Intralaminar toughness characterisation of unbalanced hybrid plain weave laminates

A numerical and experimental investigation on the mode-I intralaminar toughness of a hybrid plain weave composite laminate manufactured using resin infusion under flexible tooling (RIFT) process is presented in this paper. The pre-cracked geometries consisted of overheight compact tension (OCT), double edge notch (DEN) and centrally cracked four-point-bending (4PBT) test specimens. The position as well as the strain field ahead of the crack tip during the loading stage was determined using a digital speckle photogrammetry system. The limitation on the applicability of the standard data reduction schemes for the determination of intralaminar toughness of composite materials is presented and discussed. A methodology based on the numerical evaluation of the strain energy release rate using the J-integral method is proposed to derive new geometric correction functions for the determination of the stress intensity factor for composites. The method accounts for material anisotropy and finite specimen dimension effects regardless of the geometry. The approach has been validated for alternative non-standard specimen geometries. A comparison between different methods currently available for computing the intralaminar fracture toughness in composite laminates is presented and a good agreement between numerical and experimental results using the proposed methodology was obtained. 

Experimental investigation of thermoforming carbon fibre-reinforced polyphenylene sulphide composites

Pre-consolidated carbon fibre-reinforced polyphenylene sulphide (CF/PPS) laminates were
thermoformed into V-shaped parts via designed out of autoclave thermoforming experiments.
The different processing conditions tested in the experiment have resulted in final
part angles whose differences ranged from 2.087 to 3.431 from the original mould angle.
The test results show that processing conditions influenced finished part dimensions as the
final sample angles were found to decrease relative to the tooling dimensions, as mould
temperature increases. Higher mould temperature conditions produce thinner parts due
to the thermal expansion of mould tools. The mould temperature of 170C, which can
produce parts with high degree of crystallinity as well as small size of crystal, has been
established as the optimal thermoforming condition for CF/PPS composites.

MIXED-MODEL PRODUCTION SYSTEM DESIGN FOR AIRCRAFT ASSEMBLY

With the advancement of flexible fixture and flexible tooling, mixed production has become possible for aircraft assembly as the manufacturing processes of different aircraft/sub-assembly models are similar. However, it is a great challenge to model the problem and provide a practical solution due to the low volume and complex constraints of aircraft assemblies. To tackle this problem, this work proposes a methodology for designing the mixed production system, and a new scheduling approach is proposed by combined backward and forward scheduling methods. These methods are validated through a real-life industrial case study. Simulation results show that the number of workstations and the cycle time for making a fuselage can be reduced by 50% and 39% respectively with the newly designed mixed-model system.

Prediction of surface roughness during hard turning of AISI 4340 steel (69 HRC)

In this study, 39 sets of hard turning (HT) experimental trials were performed on a Mori-Seiki SL-25Y (4-axis) computer numerical controlled (CNC) lathe to study the effect of cutting parameters in influencing the machined surface roughness. In all the trials, AISI 4340 steel workpiece (hardened up to 69 HRC) was machined with a commercially available CBN insert (Warren Tooling Limited, UK) under dry conditions. The surface topography of the machined samples was examined by using a white light interferometer and a reconfirmation of measurement was done using a Form Talysurf. The machining outcome was used as an input to develop various regression models to predict the average machined surface roughness on this material. Three regression models - Multiple regression, Random Forest, and Quantile regression were applied to the experimental outcomes. To the best of the authors’ knowledge, this paper is the first to apply Random Forest or Quantile regression techniques to the machining domain. The performance of these models was compared to each other to ascertain how feed, depth of cut, and spindle speed affect surface roughness and finally to obtain a mathematical equation correlating these variables. It was concluded that the random forest regression model is a superior choice over multiple regression models for prediction of surface roughness during machining of AISI 4340 steel (69 HRC).

Otimização do processo de projeto de uma ferramenta progressiva para a estampagem de componentes metálicos

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica

Delamination analysis of carbon fibre reinforced laminates: evaluation of a special step drill

Drilling of carbon fibre/epoxy laminates is usually carried out using standard drills. However, it is necessary to adapt the processes and/or tooling as the risk of delamination, or other damages, is high. These problems can affect mechanical properties of produced parts, therefore, lower reliability. In this paper, four different drills – three commercial and a special step (prototype) – are compared in terms of thrust force during drilling and delamination. In order to evaluate damage, enhanced radiography is applied. The resulting images were then computational processed using a previously developed image processing and analysis platform. Results show that the prototype drill had encouraging results in terms of maximum thrust force and delamination reduction. Furthermore, it is possible to state that a correct choice of drill geometry, particularly the use of a pilot hole, a conservative cutting speed – 53 m/min – and a low feed rate – 0.025 mm/rev – can help to prevent delamination.

