Análisis del comportamiento de las tuberías de poliéster reforzado con fibra de vidrio con capa de arena

Aunque las primeras fábricas de tubos de poliéster reforzado con fibra de vidrio en España datan del año 1984, no es sino hasta el año 1996 cuando se comienza su utilización masiva como un sustituto de las tuberías de fribrocemento, que ya habían sido prohibidas por la legislación, debido a los efectos cancerígenos de este material. Desde entonces se ha prodigado la utilización de todas las diferentes tipologías de esta clase de tubería, de conformidad a los procesos de fabricación empleados que se encuentran recopilados en el AWWA Manual M45 (Fiberglass Pipe Design), obteniéndose muy diversos resultados. Durante estos años, ha surgido una creciente preocupación en los usuarios de este tipo de tuberías dadas las continuas y numerosas averías en todo el ámbito geográfico. Esto ha promovido el desarrollo de la presente investigaicón, que se ha dividido en dos partes y que ha concluido con la determinación de un nuevo mecanismo específico de fractura. La primera parte se centró en la obtención y desarrollo del modelo teórico que hemos venido a denominar como "Teoría de la Caja Mecánicamente Contaminada", y que está basado en la contaminación o separación por un impacto de dos de las tres capas que forman la tubería, la capa intermedia de arena y la capa más interna o "inner layer". La consecuencia es la disminución del canto resistente, la rotura del inner layer y la entrada de fluido a la capa de arena. Para la evaluación de la magnitud de esta separación se ha desarrollado un modelo analítico que ha determinado la existencia de una relación cuadrática que la rige, y que ha sido verificado mediante ensayos de impacto sobre probetas de tuberías, alcanzando ajustes de hasta el 92%. Así, se ha determinado que impactos de muy baja intensidad, del entorno de 90 a 160 Julios en tuberías Filament Winding continuo PN 16-20 (de 800 a 1000mm) pueden comprometer seriamente la integridad estructural de la tubería sin dejar, en un principio, muesca o traza alguna que pueda alertar del problema. Los siguientes pasos en el estudio se dirigieron a determinar qué otros mecanismos, aparte del golpe, podrían contaminar la tubería y a estudiar el consiguiente avance de la fractura a las capas externas. Se trataba además de analizar la aparición en el tubo de unas misteriosas manchas en forma de "piel de leopardo" y de otros fenómenos aparecidos en las averías como que algunas de las deformaciones de la rotura por presión interna son hacia el interior del tubo y no al revés, como habría sido de esperar a priori. Se optó entonces por comenzar la que ha constituido la segunda parte de la investigación. Para ello se recurrió a realizar ensayos hidráulicos en banco de pruebas a alta presión, cuyos resultados fueron sorprendentes al descubrir que en el proceso se producía la hidrólisis de la resina de poliéster no catalizada que fluía hacia el exterior del tubo. Como consecuencia se llevaron a cabo nuevos ensayos físicos y químicos para estudiar la migración del material y la hidrólisis producida en el proceso de fractura. En este estudio, resultó muy relevante el hecho de sobrepasar o no la presión que producía el desagarro entre las capas del tubo. En definitiva, en esta investigación, que ha constado de estudios analíticos y estudios experimentales, químicos y numéricos, se ha determinado un nuevo mecanismo de fractura que explica gran parte de los fallos acontecidos en las tuberías de poliéster reforzado con fibra de vidrio. Como aplicación se exponen recomendaciones para mejorar el comportamiento mecánico de esta tipología y evitar así los sobrecostes millonarios producidos por su reposición. Numerous and continuous failures in fiberglass reinforced polyester pipes of different companies and manufacturing processes of the AWWA Manual M45 (Fiberglass Pipe Design), have prompted the development of this research, that has concluded with a specific mechanism describing pipe fractures. This research was carried out via two independent studies. The first one is the development of the hypothesis that turned into the Mechanically Contaminated Layer Theory. This theory describes the fracture mchanism which explains a significant part of massive failures due to the existence of a sand layer placed near the neutral axis in the core making the composite very sensitive to impacts in fibreglass reinforced polyester pipes. These failures create interface delamination and consequently fluid can leak into supporting sand backfill thereby iniating the fracture process. In order to assess the delimination magnitude, an analytic method is developed and a squared root law between delamination and energy applied proposed. Vertical blunt ram testts on samples extracted from complete pipes have been carried out to verify this theory, reaching a goodness of fit up to 92%. It is concluded that low energy impacts, around 90-160J in 800-1000mm diameter PN 16-20 continuous filament winding pipes, can seriously compromise their structural integraty with no external trace. The next step in the study was to determine what other mechanism, apart from the brittle hit, could contaminate the pipe and to analyse the consequente advance of the fracture to the external layers. Another aim was to analyse two phenomena occurred in real pipe failures. The first one is the appearance on the tube of "leopard fur" stains on some of the analysed failures, and the other phenomenon is the "inverse fracture", in which the deformations of the failure due to internal pressure are towards the inside of the tube and not the other way round, as it would be expected. It was then chosen to follow a new branch of the investigation by hydraulic high-pressure bench tests that study seepage and load transmission. The results were very surprising as it was discovered that in the process, hydrolysis of the non-catalysed polyester resin occured, flowing towards the outer of the pipe, which entailed the development of chemical and physical tests of the exuded material to study material migration and hydrolysis of the fracture process. In this particular study it was relevant to exceed or not the pressure that produced the rip between the layers of the tube. In conclusion, a new breakage mechanism in FRP pies with sand-filled layer has been found, which explains a high part of the failure global cases. The whole failure process is justified by the Mechanically Contaminated Layer Theory, which has been corroborated by means of analytical, numerical and experimental studies. Several recommendations are also provided in order to improve the mechanical behaviour of this typology and avoid the millionaire overruns generated by its massive failures.

