Estudo de casos de seleção dos materiais e processos para a fabricação de fuselagens

This work proposes a study on the materials selections and processes for the manufacture of aircraft and showing a methodology to reduce the manufacturing cost. The DFMA can be understood as a methodology that aims at reducing manufacturing and assembly costs and coupled with the increase of product quality through design simplifications. The most commonly material used in the manufacture of aircraft is aluminum alloys due to these possess great structural strength, good elasticity, and being stainless having a low specific weight (about 1/3 that of steel), reducing the weight of the aircraft. A case study in which an operation in the process of verifying the quality was generating unnecessary costs time / man for the company was also developed. The problem solution was simple, just removing the attachment process. It was found that the DFMA methodology is extremely important for the simplification of processes and projects, contributing to the reduction of manufacturing costs of aircraft

Estudo da variação do limite de resistência à tração ao longo da bobina de vergalhão de alumínio 1350 AA

Therebar of aluminum 1350 AA produced by CBA are used inthe manufacture of wires and cables for electric power transmission, which marketshows increasingly favorableto aluminum due to itslow densityand high electrical conductivity, but to ensure that this materialmeets all specifications of projectsfor electricity transmission, it must have homogeneity in the chemicaland mechanicalproperties.One of the points of improvement in the process of rod production isreducing the high variation of the limitof tensile strengthalong the coils, therefore, this work seeks a better understanding of the factors that significantly influence the mechanical properties of rebar, specifically assessing the influence oftemperatureat the output of the coils, which can cause a recovery effect on the material andif thereare relevantdifferences between the two modes of rebar production: auto and manual.Samples of six coils have been specifically produced forthis study, which weresubsequently subjected to different annealing temperatures for one hour and ten minutes, similar to what occurs in the output of the coil from the machine. The tensile tests showed that aluminum 1350 AA is significantly influenced by temperature, whose behavior was very similar to that presented in the literature. It was found that the phenomenon of recovery occurred more significantly at high temperatures. Through the optical electron microscope Zeiss, 18 surface maps were made with 100x magnification for each sample in different conditions and the images were analyzed using entropy and fractal dimension, aiming to relate the condition of surface hardening on mechanical property of the samples in that condition. The results showed that these methods can be applied, provided they do not have any kind of imperfection on the surface, once they can influence the results. The study concluded that a more efficient cooling is required in ... (Complete abstract click electronic access below)

Estudo da influência da aplicação do fluido de corte no torneamento da liga de alumínio AA7075

One of the ways to minimize the effects of unproductive time caused by tool wear can be achieved by introducing an efficient system of lubrication and cooling in the process. However, in the last decade the research had the goal to restrict the maximum use of refrigerants and / or lubricants in metal-mechanical production. The important factors that justify this procedure include the operational costs of production, ecological issues, and the legal requirements of environmental conservation and preservation of human health. The purpose of the proposed work is the study of machining by turning with the focus on the influence caused by the application of cutting fluid in several ways of application (abundant and MQF) and also by comparing the results obtained by machining without the presence of fluid . For this purpose, the turning tests are conducted using an aluminum alloy (AA 7075). The response variables to be analyzed were obtained from the roughness (Ra and Ry), the stresses presented (VB) and their progression in relation to the cutting length achieved, the type of chip formed, in addition to changes in the degree of finish (roughness) presented by the turned parts. The results of this study should provide more detailed information about the actual influence of cutting fluids in turning this alloy, which are characterized by high rates of deformation when the formation of damaging your chip machining and also the quality of surface generated. Therefore, it is expected to provide subsidies to promote the optimization of machining this alloy making the most of the role of cutting fluid

