Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido

Detalhes bibliográficos
Autor(a) principal: Tiago Junio Augusto da Silva
Data de Publicação: 2024
Tipo de documento: Dissertação
Idioma: por
Título da fonte: Repositório Institucional da UFMG
Texto Completo: http://hdl.handle.net/1843/74563
Resumo: In this work, an experimental investigation concerned with helical milling was conducted to explore its effectiveness in producing holes in hardened steel. Due to the limitations faced by drilling of hardened steels, helical milling emerges as an attractive option. The principal goal of this research was to investigate the influence of the cutting parameters on the macro and microgeometric quality of holes produced by helical milling of AISI D2 steel (56 HRC) using a ball nose end milling cutter with two coated carbide inserts as cutting tool. A series of experiments was carried out using the Taguchi methodology with a L8 orthogonal array, along with analysis of variance (ANOVA). The influence of the following helical milling parameters was evaluated at two levels: cutting speed (vc), axial depth of cut (ap), feed per tooth (fz), helical eccentricity (e), and cutting direction (up and down milling). The impact of these parameters on the trial cutting time, components of helical milling force and hole quality (diameter deviation, circularity, cylindricity and roughness) was investigated. Cutting power and the morphology of the chips were also subject to analysis. Helical milling operation proved effective, achieving holes with IT7 quality and N7 class. The statistical analysis confirmed that machining depth reduced trial cutting time. Additionally, this same factor was the most influential on roughness. The up milling direction reduced the components of helical milling force (Fz and Fr). Regarding the diameter, circularity and cylindricity deviations, up milling also reduced these deviations, especially the former. Similarly to trial cutting time, form deviations were reduced by using lower eccentricity, as well as higher cutting speed, although these levels increased the hole wall roughness. Morphological analysis of chips showed that less serrated chips (GS) were associated with lower cutting power, while a higher serration frequency (f) was related to better surface quality. In this context, the optimal levels of helical milling parameters were vc = 40 m/min, ap = 0.25 mm, fz = 0.08 mm/tooth, e = 2 mm, and the up milling direction.
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spelling Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecidoFresamento helicoidalAço ABNT D2TaguchiMetal duro revestidoQualidade dos furosFresagem - Trabalhos em metalMetais - CorteUsinagemIn this work, an experimental investigation concerned with helical milling was conducted to explore its effectiveness in producing holes in hardened steel. Due to the limitations faced by drilling of hardened steels, helical milling emerges as an attractive option. The principal goal of this research was to investigate the influence of the cutting parameters on the macro and microgeometric quality of holes produced by helical milling of AISI D2 steel (56 HRC) using a ball nose end milling cutter with two coated carbide inserts as cutting tool. A series of experiments was carried out using the Taguchi methodology with a L8 orthogonal array, along with analysis of variance (ANOVA). The influence of the following helical milling parameters was evaluated at two levels: cutting speed (vc), axial depth of cut (ap), feed per tooth (fz), helical eccentricity (e), and cutting direction (up and down milling). The impact of these parameters on the trial cutting time, components of helical milling force and hole quality (diameter deviation, circularity, cylindricity and roughness) was investigated. Cutting power and the morphology of the chips were also subject to analysis. Helical milling operation proved effective, achieving holes with IT7 quality and N7 class. The statistical analysis confirmed that machining depth reduced trial cutting time. Additionally, this same factor was the most influential on roughness. The up milling direction reduced the components of helical milling force (Fz and Fr). Regarding the diameter, circularity and cylindricity deviations, up milling also reduced these deviations, especially the former. Similarly to trial cutting time, form deviations were reduced by using