géométriques d'un outil optimal passe par la caractérisation des aspects tribologiques, des caractéristiques mécaniques du matériau usiné, ainsi que la définition d'une préparation d'arête adéquate. Enfin, ce procédé étant piloté par l'énergie de la coupe, deux modèles d'effort ont été identifiés. La méthode CAM repose sur la discrétisation de l'effort de perçage lors de la phase de pénétration, alors que l'approche analytique permet de prédire l'effort à partir d'un modèle de coupe analytique identifié à partir d'essais de coupe oblique. / Self-sustained vibration drilling offers the technological breakthrough needed to increase the performance of deep drilling. A special tool holder is designed to allow axial vibration, and comes as a spring mass system, whose characteristics are identified by the use of the theory of stability lobes. Identification of the geometric characteristics of an optimal tool requires the characterization of tribological aspects, mechanical properties of the machined material, and the definition of a proper edge preparation. Finally, this process is driven by the energy of the cut, and two types of effort have been identified. The Edge-Material-Pair Method is based on the discretization of the drilling thrust force during penetration phase, while the analytical approach can predict forces from a cut pattern identified from oblique cutting tests.

Fundação de Amparo a Pesquisa do Estado de Minas Gerais / The aim of this work is to determine the life of twist drills used for dental implantology when drilling bovine tibia bones and to study the influence of the cutting conditions. The inputs variables considered were the cutting tool material, the feed velocity and the spindle speed. The outputs variables monitored were the number of drilled holes, the workpiece temperature, the thrust force and the tool wear. The tests were carried out in a CNC machine center and the cutting parameters were varied following a 23 experimental design. Three types of uncoated tool materials were used, a martensitic stainless steel (M340/Böhler), an austenitic stainless steel (AISI 316L) and a ceramic (zircon stabilized with Y2O3). The tool lives were expressed by the number of drilled holes considering a limit of the workpiece temperature of 47ºC, used as the end of tool life criterion. The temperatures were monitored by using three thermocouples of the type T (cupper-constantan) inserted in the work material samples, positioned very close to the drill wall. The thrust force was measured with a Kistler rotating dynamometer. A data acquisition board and a computer were used for automation of the measurement system. A mixture of 20% of car radiator fluid and water was applied as coolant (irrigation) with a flow rate of 160 ml/min. The results showed that the martensitic stainless steel outperformed the austenitic stainless steel and the ceramic material. The lowest temperatures and a conformity state at the clinic standard for thrust force values were obtained with the highest cutting parameters (45 mm/min and 2500 rpm). It was observed that the higher feed velocity promoted a temperature drop, while the higher spindle speed decreased the thrust force. / O objetivo deste trabalho é determinar a vida de brocas para implantodontia através de furação em tíbia bovina e estudar a influência das condições de corte utilizadas. As variáveis de entrada do trabalho foram o material de ferramenta, a velocidade de avanço e a rotação. E as variáveis de saída monitoradas foram o número de furos realizados, a temperatura próxima à parede óssea, a força de avanço e o desgaste das ferramentas. Os testes foram executados em um Centro de Usinagem variando os parâmetros de corte seguindo um planejamento experimental 23. Três tipos de materiais de ferramenta não revestidos foram utilizados, um aço inoxidável martensítico (M340/Böhler), um aço inoxidável austenítico (AISI 316L) e um cerâmico (zircônia estabilizada com Y2O3). A vida da ferramenta foi expressa pelo número de furos realizados considerando como critério de fim de vida a temperatura na peça igual a 47ºC. As temperaturas foram monitoradas pelo uso de três termopares do tipo T (cobre-constantan) inseridos no corpo-de-prova e posicionados próximo à parede do furo. A força de avanço foi medida com um dinamômetro rotativo Kistler. Uma placa de aquisição de dados e um computador foram utilizados para a automação do sistema de medição. Uma mistura de 20% de líquido de arrefecimento automotivo foi utilizada como refrigerante (irrigação) a uma vazão de 160 ml/min. Os resultados mostraram que o aço inoxidável martensítico superou o aço inoxidável austenítico e o material cerâmico. Menores temperaturas e um estado de conformidade aos padrões clínicos para valores de força de avanço foram obtidos com os maiores parâmetros de corte (45 mm/min e 2500 rpm). Observou-se que velocidade de avanço alta promove principalmente a queda da temperatura, enquanto a rotação elevada à queda na força de avanço. / Mestre em Engenharia Mecânica

Diplomová práce se zabývá analýzou technologie vysoceproduktivního vystružování. V rámci práce byly provedeny testy vystružování za různých technologických podmínek (vc=40, 60, 80, 100 m/min; f=0.2, 0.4, 0.6, 0.8 mm) na materiálu austenitické oceli DIN 1.4404 při použití vystružovací hlavicí MT3. Jednotlivé operace vystružování byly porovnány z hlediska parametrů jako tlačná síla, krouticí moment, výsledná drsnost obrobeného povrchu a dále z hlediska tvaru třísky. Následně byly vypočítány průměrné hodnoty a směrodatná odchylka naměřených parametrů. Dále bylo provedeno porovnání pomocí diagramů. Výsledky ukazují lepší kvalitu, nižší drsnost povrchu (Ra 0,37 µm) a méně zdeformovanou třísku při pomalejších řezných rychlostech (40 m/min) a menším posuvu na otáčku (0,2 mm). Výsledky také ukazují nárůst tlačné síly a krouticího momentu za uvedených technologických podmínek. Při zvyšující se řezné rychlosti vystružování tyto silové účinky klesají.