Melhoria e automação de linhas de montagem

Hoje em dia, e com os avanços tecnológicos a surgirem de forma constante, existem novas áreas que têm de ser consideradas com um foco importante por parte de todas as organizações, sendo uma delas a robótica industrial. Motivada em aumentar o seu output, as condições de trabalho para os seus colaboradores, bem como todas as condições de organização da logística interna, a Grohe Portugal, mais especificamente o departamento da montagem, achou relevante fazer um estudo de métodos e tempos, calculando os ganhos potenciais de aumento de output com introdução de robótica nas linhas dos cartuchos. Os objetivos principais seriam então, fazer uma restruturação de todo o layout dessas linhas, tendo como foco automatizar alguma(s) operação(ões), conseguindo assim uma melhoria significativa do output dessas linhas com o menor payback possível. Posto isto, esta dissertação pretende apresentar o trabalho desenvolvido junto da Grohe Portugal, que teve como objetivo fazer os estudos e a automatização de linhas de montagem de cartuchos, bem como melhorar algumas linhas de montagem tendo em conta fatores ergonómicos. Relativamente à automatização da linha dos cartuchos, foi importante estudar todos os seguintes aspetos:  utilização de unidades robóticas;  ergonomia;  ganhos de produtividade;  automatizar ou semi-automatizar operações;  simplificar processos de montagem;  simplificar setups;  solicitar orçamentos;  elaborar caderno de encargos. Para a realização deste projeto, o trabalho desenvolvido foi decomposto em várias etapas, entre as quais se destacam:  análise e estudo dos métodos e sequências de montagem;  levantamento de todos os componentes e operações de montagem até à obtenção do cartucho final;  estudo de tempos de todas essas operações de montagem;  caraterização de um novo layout para as linhas com a introdução de unidades robóticas, tanto quanto possível, mais adequadas;  elaboração de caderno de encargos para ser enviado a empresas, para estas poderem apresentar uma orçamentação, bem como indicar as unidades robóticas mais adequadas para as tarefas pretendidas;  automatização da linha dos cartuchos. Relativamente ao projeto de novas linhas de montagem tendo em conta fatores ergonómicos, de forma a melhorar os sistemas de abastecimento e as condições de trabalho por parte dos operadores, foram postos em prática diferentes passos, nomeadamente:  identificação de todos os processos de montagem realizados pelos operadores na linha a melhorar;  estudo e definição da disposição dos componentes na nova linha, bem como a sua forma de abastecimento;  projeto da nova linha de montagem em 3D com recurso ao software SolidWorks;  realização prática da linha, acompanhando e ajudando a equipa da ferramentaria. O balanço final do trabalho foi bastante positivo, tanto na automatização das linhas de montagem dos cartuchos, em que todo o seu estudo foi alcançado com sucesso, como no melhoramento ergonómico das linhas de montagem, tendo-se alcançado melhorias em alguns índices de qualidade, tempos de abastecimento, organização das linhas, e nas condições de iluminação, resultando essas melhorias numa avaliação positiva por parte dos colaboradores que nelas trabalham todos os dias.

Generating Compliant Motion of Objects with an Articulated Hand

The flexibility of the robot is the key to its success as a viable aid to production. Flexibility of a robot can be explained in two directions. The first is to increase the physical generality of the robot such that it can be easily reconfigured to handle a wide variety of tasks. The second direction is to increase the ability of the robot to interact with its environment such that tasks can still be successfully completed in the presence of uncertainties. The use of articulated hands are capable of adapting to a wide variety of grasp shapes, hence reducing the need for special tooling. The availability of low mass, high bandwidth points close to the manipulated object also offers significant improvements I the control of fine motions. This thesis provides a framework for using articulated hands to perform local manipulation of objects. N particular, it addresses the issues in effecting compliant motions of objects in Cartesian space. The Stanford/JPL hand is used as an example to illustrate a number of concepts. The examples provide a unified methodology for controlling articulated hands grasping with point contacts. We also present a high-level hand programming system based on the methodologies developed in this thesis. Compliant motion of grasped objects and dexterous manipulations can be easily described in the LISP-based hand programming language.