Machinability Study of an aluminum-copper alloy

Machinability of materials is one of the factors that make us wonder what tools to use and what material is best suited for a particular cutting tool and which process is more efficient in the production of a component. In the case of parts for the aerospace industry, manufacturing processes assume greater importance due to the extreme demands on reliability and quality.

Atomistic modeling of Ge damage accumulation, amorphization and solid phase epitaxial regrowth

En los últimos años, el Ge ha ganado de nuevo atención con la finalidad de ser integrado en el seno de las existentes tecnologías de microelectrónica. Aunque no se le considera como un canddato capaz de reemplazar completamente al Si en el futuro próximo, probalemente servirá como un excelente complemento para aumentar las propiedades eléctricas en dispositivos futuros, especialmente debido a su alta movilidad de portadores. Esta integración requiere de un avance significativo del estado del arte en los procesos de fabricado. Técnicas de simulación, como los algoritmos de Monte Carlo cinético (KMC), proporcionan un ambiente atractivo para llevar a cabo investigación y desarrollo en este campo, especialmente en términos de costes en tiempo y financiación. En este estudio se han usado, por primera vez, técnicas de KMC con el fin entender el procesado “front-end” de Ge en su fabricación, específicamente la acumulación de dañado y amorfización producidas por implantación iónica y el crecimiento epitaxial en fase sólida (SPER) de las capas amorfizadas. Primero, simulaciones de aproximación de clisiones binarias (BCA) son usadas para calcular el dañado causado por cada ión. La evolución de este dañado en el tiempo se simula usando KMC sin red, o de objetos (OKMC) en el que sólamente se consideran los defectos. El SPER se simula a través de una aproximación KMC de red (LKMC), siendo capaz de seguir la evolución de los átomos de la red que forman la intercara amorfo/cristalina. Con el modelo de amorfización desarrollado a lo largo de este trabajo, implementado en un simulador multi-material, se pueden simular todos estos procesos. Ha sido posible entender la acumulación de dañado, desde la generación de defectos puntuales hasta la formación completa de capas amorfas. Esta acumulación ocurre en tres regímenes bien diferenciados, empezando con un ritmo lento de formación de regiones de dañado, seguido por una rápida relajación local de ciertas áreas en la fase amorfa donde ambas fases, amorfa y cristalina, coexisten, para terminar en la amorfización completa de capas extensas, donde satura el ritmo de acumulación. Dicha transición ocurre cuando la concentración de dañado supera cierto valor límite, el cual es independiente de las condiciones de implantación. Cuando se implantan los iones a temperaturas relativamente altas, el recocido dinámico cura el dañado previamente introducido y se establece una competición entre la generación de dañado y su disolución. Estos efectos se vuelven especialmente importantes para iones ligeros, como el B, el cual crea dañado más diluido, pequeño y distribuido de manera diferente que el causado por la implantación de iones más pesados, como el Ge. Esta descripción reproduce satisfactoriamente la cantidad de dañado y la extensión de las capas amorfas causadas por implantación iónica reportadas en la bibliografía. La velocidad de recristalización de la muestra previamente amorfizada depende fuertemente de la orientación del sustrato. El modelo LKMC presentado ha sido capaz de explicar estas diferencias entre orientaciones a través de un simple modelo, dominado por una única energía de activación y diferentes prefactores en las frecuencias de SPER dependiendo de las configuraciones de vecinos de los átomos que recristalizan. La formación de maclas aparece como una consecuencia de esta descripción, y es predominante en sustratos crecidos en la orientación (111)Ge. Este modelo es capaz de reproducir resultados experimentales para diferentes orientaciones, temperaturas y tiempos de evolución de la intercara amorfo/cristalina reportados por diferentes autores. Las parametrizaciones preliminares realizadas de los tensores de