Análise macro e micrográfica da liga AA-356 conforme a taxa de resfriamento

The present work aims to study the characteristics of the alloy Al - 7 % Si - 0 , 3Mg ( AA356 ) , more specifically characterize the macrostructure and microstructure and mechanical properties of the alloy ingots AA356 obtained in metal molds and sand molds for power studying the structures through the difference of cooling rates . This alloy is explained by the fact of referring league has excellent combination of properties such as low solidification shrinkage and good fluidity, good weldability , high wear resistance , high strength to weight ratio, has wide application in general engineering , and particularly in the automotive and aerospace engineering . In this work we will verify this difference in properties through two different cooling rates . We monitor the solid solidification temperatures by thermocouples building with them the cooling curve as a tool that will aid us to evaluate the effectiveness of the grain refining because it achieved with some important properties of the alloy as the latent heat of solidification fraction the liquid and solid temperatures, the total solidification time, and identify the presence of inoculants for grain refinement. Thermal analysis will be supported by the study of graphic software “Origin “will be achieved where the cooling curve and its first derivative that is the cooling rate. Made thermal analysis, analysis will be made in macrographs ingots obtained for observation of macrostructures obtained in both types of ingots and also analysis of micrographs where sampling will occur in strategic positions ingots to correlate with the microstructure. Finally will be collecting data from Brinell hardness of ingots and so then correlating the properties of their respective ingots with cooling rate. We found that obtained with cast metal ingots showed superior properties to the ingots obtained with sand mold

Caracterização estrutural da Liga Al-1% Si

The aim of this study is to characterize the macrostructure and microstructure of Al - 1%Si alloy obtained in sand and metallic molds. Aluminium has good mechanical properties, but adding silicon, even in small quantities, can change the microstructure and improves mechanical behavior. Workpieces were castings in metallic and sand molds and one can see a difference in their cooling curve, macroscopic and microscopic structures. The sand mold casting has lower cooling rate and so its grains are larger. Due to the lower concentration of grain boundary, the hardness is lower compared to that found in metallic molds, which has smaller grains and a higher hardness. Therefore, it can be concluded that the cooling rate and alloying elements affect the final microstructure of the workpiece

Análise da curva de resfriamento da liga de alumínio AA 356

It is very important to study the macrostructure of a material in the crude state of solidification due to influence the mechanical properties, as well as the study of their cooling curve. In the present work was to study the alloy AA 356, its macrostructure and its cooling curve. The material was cast in two different molds, a sand and other metallic. In this paper we study the differences in its macrostructure and its cooling curves. In macrostructure can observe the absence of the three zones of solidification and the presence of large pores because of moisture in the sand. In the sample taken from the metal mold can observe the three zones of solidification: a coquilhada, columnar and equiaxed

Estudo da influência do agente nucleante )ALTi5%B1%) na microestrutura de chapas AA8011 obtidas por lingotamento contínuo

The aluminum includes several properties with excellent relation between weight and mechanical resistance. With technological advances, increasingly demand the development of new alloys and other production processes in order to reduce the cost of production and insert these new alloys in broader applications. The process of continuous caster (TRC promoted the unite of the aluminum smelting process with the first stage of rolling, making it most economical through the merger these two phases besides transform the continuous casting process. The AA8xxx series is one of the most versatile aluminum alloys and the most often used in continuous caster process provided a great potential application in the market. In order to further, optimize the process it is necessary to increase awareness of the aluminum solidification phenomena associated with the addition of grain refiner, and control of some aluminum production parameters in the process (production rate, metal temperature, etc.). In this study, AA8011 alloy samples were taken in the raw state obtained by the continuous casting process. The samples were laminated to a thickness of 7mm during the process itself and analyzed at three points along its width by microstructural analysis throughout its thickness, the variation rate of addition of the grain refiner in order to assess the influence of this addition with crystallographic formation and some formation of intermetallic precipitates during the solidification. Through this work, it was possible to improve the knowledge related to the addition of refiner with the monitoring of these production processes

Estudo do efeito do processo de shot peening na taxa de propagação de trinca por fadiga na liga aeronáutica 2024 - T3

Pós-graduação em Engenharia Mecânica - FEG

Análise da pulsação térmica do processo TIG na soldagem da liga AA6063T6

Pós-graduação em Engenharia Mecânica - FEB

Análise da reversão do fundo de latas de alumínio para bebidas - Buckle

This work approaches the main methods of plastic deformation of metals, with a focus on the deep drawing process. The mechanical properties were evaluated with the tension tests. It is presented the aluminum alloys designation, followed by applying heat treatments and the designation of tempers. The manufacture of aluminum beverage cans is described step by step, in general terms. The main objective is to analyze how different cans background geometries have great influence on the dome reversal. To be able to achieve the goal it was necessary to use cans of different manufacturers, which were used in buckle tests to obtain the reversal pressures, tensile tests and geometric analysis. Finally empirical equations were obtained correlating these variables, and it was observed that the conformation of reforming change significantly it's behavior

