Lean six sigma como estratégia para o aumento de eficiência em laminação de alumínio

This study aims to assess the implementation of Lean Six Sigma in the preparation of plates and hot lamination process for a company of aluminum rolled products, to improve the quality, productivity and process efficiency. As a basis for achieving these goals, the DMAIC methodology and various quality tools such as Cause Effect Diagram, Process Flow, SIPOC, Pareto, FMEA and Control Chart were used, trying to propose improvements to processes and increase their efficiency. The results were significant and were the basis for the continuation of a continuous improvement project throughout the factory

Caracterização físico-mecânica de painel de MDP produzido com madeira de Eucalipto e Bracatinga

This work is the production of particleboard of particles reconstituted from MDP (Medium Density Particleboard) adding particles in the inner layer of Mimosa Scarelli, popularly known as bracatinga, the ratios of 0%, 25%, 50%, 75% and 100%. The panel produced is composed of three layers, two external particles with smaller particle size and an inner layer composed of particles of larger particle sizes. Assays were performed based on physical and mechanical NBR 14.810/2006 for the determination of the board density, thickness swelling, water absorption, moisture content, bending strength, shear strength and residual moisture, and testing of particle size not existing in the standard cited. The results were analyzed and compared the results of the commercial boards made from 100% eucalyptus, based on the limits specified by the ABNT NBR 14.810/2006. The values of the tests were close to the normative specifications indicating positively the production of MDP with wood decay.

Análise granulométrica do compósito cimentício produzido com adição de resíduos de madeira e escória

Since the early twenty-first century, the construction sector has been the second largest on the rise in the Brazilian industrial sector, with a growth of 1.4% in 2012, and is likely to remain at this level for a long time. However, unlike decades ago, the industry has been seeking in its manufacturing process, sustainable materials, encompassing in their works the concept of sustainability. Thus, the timber sector seeks to satisfy a market increasingly demanding, innovating techniques and utilization being less aggressive to the environment. The purpose of this study was to produce and evaluate the mechanical strength of the composite cement with the addition of wood residues and slag low oven. Therefore, it was made 42 specimen cement-slag-wood, carried out in two steps. Since at the first, it was varied only the slag particle size, and at the second, through the best result of the previous step, it was varied the wood particles granulometry. The mechanical performance of the composite was evaluated by the results obtained in the compression test and the physical test for determining the density of the material. In the first step of the process can be concluded that the best result was achieved with the use of slag particles retained on the 60 mesh sieve. In the second phase of the study concluded that the best results were achieved with wood particles with the large particles, i.e. particles retained on the 10 mesh sieve. Both in the first and in the second step it can be seen that there has been the influence of the particle size of the waste materials. With the obtained results, could be evaluated that the use of waste for the production of cement-slag-wood composite showed lower performance when compared to the results obtained in studies without the use of waste. However, some applications are feasible to be performed with the use of composite wood-cement-slag

Estudo da usinagem por torneamento de ligas de alumínio

The non-ferrous materials have got so many mechanical, physical and chemical advantageous properties so that is provided to them consolidated position in industry. In this context, aluminium alloys have been seen a lot on many applications of engineering areas – specially on automotive, aeronautical and aerospace due to their main properties such as low density, high corrosion resistance, favorable structure weight / material resistance relation, among others characteristics that are mencioned through this study. This study aims to analyze the aluminium alloys behavior on a general context when they are used on turning process, taking for examples the 6262 and 7050 aluminium alloys. In this way, the analysis studies the datas obtained during the turning tests realized on 3 steps each one; those datas are concerning the medium and total rugosities – obtained with the assistance of a portable Surface Roughness Finish Tester, as well as the chips obtained during the tests - visual analysis, and the cutting tools wear – with the assistance of an optical microscope, under different conditions of application of cutting fluids (dry machining, application of coolant in abundance and MQL – Minimum Quantity of Lubricant). The results concerning this study show detailed information about influence of cutting fluids on the machining by turning of the aluminium alloys related on this work and also about aluminium alloys in general when they are used on turning processes with different conditions from one another. By this way, it was evident the MQL technique is the best one for the 6262 alloy. However, for 7050 alloy, it was evident that the dry machining is responsible for the best results