activación de tensiones son también capaces de proveer una buena correlación entre las simulaciones y los resultados experimentales de velocidad de SPER a diferentes temperaturas bajo una presión hidrostática aplicada. Los estudios presentados en esta tesis han ayudado a alcanzar un mejor entendimiento de los mecanismos de producción de dañado, su evolución, amorfización y SPER para Ge, además de servir como una útil herramienta para continuar el trabajo en este campo. In the recent years, Ge has regained attention to be integrated into existing microelectronic technologies. Even though it is not thought to be a feasible full replacement to Si in the near future, it will likely serve as an excellent complement to enhance electrical properties in future devices, specially due to its high carrier mobilities. This integration requires a significant upgrade of the state-of-the-art of regular manufacturing processes. Simulation techniques, such as kinetic Monte Carlo (KMC) algorithms, provide an appealing environment to research and innovation in the field, specially in terms of time and funding costs. In the present study, KMC techniques are used, for the first time, to understand Ge front-end processing, specifically damage accumulation and amorphization produced by ion implantation and Solid Phase Epitaxial Regrowth (SPER) of the amorphized layers. First, Binary Collision Approximation (BCA) simulations are used to calculate the damage caused by every ion. The evolution of this damage over time is simulated using non-lattice, or Object, KMC (OKMC) in which only defects are considered. SPER is simulated through a Lattice KMC (LKMC) approach, being able to follow the evolution of the lattice atoms forming the amorphous/crystalline interface. With the amorphization model developed in this work, implemented into a multi-material process simulator, all these processes can be simulated. It has been possible to understand damage accumulation, from point defect generation up to full amorphous layers formation. This accumulation occurs in three differentiated regimes, starting at a slow formation rate of the damage regions, followed by a fast local relaxation of areas into the amorphous phase where both crystalline and amorphous phases coexist, ending in full amorphization of extended layers, where the accumulation rate saturates. This transition occurs when the damage concentration overcomes a certain threshold value, which is independent of the implantation conditions. When implanting ions at relatively high temperatures, dynamic annealing takes place, healing the previously induced damage and establishing a competition between damage generation and its dissolution. These effects become specially important for light ions, as B, for which the created damage is more diluted, smaller and differently distributed than that caused by implanting heavier ions, as Ge. This description successfully reproduces damage quantity and extension of amorphous layers caused by means of ion implantation reported in the literature. Recrystallization velocity of the previously amorphized sample strongly depends on the substrate orientation. The presented LKMC model has been able to explain these differences between orientations through a simple model, dominated by one only activation energy and different prefactors for the SPER rates depending on the neighboring configuration of the recrystallizing atoms. Twin defects formation appears as a consequence of this description, and are predominant for (111)Ge oriented grown substrates. This model is able to reproduce experimental results for different orientations, temperatures and times of evolution of the amorphous/crystalline interface reported by different authors. Preliminary parameterizations for the activation strain tensors are able to also provide a good match between simulations and reported experimental results for SPER velocities at different temperatures under the appliance of hydrostatic pressure. The studies presented in this thesis have helped to achieve a greater understanding of damage generation, evolution, amorphization and SPER mechanisms in Ge, and also provide a useful tool to continue research in this field.