Estudo da fadiga em liga de alumínio aeronáutico 7475-T761

This work will address the study of fatigue conditions with constant load in an alloy of aluminum analysis 7475 - T761, so we can better understand the conditions of the aircrafts which contain this alloy in their structures. A literature review, which was discussed the concepts of fracture mechanics, fatigue, aeronautical components, chemical analysis of aluminum alloys, fatigue problems that appears in the aircrafts, metallographic analysis, and testing of optical microscopy tensile, fatigue and microhardness, surface analysis (MEV) study of the chemical composition of the alloy in question, the main causes of crashes, was performed, completing the work, analysis of data from tensile test, hardness and fatigue together with the interpretation of images of optical microscopy and scanning electron was taken. The data indicated the high mechanical strength of the alloy, along with its microstructure indicating elongated grains and high surface contour, which shows such resistance by hindering the movement of dislocations. The grooves are clearly shown in the MEV images as well as the classic with increased fatigue loading and subsequent reduction of the number of cycles to rupture behavior shown in the graphs. Therefore we observed the optimal behavior is supported by the league when subjected to fatigue loadings

Influência do desbalanceamento da onda retangular na liga de alumínio 6063-T6 soldada pelo processo TIG-CA

Pós-graduação em Ciência e Tecnologia de Materiais - FC

Utilização de lama vermelha para oxidação eletrolítica assistida por plasma de liga de alumínio

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Usinagem do alumínio da classe 6005 com uso de ferramenta cerâmica

The machining process is so much important in the economic world. Many machining parameters have been studied to maximize results, in terms of cost and lifetime. (decrease of cutting tool wear, improved surface finish, among others). The objective of this study is to evaluate the wear of a ceramic tool in the machining of the aluminum alloy 6005 A. The analysis of the wear of the cutting tools is very important due to its big impact on the final finishing of the piece as a whole. The evaluation took place in two stages, first it was done a detailed study of the literature of the whole machining process, where the study of the formation and swarf classification were among the most important steps in this phase. The second step consisted in the machining of the piece of aluminum 6005 A with a ceramic cutting tool constituded of aluminum oxide and magnesium oxide with silicon carbide impregnation. The swarf generated in this process was then photographed with a Zeiss optical microscope and analyzed for its size and shape. Through this comparison it was concluded that the swarf are generated shear swarfs, shaped like a tangled, fragmented and arcs connected, thus classifying the material as medium difficulty machining. Through the image analysis tool it was concluded that the parameter of lower wear was the: Vc = 500m / min, f = 0.10mm / rev and ap = 0.5mm

Torneamento da liga de alumínio da classe 6005 utilizando ferramenta cerâmica

Machining processes are one of the most important manufacturing processes in the modern world. In these processes, there are many elements which will influence in the final result of the machined part. Among them, the tools are the principal factor of the rising cost, because its global influence on the process. In aeronautical industries, this can be more evidenced due the need to machining several alloys, between them, aluminum alloys. These alloys have to demonstrate a specific surface finishing to be used in aircraft's fuselage. This kind of industry is one of the segments which is still rising in Brazil, and they are looking viable alternatives in the manufacturing processes of materials, due the need to produce more and more parts and equipment, with costs increasingly reduced. The purpose of this project is the development of a ceramic with differentiated properties. The ceramics were developed using a pre-sintering at 1200 °C, with posterior sintering at 1600°C, and subjected to dry turning process on aluminum alloy 6005. The characterizations showed that ceramics presented with toughness on the center of 1700 MPa and on the surface of 1950 MPa, density 98,5 ±0,14. g/cm³. Ceramics were grinded and faceted, according to ISO standard 1832, and subjected to turning tests in a ROMI lathe brand, model GL240M, using cutting speeds of 500, 800 and 1000 m/min with different feed rates. The machining results showed low occurrence of flank wear to all cutting speeds, and better surface finishing average values of Ra = 0,4935 μm and Rt = 8,112 μm. In general, it could be seen that the tool presents important potential to machining 6005 alloy, and that the use of correct parameters can decrease and/or eliminate subsequent processes, providing important reductions in costs related to the machining processes