Desenvolvimento de um protetor lateral em alumínio

In view of the need to develop a device for security and lateral protection, due to the Resolution 323/09 of CONTRAN, which requires the use of such equipment for most trucks and tow trucks, the objective of this work is to develop a project for an aluminum lateral protection device, according to the ABNT NBR 14.148 regulation, that, among many specifications, stipulates that the equipment must support a load of 5 kN and suffer a maximum deflection of 30mm, but does not say what material it should be made of. The reason for choosing aluminum is because of its low density, so as not to significantly increase the curb weight of the truck, which, consequently, reduces CO2 emissions and maintenance expenses. Additionally, this material presents a good resistance/weight ratio, high resistance to corrosion, excellent surface finish and it's fully recyclable; reason why it has been gaining the attention of many industry segments. For the realization of the project, profiles were chosen to make the assembly of the set, and then a finite elements analysis was performed in the HyperWorks software, to verify if the designed device would support the loads stipulated by the regulation. One details to note is that these simulation programs could show inaccuracies, because of the size and shape of the elements that compose the mesh, and for many other reasons, so it is necessary that, even with the results coming back satisfactory, actual physical tests are conducted to validate the proper functioning of the equipment, which was not done for this study

Efeito do fornecimento de diferentes níveis de alumínio dietético na qualidade óssea de codornas poedeiras (Coturnix japonica)

O alumínio está presente de forma marcante em nosso cotidiano, com várias possibilidades de contaminação para o ser humano e animais, através da ingestão de alimentos ou aditivos presentes nos alimentos ou, também, através do uso de medicamentos. Por apresentar uma forte carga elétrica, um forte poder de polarização e características similares com elementos da hidroxiapatita, o alumínio age como um competidor de nutrientes na matriz óssea, Por isso, ele pode ser causa danos à saúde dos seres vivos, como a osteoporose. Diante disso, a presente pesquisa teve como objetivos estudar a influência de diferentes níveis de alumínio na dieta de codornas poedeiras, sobre as características físicas e químicas de seus ossos. A densidade e a porosidade óssea foram determinadas pelo método de imersão em água, utilizando o princípio de Arquimedes. Os resultados obtidos mostraram que concetrações até 20 mg de alumínio por kg de ração fornecida causa uma diminuição na densidade óssea e volta a aumentar para concetrações maiores que este limiar. A porosidade óssea, segue o inverso da densidade. Ela aumenta com concetrações até 20 mg de alumínio por kg de ração fornecida e volta a diminuir para concetrações menores

Produção e caracterização físico-mecânica de painel de compensado de Eucalyptus sp. e adesivo PVA

Studies on new adhesives and resins for bonding wood and wood products are being conducted with the intention of improving their properties, taking into account a lower environmental impact. For this reason new formulations of polyvinyl acetate (PVA) adhesives have been developed, because they have no chemicals in its composition extremely polluting and harmful to health, as is the case of formaldehyde-based resins, which in turn are the most commonly used today for wood panels production. This study tested three different formulations of PVA adhesives, with different times and temperatures of pressing for the production of Eucalyptus sp. Plywood, coming up in satisfactory results with respect to shear strength at the bondline, which was higher for the PVA adhesives compared with urea-formaldehyde and phenol. The results of MOE and MOR were lower than those values of the panels produced with urea and phenol-formaldehyde, and the results of physical tests showed to be close to the panels produced with these same adhesives

Aproveitamento de resíduos na composição de painel sarrafeado amarrado: um estudo econômico

The manufacture of plywood panel already has about eighty years in Brazil. In general, plywood panels differ by their nature, composition and manufacturing; the most common MDF, OSB, particle and the joist. Some of these products can be generated fromindustrial waste, as the panelblockboard, you can use in their training waste destop boards (Battens), from industrial processes or processing of primary wood. This work aims to present the detailed study of the economic viability of utilization of industrial solid waste timber through the acquisition of a machine amarradeira of joists in a wood processing unit in city Itapeva-SP. We studied the application of wastein the composition of kernels blockboard panel tied its commercial acceptance and future prospects market. We noticed great economic advantage in investing in the study, compared with the transformation process of the joists in biomass energy, although the investment decision involves not only financial matters but also the acceptance market the product to be manufactured