Microfabrication processes for microfluidic devices on a single laser Workstation: direct writing lithography on SU-8, laser ablation on polymers and mask manufacturing

We demonstrate the capability of a laser micromachining workstation for cost-effective manufacturing of a variety of microfluidic devices, including SU-8 microchannels on silicon wafers and 3D complex structures made on polyimide Kapton® or poly carbonate (PC). The workstation combines a KrF excimer laser at 248 nm and a Nd3+:YVO4 DPSS with a frequency tripled at 355 nm with a lens magnification 10X, both lasers working at a pulsed regime with nanoseconds (ns) pulse duration. Workstation also includes a high-resolution motorized XYZ-tilt axis (~ 1 um / axis) and a Through The Lens (TTL) imaging system for a high accurate positioning over a 120 x 120 mm working area. We have surveyed different fabrication techniques: direct writing lithography,mask manufacturing for contact lithography and polymer laser ablation for complex 3D devices, achieving width channels down to 13μ m on 50μ m SU-8 thickness using direct writing lithography, and width channels of 40 μm for polyimide on SiO2 plate. Finally, we have tested the use of some devices for capillary chips measuring the flow speed for liquids with different viscosities. As a result, we have characterized the presence of liquid in the channel by interferometric microscopy.

An Alternative Method to Achieve Metrological Confirmation in Measurement Processes

Metrological confirmation process must be designed and implemented to ensure that metrological characteristics of the measurement system meet metrological requirements of the measurement process. The aim of this paper is to present an alternative method to the traditional metrological requirements about the relationship between tolerance and measurement uncertainty, to develop such confirmation processes. The proposed way to metrological confirmation considers a given inspection task of the measurement process into the manufacturing system, and it is based on the Index of Contamination of the Capability, ICC. Metrological confirmation process is then developed taking into account the producer risks and economic considerations on this index. As a consequence, depending on the capability of the manufacturing process, the measurement system will be or will not be in adequate state of metrological confirmation for the measurement process.

Arquitectura de información para medicion de rendimiento en entornos e-manufacturing

La implantación de las tecnologías Internet ha permitido la extensión del uso de estrategias e-manufacturing y el desarrollo de herramientas para la recopilación, transformación y sincronización de datos de fabricación vía web. En este ámbito, un área de potencial desarrollo es la extensión del virtual manufacturing a los procesos de Performance Management (PM), área crítica para la toma de decisiones y ejecución de acciones de mejora en fabricación. Este trabajo doctoral propone un Arquitectura de Información para el desarrollo de herramientas virtuales en el ámbito PM. Su aplicación permite asegurar la interoperabilidad necesaria en los procesos de tratamiento de información de toma de decisión. Está formado por tres sub-sistemas: un modelo conceptual, un modelo de objetos y un marco Web compuesto de una plataforma de información y una arquitectura de servicios Web (WS). El modelo conceptual y el modelo de objetos se basa en el desarrollo de toda la información que se necesita para definir y obtener los diferentes indicadores de medida que requieren los procesos PM. La plataforma de información hace uso de las tecnologías XML y B2MML para estructurar un nuevo conjunto de esquemas de mensajes de intercambio de medición de rendimiento (PMXML). Esta plataforma de información se complementa con una arquitectura de servicios web que hace uso de estos esquemas para integrar los procesos de codificación, decodificación, traducción y evaluación de los performance key indicators (KPI). Estos servicios realizan todas las transacciones que permiten transformar los datos origen en información inteligente usable en los procesos de toma de decisión. Un caso práctico de intercambio de datos en procesos de medición del área de mantenimiento de equipos es mostrado para verificar la utilidad de la arquitectura. ABSTRAC The implementation of Internet technologies has led to e-Manufacturing technologies becoming more widely used and to the development of tools for compiling, transforming and synchronizing manufacturing data through the Web. In this context, a potential area for development is the extension of virtual manufacturing to Performance Measurement (PM) processes, a critical area for decision-making and implementing improvement actions in manufacturing. This thesis proposes a Information Architecture to integrate decision support systems in e-manufacturing. Specifically, the proposed architecture offers a homogeneous PM information exchange model that can be applied trough decision support in emanufacturing environment. Its application improves the necessary interoperability in decision-making data processing tasks. It comprises three sub-systems: a data model, a object model and Web Framework which is composed by a PM information platform and PM-Web services architecture. . The data model and the object model are based on developing all the information required to define and acquire the different indicators required by PM processes. The PM information platform uses XML and B2MML technologies to structure a new set of performance measurement exchange message schemas (PM-XML). This PM information platform is complemented by a PM-Web Services architecture that uses these schemas to integrate the coding, decoding, translation and assessment processes of the key performance indicators (KPIs). These services perform all the transactions that enable the source data to be transformed into smart data that can be used in the decision-making processes. A practical example of data exchange for measurement processes in the area of equipment maintenance is shown to demonstrate the utility of the architecture.