lower eccentricity, as well as higher cutting speed, although these levels increased the hole wall roughness. Morphological analysis of chips showed that less serrated chips (GS) were associated with lower cutting power, while a higher serration frequency (f) was related to better surface quality. In this context, the optimal levels of helical milling parameters were vc = 40 m/min, ap = 0.25 mm, fz = 0.08 mm/tooth, e = 2 mm, and the up milling direction.Neste trabalho, foi realizada uma investigação experimental da operação de fresamento helicoidal para explorar sua efetividade na produção de furos em aço endurecido. Diante dos dificuldade que a furação convencional enfrenta, especialmente em materiais de alta dureza, o fresamento helicoidal emerge como uma opção atraente. O objetivo geral foi investigar a influência dos parâmetros de corte sobre a qualidade macro e microgeométrica de furos produzidos pela operação de fresamento helicoidal no aço ABNT D2 (56 HRC). A ferramenta de corte utilizada foi uma fresa de topo esférica intercambiável equipada com dois insertos de metal duro revestidos. Para alcançar este objetivo, uma série de ensaios foi realizada utilizando a metodologia de Taguchi, com um arranjo ortogonal L8, juntamente com a análise de variância (ANOVA). Foi avaliada a influência dos seguintes parâmetros de fresamento helicoidal em dois níveis: velocidade de corte (vc), profundidade de usinagem (ap), avanço por dente (fz), excentricidade helicoidal (e) e o sentido de corte (discordante/concordante). Foi analisado o impacto destes parâmetros sobre o tempo de corte experimental, as componentes da força de fresamento helicoidal e qualidade dos furos (desvio diametral, circularidade, cilindricidade e rugosidade) foi analisado. A potência de corte e a morfologia dos cavacos gerados também foram objeto de análise. A operação de fresamento helicoidal mostrou-se eficaz, resultando em furos de qualidade IT7 e classe N7. A análise estatística confirmou que profundidade de usinagem reduziu o tempo de corte experimental. Além disso, este mesmo fator foi o mais influente sobre a rugosidade. O sentido de corte discordante reduziu as componentes da força de fresamento helicoidal (Fz e Fr). Em relação aos desvios diametral, circularidade e de cilindricidade, o sentido de corte discordante também reduziu esses desvios, especialmente o desvio diametral. Assim como o tempo de corte experimental, os desvios de forma foram reduzidos ao utilizar uma excentricidade helicoidal mais baixa, bem como uma velocidade de corte mais alta, embora estes níveis tenham aumentado a rugosidade. A análise morfológica dos cavacos mostrou que cavacos menos serrilhados (GS) estão associados a uma menor potência de corte, enquanto uma maior frequência do serrilhado (f) está relacionada a uma melhor qualidade superficial. Neste contexto, os melhores níveis de parâmetros de fresamento helicoidal foram vc = 40 m/min, ap = 0,25 mm, fz = 0,08 mm/dente e = 2 mm e o uso do sentido de corte discordante.CAPES - Coordenação de Aperfeiçoamento de Pessoal de Nível SuperiorUniversidade Federal de Minas GeraisBrasilENG - DEPARTAMENTO DE ENGENHARIA MECÂNICAPrograma de Pós-Graduação em Engenharia MecanicaUFMGAlexandre Mendes Abrãohttp://lattes.cnpq.br/4498255089432603Marcelo Araújo CâmaraAnna Carla Monteiro de AraújoRicardo Augusto GonçalvesTiago Junio Augusto da Silva2024-08-21T15:33:49Z2024-08-21T15:33:49Z2024-04-08info:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/masterThesisapplication/pdfhttp://hdl.handle.net/1843/74563porinfo:eu-repo/semantics/openAccessreponame:Repositório Institucional da UFMGinstname:Universidade Federal de Minas Gerais (UFMG)instacron:UFMG2024-08-26T20:06:10Zoai:repositorio.ufmg.br:1843/74563Repositório InstitucionalPUBhttps://repositorio.ufmg.br/oairepositorio@ufmg.bropendoar:2024-08-26T20:06:10Repositório Institucional da UFMG - Universidade Federal de Minas Gerais (UFMG)false
dc.title.none.fl_str_mv Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido
title Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido
spellingShingle Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido
Tiago Junio Augusto da Silva
Fresamento helicoidal
Aço ABNT D2
Taguchi
Metal duro revestido
Qualidade dos furos
Fresagem - Trabalhos em metal
Metais - Corte
Usinagem
title_short Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido
title_full Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido
