Beruflich Dokumente
Kultur Dokumente
RESUMO
ABSTRACT
The face milling operation purpose is providing flat machined surfaces free from residual
strains at the cross section of the workpiece. On the other hand, the evidences presented in this
thesis are enough to demonstrate that the strain exists and its behavior can be related to technical
measurements such as the cutting tool helical profile, the feed rate, the cutting speed beyond the
materials mechanical and metallurgical properties.
Several face milling operation under conventional cutting conditions onto two super
alloys have been performed. A nickel base alloy and a cobalt base were observed. A titanium
base alloy has also been observed. The feed rate, the rake angle and the cutting speed were
manipulated aiming the evaluation of the residual strains under different strain rates. The
specimen has been evaluated in its strained condition throughout the use of scanning electronic
microscopy. Furthermore with the mathematical modeling it has been possible to conclude that
the residual strain at the cross sectional surface is supportable and the strained profile can be
evaluated through the use of the Slip Line Field plasticity theory.
The plastic behavior of the material has been evaluated with the Slip Line Field plasticity
theory with the Johnson-Cooks constitutive materials model. The cutting force estimation has
used the modified parallel shear plane zone machining model assured by P.L.B. Oxley and an
ancient Slip Line solution presented by Lee and Shaffer.
All of the details of this thesis which collaborate with the contribution concept have been
pointed out along this research, especially the derivation of the helical area profile as well as the
criticism related with the shear plane initial value definition and temperature estimation.
The continuum plasticity has been the main aspect to evaluate the stresses and also the
strains in the workpiece and also at the chip.
The materials strain hardening index is main point for a new evaluation of the P.L.B
Oxley machining model, and the understanding of how the mechanical properties related with
this index influence the residual plane strain and the other convergence conditions of strain
during the machining are suggested in order to build up the understanding of this contribution.
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SUMRIO
RESUMO ___________________________________________________________________i
ABSTRACT _________________________________________________________________ii
1. INTRODUO
1.1 Os elementos envolvidos na formao do cavaco _________________________________1
1.2 As operaes de corte ______________________________________________________2
1.3 A plasticidade do contnuo e seus efeitos na mecnica da formao do cavaco _________3
1.4 As superligas a base de nquel, cobalto e titnio _________________________________5
1.5 Objetivo ________________________________________________________________6
2. REVISO DA LITERATURA
2.1 O contato mestre-escravo na formao do cavaco ________________________________7
2.2 As velocidades envolvidas no processo de usinagem _____________________________20
2.3 A fora na formao do cavaco ______________________________________________23
2.4 A potncia de usinagem ____________________________________________________51
2.5 Condies tribolgicas do contato mestre-escravo _______________________________52
2.5.1 Consideraes sobre o atrito _________________________________________53
2.5.2 Consideraes sobre a lubrificao ____________________________________54
2.5.3 Consideraes sobre o desgaste ______________________________________55
2.5.4 Consideraes sobre a rea de contato _________________________________57
3. MATERIAIS E MTODOS
3.1 Introduo ______________________________________________________________ 116
3.2 Materiais _______________________________________________________________ 116
3.3 Metodologia experimental _________________________________________________ 119
4. RESULTADOS E DISCUSSO
5. CONSIDERAES FINAIS
5.1 Concluso _____________________________________________________________ 209
5.2 Trabalhos futuros _______________________________________________________ 213