Torneamento do aço ABNT 52100 endurecido utilizando ferramentas experimentais cerâmicas Al2O3+Cr2O3 e Al2O3+MgO
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Data
2023-03-06
Autores
Rodrigues, Glaydson André Siqueira
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Editor
Universidade Estadual Paulista (Unesp)
Resumo
Nos processos de fabricação por usinagem de aços endurecidos, o principal objetivo é eliminar a etapa de retificação produzindo maior produtividade e importante redução de custos. A qualidade da usinagem desses materiais proporciona aumento da vida à fadiga da peça, porém, as ferramentas de corte sofrem degradação com consequente redução de vida. Entre os aços endurecidos, o aço ABNT 52100 é utilizado principalmente na produção de rolamentos devido ao elevado teor de carbono, além de outros elementos de ligas como o cromo. Os elementos de ligas utilizado promove elevada dureza, que após a têmpera pode chegar a 66 HRC. Este estudo tem como objetivo analisar a usinabilidade do aço ABNT 52100 endurecido pelo processo de torneamento sem a utilização de fluido de corte com duas ferramentas cerâmica, uma base de Al2O3+Cr2O3 e a segunda à base de Al2O3+MgO. Com o objetivo de analisar a usinabilidade do aço ABNT 52100 endurecido no processo de torneamento e a viabilidade das ferramentas de corte, foi verificado o comportamento das variáveis de saída do processo como rugosidade, desgaste, avarias das ferramentas, potência de usinagem, vibração, emissão acústica, tipo e formas de cavaco. Utilizando um arranjo fatorial completo onde foram utilizadas duas velocidades de corte Vc (120 e 160 m/min.), três profundidades de usinagem ap (0,75;1,0 e 1,25 mm) para as duas ferramentas cerâmicas usinando sem fluido de corte. Observou-se que com diferentes dopagens é possível obter diferentes resultados no comportamento das ferramentas em usinagem e que a profundidade de usinagem (ap) é o fator que mais influenciou nos resultados de rugosidade. Os resultados obtidos demonstram que é possível, em superfícies torneadas do Aço ABNT 52100 endurecido, atingir rugosidades compatíveis com o processo de retificação utilizando ferramentas cerâmicas experimentais sem refrigeração, sendo que a ferramenta dopada com óxido de magnésio proporcionou resultados mais promissores.
In the manufacturing processes by machining of hardened steels, the main objective is to eliminate the grinding step producing higher productivity and important cost reduction. The quality of the machining of these materials provides increased fatigue life of the workpiece, but the cutting tools suffer degradation with consequent reduction in life. Among hardened steels, ABNT 52100 steel is used mainly in the production of bearings due to its high carbon content, in addition to other alloying elements such as chromium. The alloying elements used promotes high hardness, which after hardening can reach 66 HRC. This study aims to analyze the machinability of ABNT 52100 steel hardened by turning process without the use of cutting fluid with two ceramic tools, one based on Al2O3+Cr2O3 and the second based on Al2O3+MgO. In order to analyze the machinability of hardened ABNT 52100 steel in the turning process and the feasibility of the cutting tools, the behavior of the process output variables such as roughness, wear, tool failures, machining power, vibration, acoustic emission, chip type and forms were verified. Using a full factorial arrangement where two cutting speeds Vc (120 and 160 m/min.), three machining depths ap (0.75;1.0 and 1.25 mm) were used for the two ceramic tools machining without cutting fluid. It was observed that with different doping it is possible to obtain different results in the behavior of the tools in machining and that the machining depth (ap) is the factor that most influenced the roughness results. The results obtained show that it is possible, on turned surfaces of hardened ABNT 52100 steel to achieve roughness compatible with the grinding process using experimental ceramic tools without cooling, and the tool doped with magnesium oxide provided more promising results.
In the manufacturing processes by machining of hardened steels, the main objective is to eliminate the grinding step producing higher productivity and important cost reduction. The quality of the machining of these materials provides increased fatigue life of the workpiece, but the cutting tools suffer degradation with consequent reduction in life. Among hardened steels, ABNT 52100 steel is used mainly in the production of bearings due to its high carbon content, in addition to other alloying elements such as chromium. The alloying elements used promotes high hardness, which after hardening can reach 66 HRC. This study aims to analyze the machinability of ABNT 52100 steel hardened by turning process without the use of cutting fluid with two ceramic tools, one based on Al2O3+Cr2O3 and the second based on Al2O3+MgO. In order to analyze the machinability of hardened ABNT 52100 steel in the turning process and the feasibility of the cutting tools, the behavior of the process output variables such as roughness, wear, tool failures, machining power, vibration, acoustic emission, chip type and forms were verified. Using a full factorial arrangement where two cutting speeds Vc (120 and 160 m/min.), three machining depths ap (0.75;1.0 and 1.25 mm) were used for the two ceramic tools machining without cutting fluid. It was observed that with different doping it is possible to obtain different results in the behavior of the tools in machining and that the machining depth (ap) is the factor that most influenced the roughness results. The results obtained show that it is possible, on turned surfaces of hardened ABNT 52100 steel to achieve roughness compatible with the grinding process using experimental ceramic tools without cooling, and the tool doped with magnesium oxide provided more promising results.
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Palavras-chave
Aços endurecidos, Aplicações industriais, Acabamento superficial, Desgaste de flanco, Hardened steels, Industrial applications, Surface finishing, Flank wear