No abstract

In this work, parts with complex geometry were machined in hardened H13 steel using different tool path strategies for roughing and finishing, seeking to evaluate how the tool paths and cutting conditions influence machining time, surface roughness, and geometric precision. The results showed a reduction of up to 7.8% in roughing time and 25% reduction in finishing time among the evaluated tool paths. The roughness of the complex surface depends significantly on the tool path used and is significantly impaired by the increase in the feed per tooth. The geometric deviations varied from 0.02 to 0.23 mm depending on the adopted tool path.

In the present work, the surface integrity and flank wear of uncoated cermet inserts in dry turning of AISI 1045 steel were evaluated. Three-dimensional techniques were used to assess the surface roughness. Previously, finite element analysis was carried out to predict the cutting forces and heat distribution in the chip formation region. Cutting speed and feed were the parameters varied in the experiments. Feed is decisive in the final quality of the turned surface and cutting speed had little influence on this aspect. The surface was significantly damaged with the progression of the insert flank wear. Considering an average flank wear VBB of 0.1 mm, a tool life of 35 min was achieved using a cutting speed of 175 m/min, and of 23 min for a cutting speed of 275 m/min. Abrasive wear was predominant during the experiments. No microstructure defects were observed, as well as crack propagation or accentuated deformations near the machined surface region. Therefore, the dry turning of 1045 steel with cermet inserts route has proven extremely viable from the standpoints of tool life, surface integrity, chip formation, and sustainability.

Digitization and virtualization represent key factors in the era of Industry 4.0. Digital twins (DT) can certainly contribute to increasing the efficiency of various productive sectors as they can contribute to monitoring, managing, and improvement of a product or process throughout its life cycle. Although several works deal with DTs, there are gaps regarding the use of this technology when a Flexible Manufacturing System (FMS) is used. Existing work, for the most part, is concerned with simulating the progress of manufacturing without providing key production data in real-time. Still, most of the solutions presented in the literature are relatively expensive and may be difficult to implement in most companies, due to their complexity. In this work, the digital twin of an FMS is conceived. The specific module of an ERP (Enterprise Resources Planning) system is used to digitize the physical entity. Production data is entered according to tryouts performed in the FMS. Sensors installed in the main components of the FMS, CNC (computer numerical control) lathe, robotic arm, and pallet conveyor send information in real-time to the digital entity. The results show that simulations using the digital twin present very satisfactory results compared to the physical entity. In time, information such as production rate, queue management, feedstock, equipment, and pallet status can be easily accessed by operators and managers at any time during the production process, confirming the MES (manufacture execution system) efficiency. The low-cost hardware and software used in this work showed its feasibility. The DT created represents the initial step towards designing a metaverse solution for the manufacturing unit in question, which should operate in the near future as a smart and autonomous factory model.