Processo de fabricação de tarugos pelo método HotTop de ligas de alumínio da série 6XXX e as não conformidades desse processamento

The goal of this work is to report some problems that occur in the in the production of aluminum billets (series 6XXX) produced by the hot top process in the Alcoa aluminum Inc. The aluminum fabrication process is described from its first stage, since the mining until the reduction, smelting and treatment of the metal. One of the plant’s final product, are billets for clients that produce profiles by extrusion. The product’s final quality highly depends on the whole production process. Therefore it’s necessary to use good practices in the treatment of the metal, follow up its fabrication and control its thermal treatment, in order to meet the required standards to satisfy the clients. The billet’s production method and its variables will be detailed through temperature and casting speed, cone of water flow, cooling rate, duration of thermal treatment, degassing and metal “in line “filtering, in other words when it’s still found in its liquid state. The non-conformities of the process were studied by metallographic analysis, both macrostutural and microstructural that will be described and discussed in this work

Análise da curva de resfriamento e refino de grão da liga de alumínio AA 356

The macrostructure of an alloy solidification in the raw state is of utmost importance due to its influence on mechanical properties. A structure showing columnar grains is generally undesirable in most applications of cast products and grain refining aims to suppress the formation of these grains and get a fine-grained equiaxed structure that improves the supply of liquid metal and the mechanical properties, as yield strength and tensile strength limit, as well as the tendency of formation of hot cracks. The type and size of grains formed are determined by chemical composition, cooling rate and the use of inoculum for grain refining. Titanium and boron are the major refiners in the aluminum industry and can be added to the molten metal in the form of alloys such as Al-Ti, Al-Ti-B or Al-B. In this paper we will discuss the information obtained from cooling curves and first derivative of the cooling curve to obtain the thermal parameters that influence the process of grain refining alloy AA 356.0

Comparação de compósitos obtidos via RTM de resina epóxi e fibra de carbono com e sem descontinuidade nos tecidos

Technology is growing interest in the use of composites, due to the requirement of lighter materials and more resistant, factors essential to meet the project specifications and reduce the operational cost. In the production of high performance structural composites, considering the aerospace criteria, the domestic industry has shown interest in the process of resin transfer molding (RTM) for reproducibility and low cost. This process is suitable for producing components of polymeric composites with relatively simple geometries, consistent thicknesses, high quality finish with no size limitations. The objective of this work was machined carbon steel to make a matched-die tooling for RTM and produce two composite plates of epoxy resin and carbon fiber fabric with and without induced discontinuities, which were compared towards their impregnation with ultrasound, their properties via tensile tests and thermal analysis. In ultrasonic inspection, it was found good impregnation of the preform of both composites. In the thermal analysis it was possible to check the degradation temperature of the composites, the glass transition temperature and it was found that the composites showed no effective cure cycles, but presented good performance in the tensile test when compared with aluminum alloy 7050 T7451 . The results showed that the injection strategy was appropriate since the laminate exhibited a good quality for the proposed application