title_fullStr Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido
title_full_unstemmed Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido
title_sort Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido
author Tiago Junio Augusto da Silva
author_facet Tiago Junio Augusto da Silva
author_role author
dc.contributor.none.fl_str_mv Alexandre Mendes Abrão
http://lattes.cnpq.br/4498255089432603
Marcelo Araújo Câmara
Anna Carla Monteiro de Araújo
Ricardo Augusto Gonçalves
dc.contributor.author.fl_str_mv Tiago Junio Augusto da Silva
dc.subject.por.fl_str_mv Fresamento helicoidal
Aço ABNT D2
Taguchi
Metal duro revestido
Qualidade dos furos
Fresagem - Trabalhos em metal
Metais - Corte
Usinagem
topic Fresamento helicoidal
Aço ABNT D2
Taguchi
Metal duro revestido
Qualidade dos furos
Fresagem - Trabalhos em metal
Metais - Corte
Usinagem
description In this work, an experimental investigation concerned with helical milling was conducted to explore its effectiveness in producing holes in hardened steel. Due to the limitations faced by drilling of hardened steels, helical milling emerges as an attractive option. The principal goal of this research was to investigate the influence of the cutting parameters on the macro and microgeometric quality of holes produced by helical milling of AISI D2 steel (56 HRC) using a ball nose end milling cutter with two coated carbide inserts as cutting tool. A series of experiments was carried out using the Taguchi methodology with a L8 orthogonal array, along with analysis of variance (ANOVA). The influence of the following helical milling parameters was evaluated at two levels: cutting speed (vc), axial depth of cut (ap), feed per tooth (fz), helical eccentricity (e), and cutting direction (up and down milling). The impact of these parameters on the trial cutting time, components of helical milling force and hole quality (diameter deviation, circularity, cylindricity and roughness) was investigated. Cutting power and the morphology of the chips were also subject to analysis. Helical milling operation proved effective, achieving holes with IT7 quality and N7 class. The statistical analysis confirmed that machining depth reduced trial cutting time. Additionally, this same factor was the most influential on roughness. The up milling direction reduced the components of helical milling force (Fz and Fr). Regarding the diameter, circularity and cylindricity deviations, up milling also reduced these deviations, especially the former. Similarly to trial cutting time, form deviations were reduced by using lower eccentricity, as well as higher cutting speed, although these levels increased the hole wall roughness. Morphological analysis of chips showed that less serrated chips (GS) were associated with lower cutting power, while a higher serration frequency (f) was related to better surface quality. In this context, the optimal levels of helical milling parameters were vc = 40 m/min, ap = 0.25 mm, fz = 0.08 mm/tooth, e = 2 mm, and the up milling direction.
publishDate 2024
dc.date.none.fl_str_mv 2024-08-21T15:33:49Z
2024-08-21T15:33:49Z
2024-04-08
dc.type.status.fl_str_mv info:eu-repo/semantics/publishedVersion
dc.type.driver.fl_str_mv info:eu-repo/semantics/masterThesis
format masterThesis
status_str publishedVersion
dc.identifier.uri.fl_str_mv http://hdl.handle.net/1843/74563
url http://hdl.handle.net/1843/74563
dc.language.iso.fl_str_mv por
language por
dc.rights.driver.fl_str_mv info:eu-repo/semantics/openAccess
eu_rights_str_mv openAccess
dc.format.none.fl_str_mv application/pdf
dc.publisher.none.fl_str_mv Universidade Federal de Minas Gerais
Brasil
ENG - DEPARTAMENTO DE ENGENHARIA MECÂNICA
Programa de Pós-Graduação em Engenharia Mecanica
UFMG
publisher.none.fl_str_mv Universidade Federal de Minas Gerais
Brasil
ENG - DEPARTAMENTO DE ENGENHARIA MECÂNICA
Programa de Pós-Graduação em Engenharia Mecanica
UFMG
dc.source.none.fl_str_mv reponame:Repositório Institucional da UFMG
instname:Universidade Federal de Minas Gerais (UFMG)
instacron:UFMG
instname_str Universidade Federal de Minas Gerais (UFMG)
instacron_str UFMG
institution UFMG
reponame_str Repositório Institucional da UFMG
collection Repositório Institucional da UFMG
repository.name.fl_str_mv Repositório Institucional da UFMG - Universidade Federal de Minas Gerais (UFMG)
repository.mail.fl_str_mv repositorio@ufmg.br
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