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Rotating bed reactors are used throughout the process industry. They are usedboth in the chemical industry and other industrial sectors, such as pharmaceuticals and the textile industry in decolorization due to by-products or contaminants.SpinChem AB manufactures rotary bed reactors (RBRs) to perform chemical reactions between liquids and solids. The solid material consists of spherical particles0.1 mm - 1 mm in diameter that are packed between two cylindrical spaces in theRBR. The goal of this project work is to determine the power number, the axial force thatthe RBRn experiences, the torque requirement on the motor and power consumptionof the the RBR when a fully developed turbulent flow is achieved. The purpose ofthe work is to optimize the technology from the energy usage point of view, makethe product simple and easily accessible for chemical and industrial processes as acontribution to the development of sustainable society. In order to achieve the purpose and goal of the projects, Computational Fluid Dynamics (CFD) combined withexperimental models were used. Computation were made in COMSOL Multiphysicsfor two turbulence models. In it, the rotating machinery was used with moving meshtechnique for both the standard k−ε model and the SST k−ω turbulence models.The result is then compared with the empirical models. Investigation were done for two models of the rotating bed reactors (RBRs). Onemodel is called RBR S2 with relatively small size and RBR S14 which is a muchlarger version. For RBR S2 the experimental results turned out to be, an output ofpower number which is 3.4, torque requirement of 0.03 Nm, power consumption of3 W and a thrust force of 0.11 N. While the simulation results turned out to bean output of power number which is about 1.2, torque requirement of 0.013 Nm, apower consumption of 2 W and thrust force of 0.8 N. Similarly, the experimentalresult for RBR S14 was as follows. A power number of 0.53, torque requirement of0.41 Nm, power consumption of 6 W and a thrust force of 4.16 N. The simulationresults turned out to be, a power number of 0.34, torque requirement of 0,40 Nm,a power consumption of 4.14 W and thrust force of 3.61 N. With the help of the calculated power numbers, the power required to rotate theRBR can then be determined. Power number is determined when a fully developedturbulent flow is achieved. For RBRS2, a fully developed turbulent flow is achievedat Re = 2.8·104 and the angular velocity at that Reynolds number is about 830RPM. At that speed, the power is shown to be about 4 W for RBRS2. For RBRS14,a fully developed turbulent flow is achieved at Re = 1.5 · 105 and then the speed atthat Reynols number is about 83 RPM. The power need at that stage is shown tobe about 20 W. / Roterande bäddreaktorer används inom hela processindustrin. De används bådeinom den kemiska industrin och andra industriella sektor såsom, läkemedel och textilindustrin vid avfärgning på grund av biprodukter eller föroreningar. SpinChemAB tillverkar roterande bed reaktorer (RBR) för att utföra kemiska reaktioner mellan vätska och fasta material. Det fasta materialet består av sfäriska partiklar på0,1 mm - 1 mm i diameter som packas mellan två cylindrar i RBRn. Målet med detta projektarbete var att bestämma effekt nummer, effekt som krävsvid det effekt nummer, kravet på vridmoment från motorn samt den axiella kraftensom den roterande bäddreaktorn upplever när ett fullt utvecklat turbulent flöde uppnåtts. Syftet med arbetet var optimera teknologin ur energianvändningssynpunkt, göra den enkel och lättillgänglig för kemiska och industriella processer som ett bidragför hållbar samhällsutveckling. För att kunna uppnå syftet och målet med projekten användes, avancerade beräkningsmetoder i födes mekanik (CFD) i kombinationmed experimentella modeller. Beräkningar gjordes i COMSOL Multiphysics för tvåturbulenta modeller. I de användes roterande maskineriet med en medföljande mesh (moving mesh) för både standard k-ε modellen och SST k-ω modellen. Resultatet jämfördes sedan med de empiriska modellerna. Undersökningarna gjordes för två modeller av RBR. Ena modellen heter RBR S2med relativt små tillstorlek och RBR S14 som är mycket större version. För RBR S2visar den experimentella resultaten ett effekt nummer på 3,4, vridmoment på 0,03Nm, effekt förbrukning på 3 W och en axiellkraft ("thrust force") på 0,11 N. Simuleringsresultatet visar ett effekt nummer på 1,2, vridmoment på 0,013 Nm, effektförbrukning på 2 W och en axiellkraft på 0,8 N. För RBR S14 visade det experimentella resultatet ett effekt nummer på 0,53, vridmoment på 0,41 Nm, effektförbrukning på 6 W och en axiellkraft ("thrust force") på 4,16 N. Simuleringsresultatetvisade att effekt nummer var 0,34, vridmoment på 0,40 Nm, effektförbrukning på4,14 W och en axiellkraft på 3,61 N. Med hjälp av de framräknade effektnummer kan effekten som behövs rotera RBRnbestämmas. Effektnummer bestäms när ett fullt utvecklat turbulent flöde uppnåtts. För RBRS2 uppnås ett fullt utvecklat turbulent flöde vid Re = 2,8·04 och vinkelhastigheten är 830 RPM vid det Reynolds nummer. Effekten som krävs för att drivaRBRn vid det läge är ca 4 W för RBRS2. För RBRS14 uppnås ett fullt utvecklatturbulent flöde vid Re = 1,5·105 och då har vi en hastighet på 83 RPM. Vid denhastighet visas effekten vara ca 20 W.

The thesis deals with the construction design of reversible swirl turbine used in a tidal range power plant for bidirectional operation. The theoretical part provides an overview of state-of-the-art technologies in the usage of tidal energy, mostly by means of tidal range and stream tidal power plants. It also analyses respective designs of tidal turbines and their advantages and disadvantages. The practical part of the thesis demonstrates individual steps applied when examining loading forces and also shows the design method and strength inspection procedure of the turbine and its parts, especially of the impeller, gears, shafts and bearings. Lastly, the paper outlines the selection approach of the most appropriate water plant generator.