Performance measurement integrated information framework in e-Manufacturing

The implementation of Internet technologies has led to e-Manufacturing technologies becoming more widely used and to the development of tools for compiling, transforming and synchronising manufacturing data through the Web. In this context, a potential area for development is the extension of virtual manufacturing to performance measurement (PM) processes, a critical area for decision making and implementing improvement actions in manufacturing. This paper proposes a PM information framework to integrate decision support systems in e-Manufacturing. Specifically, the proposed framework offers a homogeneous PM information exchange model that can be applied through decision support in e-Manufacturing environment. Its application improves the necessary interoperability in decision-making data processing tasks. It comprises three sub-systems: a data model, a PM information platform and PM-Web services architecture. A practical example of data exchange for measurement processes in the area of equipment maintenance is shown to demonstrate the utility of the model.

CSR Policies: Effects on Labour Productivity in Spanish Micro and Small Manufacturing Companies

This paper analyses empirical evidence of efforts to enable Spanish micro and small manufacturing companies to boost their labour productivity rates through the development of the main pillars of their corporate social responsibility (CSR) policies. This study aims to develop new approaches and sensibilities towards work from an ethical, values (virtues) and CSR perspective, showing how internal dimensions of CSR, such those related to relationships with employees and responsibility in processes and product quality, can improve labour performance and labour efficiency, thereby contributing to a better society. The results of a sample of 929 small businesses indicate that the social responsibility policies that most contributed to a short-term increase in labour productivity are those related to internal aspects of the company, in particular its involvement in the quality of processes and products, promotion of innovation and employee care. However, the impact on labour productivity of CSR policies related to external factors, such as relationship with stakeholders and environmental concern, could not be empirically proven in this paper.

Improving manufacturing performance by standardization of interprocess communication

A number of environmental forces such as increasing value chain network complexity, decreasing product life-cycle cost, and time-to-market requirements or increasing product complexity act upon manufacturing organizations, enhancing the acute need for organizational routines that foster efficient and effective communication between processes. Such organizational routines erode quickly in the absence of common standards for knowledge sharing, that is why successful manufacturing systems benefit from interprocess standardization. The purpose of this paper is to offer a standardization model of interprocess communication that increases manufacturing operational performance (MOP). First, we propose a novel holistic model that makes standardized interprocess communication possible in manufacturing organizations. Second, we propose a model for quantifying the implications of standardizing interprocess communication upon MOP. Finally, as a matter of application, we show the results of its successful implementation in one Japanese manufacturing organization.

