Estudo de Ferramentas FEA Comerciais na Simulação Numérica de Processos de Conformação de Chapas Metálicas. Aplicação à Indústria Automóvel.

Os componentes obtidos através da conformação plástica de chapas têm uma grande importância, tanto na etapa de concepção do produto como na etapa de produção na indústria automóvel. Isto comprova-se pelo facto de, em média, cada automóvel integrar cerca de 500 componentes estampados para construir o chassis e a carroçaria [Alves 2003]. Deste total de componentes, 50 são de grandes dimensões (portas, tejadilho, painéis inferior e laterais, entre outros) e necessitam, em média, de cinco ferramentas para o seu fabrico, sendo o custo estimado para cada ferramenta de 230 000 € [Col 2000, Alves 2003]. Para além da indústria automóvel, a conformação plástica de chapas metálicas é um processo tecnológico presente nas indústrias relativas à aeroespacial, petrolífera, decoração, alimentar, entre outras. Do ponto de vista do enquadramento económico, cerca de 20% do custo total de um automóvel novo é devido à incorporação de componentes metálicos estampados. [Alves 2003]. A pressão do “Mercado Global” faz com que os custos relativos à matéria-prima, energia e mão-de-obra sejam uma constante em termos de redução do seu impacte no orçamento das empresas fornecedoras destes produtos. É neste contexto que surge a necessidade da realização deste estudo de Benchmark de Softwares, tornando-se bastante importante, quer ao nível da competitividade industrial, quer ao nível da inovação para novos produtos. A análise por elementos finitos desempenha um papel primordial no tryout virtual e otimização das ferramentas e processos de conformação plástica. Os objetivos principais deste estudo de simulação numérica são a identificação e comparação dos resultados obtidos pelo AUTOFORM e pelo PAMSTAMP, para cada uma das variáveis identificadas como as mais influentes na robustez dos processos de estampagem de chapa metálica. Estas variáveis identificadas são: consumo de material (Draw-in) após conformação; forças de conformação; valores de variação de espessura e dos valores de extensão e resultados de Springback. Os resultados obtidos são comparados com os resultados experimentais e, desta forma, avalia-se a capacidade inovadora e a eficácia de cada um dos softwares, obtendo-se assim, uma orientação mais real para o software mais indicado aos objetivos impostos pela indústria automóvel. Para este efeito, a indústria automóvel, como maior impulsionador e motor da investigação na área da simulação numérica aplicada aos processos de estampagem, tem aderido em peso ao Benchmarking. Um exemplo disto, é o que acontece nas conferências Numisheet. O Benchmark #2 da conferência Numisheet 2008 é analisado pormenorizadamente e os resultados numéricos e experimentais são comparados e apresentados. Dois materiais distintos (aço HC260LAD e liga de alumínio AC170), assim como três modelos com geometrias diferentes (com e sem freios) são apresentados neste relatório. Com vista à redução dos ciclos tentativa-erro, tem-se adotado ciclos virtuais ou numéricos e tem-se incrementado a interatividade entre as fases de concepção e projeto, num conceito muito próprio, mas cada vez mais abrangente, denominado “produção virtual”. É nesta filosofia que se insere a simulação numérica dos processos de conformação de chapa.

Study of membrane emulsification process as a pre-step for the microencapsulation of lipid compounds by spray drying

Dissertation presented to Faculdade de Ciências e Tecnologia, Universidade Nova de Lisboa for obtaining the master degree in Membrane Engineering

Morphological diversification through the evolution of developmental hierarchies

Changes in development impact the final form of organisms and compose the natural variation that is the raw material for evolution. Development is hierarchically structured in progressive series of cell fate determination and differentiation. How does variation in different stages of development contribute to morphological diversification?

NHL 3.5 mortars with scrap tire rubber

The use of wastes and industrial by-products as building materials is an important issue in order to decrease costs with waste management and the embodied energy of building products. Scrap tire rubber has been studied as aggregate for cementitious materials. Natural hydraulic limes are natural binders with particular characteristics of both air and hydraulic binders. Their specifications became stricter with the last version of EN 459-1:2010. In this study scrap tire rubber was used as additional aggregate of mortars, based on NHL3.5 and natural sand. Different particle size fractions and proportions of scrap tire rubber were used: a mix obtained almost directly from industry (only after sieving for preparation of particle sizes similar to mortar aggregate) and separated fine, medium and coarse fractions; 0%, 18%, 36% and 54% weight of binder, corresponding to 2.5%, 5% and 7.5% weight of sand. The influence of the rubbers´ additions on the mortars´ fresh state, mechanical and physical performance is presented, namely by flow table consistency, water retention, fresh bulk density, dynamic elasticity modulus, flexural and compressive strength, open porosity and bulk density, capillary absorption, drying and thermal conductivity. The use of the rubber mix coming from the waste tire industry seems advantageous and may open possibilities for use as raw material by the mortars industry.

Natural hydraulic lime (nhl3.5) mortars with scrap tire rubber

The use of wastes and industrial by-products as building materials is an important issue in order to decrease costs with waste management and the embodied energy of building products. In this study scrap tire rubber was used as additional aggregate of mortars based on natural hydraulic lime NHL 3.5 and natural sand. Different particle size fractions and proportions of scrap tire rubber were used: a mix obtained directly from industry and separated fine, medium and coarse fractions; 0 %, 18 %, 36 % and 54 % of the weight of binder, corresponding to 2.5 %, 5 % and 7.5 % of the weight of sand. As mortars based on NHL specifications became stricter with the current version of EN 459–1:2015, the influence of the rubber’s additions on the mortars’ fresh state, mechanical and physical performance is presented in this work: flow table consistency, water retention, dynamic elasticity modulus, flexural and compressive strength, open porosity and bulk density, capillary absorption, drying and thermal conductivity are studied. The use of the rubber mix coming from the waste tire industry seems advantageous and may open possibilities for use as raw material by the mortars industry.

