Investigação experimental sobre a operação de fresamento helicoidal do aço ABNT D2 endurecido
Autor(a) principal: | |
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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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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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1816829582077067264 |