Analysing the complexity of the model-based decision making processes within the industrial management context

PURPOSE The decision-making process plays a key role in organizations. Every decision-making process produces a final choice that may or may not prompt action. Recurrently, decision makers find themselves in the dichotomous question of following a traditional sequence decision-making process where the output of a decision is used as the input of the next stage of the decision, or following a joint decision-making approach where several decisions are taken simultaneously. The implication of the decision-making process will impact different players of the organization. The choice of the decision- making approach becomes difficult to find, even with the current literature and practitioners’ knowledge. The pursuit of better ways for making decisions has been a common goal for academics and practitioners. Management scientists use different techniques and approaches to improve different types of decisions. The purpose of this decision is to use the available resources as well as possible (data and techniques) to achieve the objectives of the organization. The developing and applying of models and concepts may be helpful to solve managerial problems faced every day in different companies. As a result of this research different decision models are presented to contribute to the body of knowledge of management science. The first models are focused on the manufacturing industry and the second part of the models on the health care industry. Despite these models being case specific, they serve the purpose of exemplifying that different approaches to the problems and could provide interesting results. Unfortunately, there is no universal recipe that could be applied to all the problems. Furthermore, the same model could deliver good results with certain data and bad results for other data. A framework to analyse the data before selecting the model to be used is presented and tested in the models developed to exemplify the ideas. METHODOLOGY As the first step of the research a systematic literature review on the joint decision is presented, as are the different opinions and suggestions of different scholars. For the next stage of the thesis, the decision-making process of more than 50 companies was analysed in companies from different sectors in the production planning area at the Job Shop level. The data was obtained using surveys and face-to-face interviews. The following part of the research into the decision-making process was held in two application fields that are highly relevant for our society; manufacturing and health care. The first step was to study the interactions and develop a mathematical model for the replenishment of the car assembly where the problem of “Vehicle routing problem and Inventory” were combined. The next step was to add the scheduling or car production (car sequencing) decision and use some metaheuristics such as ant colony and genetic algorithms to measure if the behaviour is kept up with different case size problems. A similar approach is presented in a production of semiconductors and aviation parts, where a hoist has to change from one station to another to deal with the work, and a jobs schedule has to be done. However, for this problem simulation was used for experimentation. In parallel, the scheduling of operating rooms was studied. Surgeries were allocated to surgeons and the scheduling of operating rooms was analysed. The first part of the research was done in a Teaching hospital, and for the second part the interaction of uncertainty was added. Once the previous problem had been analysed a general framework to characterize the instance was built. In the final chapter a general conclusion is presented. FINDINGS AND PRACTICAL IMPLICATIONS The first part of the contributions is an update of the decision-making literature review. Also an analysis of the possible savings resulting from a change in the decision process is made. Then, the results of the survey, which present a lack of consistency between what the managers believe and the reality of the integration of their decisions. In the next stage of the thesis, a contribution to the body of knowledge of the operation research, with the joint solution of the replenishment, sequencing and inventory problem in the assembly line is made, together with a parallel work with the operating rooms scheduling where different solutions approaches are presented. In addition to the contribution of the solving methods, with the use of different techniques, the main contribution is the framework that is proposed to pre-evaluate the problem before thinking of the techniques to solve it. However, there is no straightforward answer as to whether it is better to have joint or sequential solutions. Following the proposed framework with the evaluation of factors such as the flexibility of the answer, the number of actors, and the tightness of the data, give us important hints as to the most suitable direction to take to tackle the problem. RESEARCH LIMITATIONS AND AVENUES FOR FUTURE RESEARCH In the first part of the work it was really complicated to calculate the possible savings of different projects, since in many papers these quantities are not reported or the impact is based on non-quantifiable benefits. The other issue is the confidentiality of many projects where the data cannot be presented. For the car assembly line problem more computational power would allow us to solve bigger instances. For the operation research problem there was a lack of historical data to perform a parallel analysis in the teaching hospital. In order to keep testing the decision framework it is necessary to keep applying more case studies in order to generalize the results and make them more evident and less ambiguous. The health care field offers great opportunities since despite the recent awareness of the need to improve the decision-making process there are many opportunities to improve. Another big difference with the automotive industry is that the last improvements are not spread among all the actors. Therefore, in the future this research will focus more on the collaboration between academia and the health care sector.