Lightweight concrete masonry units based on processed granulate of corn cob as aggregate

A research work was performed in order to assess the potential application of processed granulate of corn cob (PCC) as an alternative lightweight aggregate for the manufacturing process of lightweight concrete masonry units (CMU). Therefore, CMU-PCC were prepared in a factory using a typical lightweight concrete mixture for non-structural purposes. Additionally, lightweight concrete masonry units based on a currently applied lightweight aggregate such as expanded clay (CMU-EC) were also manufactured. An experimental work allowed achieving a set of results that suggest that the proposed building product presents interesting material properties within the masonry wall context. Therefore, this unit is promising for both interior and exterior applications. This conclusion is even more relevant considering that corn cob is an agricultural waste product.

The ceramic artifacts in archaeological black earth (terra preta) from Lower Amazon Region, Brazil: chemistry and geochemical evolution

This paper carried out a chemical investigation of archaeological ceramic artifacts found in archaeological sites with Black Earth (ABE) in the Lower Amazon Region at Cachoeira-Porteira, State of Pará, Brazil. The ceramic artifacts, mostly of daily use, belong to Konduri culture (from 900 to 400 years BP). They are constituted of SiO2, Al2O3, Fe2O3, Na2O and P2O5; SiO2 and Al2O3 together add up to 80 % and indicate influence of acid rocks, transformed into clay minerals basically kaolinite. The relative high contents of P2O5 (2.37 % in average) come out as (Al,Fe)-phosphate, an uncommon fact in primitive red ceramics, but found in some roman and egyptian archaeological sites. The contents of the trace elements are similar or below the Earth's crust average. This chemical composition (except P2O5) detaches saprolite material derived acid igneous rocks or sedimentary ones as the main raw material of the ceramics. The contents of K, Na and Ca represent the feldspars and rock fragments possibly introduced into saprolitic groundmass, indicated by mineralogical studies. The presence of cauixi and cariapé as well as quartz sand was confirmed by optical microscope, SEM analyses and by the high silica contents of ceramic fragments. Phosphorus was possibly incorporated into groundmass during cooking of foods, and ABE soil profile formation developed on yellow Latosols. The raw materials and its tempers (cauixi, or cariapé, feldspar, crushed rocks, old ceramic artifacts and quartz fragments) are found close to the sites and therefore and certainly came from them.

Fused deposition modeling with polypropylene

This paper addresses the potential of polypropylene (PP) as a candidate for fused deposition modeling (FDM)-based 3D printing technique. The entire filament production chain is evaluated, starting with the PP pellets, filament production by extrusion and test samples printing. This strategy enables a true comparison between parts printed with parts manufactured by compression molding, using the same grade of raw material. Printed samples were mechanically characterized and the influence of filament orientation, layer thickness, infill degree and material was assessed. Regarding the latter, two grades of PP were evaluated: a glass-fiber reinforced and a neat, non-reinforced, one. The results showed the potential of the FDM to compete with conventional techniques, especially for the production of small series of parts/components; also, it was showed that this technique allows the production of parts with adequate mechanical performance and, therefore, does not need to be restricted to the production of mockups and prototypes.

Desenvolvimento de estruturas fibrosas com comportamento auxético

Tese de Doutoramento Engenharia Têxtil

An evaluation of fibrous structure and physical characteristics of Cutia nut (Couepia edulis Prance) shell

The Cutia-nut (Couepia edulis Prance), a species originally from the Amazon region, has a kernel with reasonable nutritional value and a hard and thick woody shell that constitute most of the fruit. After the kernel removal, the shells are regarded as waste. The possibility of using such shells, as raw material for burning or charcoal production, as well as milled residue for structural reinforcement materials is quite feasible, considering environmental and economical aspects. There is, however, a complete lack of characterization of the Cutia-nut shell and other similar species which can aggregate desirable qualities for application as engineering material. In this study some analyses are presented aiming at providing information for potential uses of these residues. In general, the shells follow a regular shape with certain dimensional proportionality to the kernel. The shell is a fibrous material with high lignin content, present low water absorption and high resistance to natural degradation.

“ Da Moda ao Resíduo e do Resíduo à Moda”: um contributo sustentável no uso da pele residual na Indústria do calçado

Dissertação de mestrado em Design e Marketing

Melhoria de processos numa indústria têxtil através da aplicação do paradigma Lean

Dissertação de mestrado em Engenharia Industrial

Gestão de inventários numa empresa de produção de linhas de costura

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Development of high specific strength components, with internal cellular structure, for several applications

Dissertação de mestrado em Engenharia Mecânica

Anatomical and energy characteristics of charcoal made from five species

Charcoal is an important energy raw material and its properties are influenced by the wood's anatomical and chemical composition and the production process. The aim of this study was to evaluate the anatomical characteristics, calorific power and volatiles and ash content of carbonized wood from Byrsonima spicata, Calophyllum brasiliense, Cecropia sciadophylla, Cochlospermum orinocense and Schefflera morototoni. The calorific power varied from 26,878 to 31,117 kJ kg-1; the content of volatile materials ranged from 20.9 to 31.7%; ash content ranged from 0.1 to 3.8%; and carbon content varied from 68.2 to 75.3%. Anatomical structures of charcoal can be used for species identification. The studied species are not indicated for charcoal production because the levels of ash and volatile compounds are higher than those recommended for charcoal produced for household use. In addition, the calorific power and level of carbon content are insufficient for use in the steel industry.