Tratamento da superfície do alumínio via eletrólise a plasma

This paper presents the study on the application of the electrolytic plasma for surface treatment of aluminum. A bibliographical study on the material of interest was preliminarily performed and later designed and built an electrolytic cell, including the excitation source. Unlike conventional electrolysis process, the plasma assisted carry on in the non-linear region of characteristic current/voltage curve. Therefore it requires for the on set of the process that the power supply operates on harder conditions than those on high current process. The plasma produced during the present investigation has temperatures in the range o 6,0.10 3 -7,0 .10 3 K, well above those found in conventional chemical process. It also shows a particular dynamic to promote changes on surface and to produce new materials. The plasma is generated by microdischarge in vapor or gas bubbles involved in physic-chemical processes in electrode regions of the electrolytic cell. The electrode material was the aluminum (7075). The Process Electrolytic Plasma Processing (EPP) is sensitive to various parameters such as operating voltage, current density, electrolyte, concentration of electrolyte, geometry of reactor, temperature of electrolytic solution and dynamic of the fluid in the cell. The experiments were carried on in order to find parameters for a stable abd steady operation. The choice for the electrolytic was silicate/alkali solution in various concentrations to operate in various voltage as well. Plasma was produced on negative (cathode) and positive (anode) electrode, in specific conditions. A stable operation on the cathode process was obtained with low concentration of the electrolytic in aqueous solution, current density around 250V effective voltage. For the evolution of plasma in anodic process it was required higher concentrations and higher... (Complete abstract click electronic access below)

Análise das propriedades físico-mecânicas de painel particulado de eucalipto composto por três camadas com duas variações de pressão

The research aimed to produce sheets of particles with waste processing of Eucalyptus sp bonded with urea-formaldehyde and evaluate the effect of pressure variation in the quality of the boards produced. To do so, the Boards made were divided into two treatments depending on the pressing pressure of 30 to 40 kgf / cm². Once pressings, climatized, the particleboards have been sectioned in test samples, and underwent physical-mechanical tests for determining density, swelling and water absorption, modulus of rupture and elasticity in static bending and internal linking. The particleboards pressed at 40 kgf / cm ² showed the best results

Cinética de degradação do sistema resina epóxi/fibra de carbono

With the increasing demand for electricity, the retraining of transmission lines is necessary despite environmental restrictions and crossings in densely populated areas to build new transmission and distribution lines. Solution is reuse the existent cables, replacing the old conductor cables for new cables with higher capacity power transmission, and control of sag installed. The increasing demand for electrical power has increased the electric current on the wires and therefore, it must bear out temperatures of 150°C or more, without the risk of the increasing sag beyond the established limits. In the case of long crossings or densely populated areas, sag is due to high weight of the cable on clearance. The cable type determines the weight, sag, height and the towers dimensions, which are the items that most influence the investment of the transmission line. Hence, to reduce both cost of investment and maintenance of the line, the use of a lighter cable can reduce both number and the height of the towers, with financial return on short and long term. Therefore, in order to increase the amount of transmitted energy and reduce the number of built towers and sag, is recommended in the current work substitute the current core material (steel or aluminium) for alternatives alloys or new materials, in this case a composite, which has low density, elevated stiffness (elasticity module), thus apply the pultruded carbon fiber with epoxy resin as matrix systems and perform the study of the kinetics of degradation by thermogravimetric analysis (TGA), dynamic mechanical analysis (DMA) and differential scanning calorimetry (DSC), according to their respective standards

Processamento do compósito de fibra de capim-sapê / epóxi e avaliação da resistência à flexão “t” de Student

In recent years a great worldwide interest has arisen for the development of new technologies that enable the use of products with less environmental impact. The replacement of synthetic fiber plants is a possibility very important because this fiber is renewable, biodegradable and few cost and cause less environmental impact. Given the above, this work proposes to develop polymeric composites of epoxy resin and study the behavior of these materials. Both, the epoxy resin used as matrix in the manufacture of sapegrass fiber composite, as tree composites formed by: epoxy/unidirectional sapegrass long fiber, 75% epoxy/25% short fiber, by volume, and 80% epoxy/20% short fiber, by volume, were characterized by bending, and the composites produced with short fibers random were inspected by Optical Microscopy and Acoustics Inspection (C-Scan). For the analysis of the sapegrass fiber morphology, composites 75% epoxy/25% short fiber (sheet chopped) and 80% epoxy/20% short fiber images were obtained by optical microscope and the adhesion between polymer/fiber was visualized. As results, the flexural strength of composites epoxy/unidirectional long fibers, 75% epoxy/25% short fiber and 80% epoxy/20% short fiber were 70.36 MPa, 21.26 MPa, 25.07 MPa, respectively. Being that composite showed that the best results was made up of long fibers, because it had a value of higher flexural strength than other composites analyzed