A importância da marca na Indústria Portuguesa de Moldes

A recente criação de uma marca colectiva para promover o cluster de tooling português nos mercados internacionais, como meio de apropriação de valor evidencia a necessidade de compreender qual a importância da marca para as empresas portuguesas. Isto implica aferir qual o posicionamento que a marca está a assumir na mente dos clientes, assim como o seu grau de notoriedade e reconhecimento. O presente estudo pretende analisar a importância da marca segundo os vários stakeholders do cluster, nomeadamente empresas, instituições de ensino e investigação e desenvolvimento, fornecedores, associações e clientes. Sendo este estudo realizado numa fase precoce da implementação da marca «Engineering & Tooling from Portugal» verifica-se que esta é vista como um factor importante para a competitividade das empresas portuguesas, pese embora o nível de reconhecimento da marca seja ainda redutor. Este trabalho procura também sugerir orientações que permitam ao cluster maximizar o valor da marca, sendo proposto um reforço do plano de promoção e a focalização dos atributos-chave da marca.

Rotational aesthetics: Michael Bay and contemporary cinema’s machine movement

Digital imaging technologies enable a mastery of the visual that in recent mainstream cinema frequently manifests as certain kinds of spatial reach, orientation and motion. In such a context Michael Bay’s Transformers franchise can be framed as a digital re-tooling of a familiar fantasy of vehicular propulsion, US car culture writ large in digitally crafted spectacles of diegetic speed, the vehicular chase film ‘2.0’. Movement is central to these films, calling up Scott Bukatman’s observation that in spectacular visual media ‘movement has become more than a tool of bodily knowledge; it has become an end in itself’ (2003: 125). Not all movements and not all instances of vehicular propulsion are the same however. How might we evaluate what is at stake in a film’s assertion of movement as an end in itself, and the form that assertion takes, its articulations of diegetic velocity, corporeality, and spatial penetration? Deploying an attentiveness towards the specificity of aesthetic detail and affective impact in Bay’s delineation of movement, this essay suggests that the franchise poses questions about the relationship of human movement to machine movement that exceed their narrative basis. Identifying a persistent rotational trope in the franchise that in its audio-visual articulation combines oddly anachronistic elements (evoking the mechanical rather than the digital), the article argues that the films prioritise certain fantasies of transformation and spatial penetration, and certain modes of corporeality, as one response to contemporary debates about digital technologisation, sustainable energy, and cinematic spectacle. In this way the franchise also represents a particular moment in a more widely discernible preoccupation in contemporary cinema with what we might call a ‘rotational aesthetics’ of action, a machine movement made possible by the digital, but which invokes earlier histories and fantasies of animation, propulsion, mechanization and mechanization to particular ends.

3D roll-forming of hat-profile with variable depth and width

The use of roll-formed products in automotive, furniture, buildings etc. increases every year due to the low part-production cost and the complicated cross-sections that can be produced. The limitation with roll-forming until recent years is that one could only produce profiles with a constant cross-section in the longitudinal direction. About eight years ago ORTIC AB [1] developed a machine in which it was possible to produce profiles with a variable width (“3D roll-forming”) for the building industry. Experimental equipment was recently built for research and prototyping of profiles with variable cross-section in both width and depth for the automotive industry. The objective with the current study is to investigate the new tooling concept that makes it possible to roll-form hat-profiles, made of ultra high strength steel, with variable cross-section in depth and width. The result shows that it is possible to produce 3D roll-formed profiles with close tolerances.

Experimental and computational investigation of the roll forming process

One of the first questions to consider when designing a new roll forming line is the number of forming steps required to produce a profile. The number depends on material properties, the cross-section geometry and tolerance requirements, but the tool designer also wants to minimize the number of forming steps in order to reduce the investment costs for the customer. There are several computer aided engineering systems on the market that can assist the tool designing process. These include more or less simple formulas to predict deformation during forming as well as the number of forming steps. In recent years it has also become possible to use finite element analysis for the design of roll forming processes. The objective of the work presented in this thesis was to answer the following question: How should the roll forming process be designed for complex geometries and/or high strength steels? The work approach included both literature studies as well as experimental and modelling work. The experimental part gave direct insight into the process and was also used to develop and validate models of the process. Starting with simple geometries and standard steels the work progressed to more complex profiles of variable depth and width, made of high strength steels. The results obtained are published in seven papers appended to this thesis. In the first study (see paper 1) a finite element model for investigating the roll forming of a U-profile was built. It was used to investigate the effect on longitudinal peak membrane strain and deformation length when yield strength increases, see paper 2 and 3. The simulations showed that the peak strain decreases whereas the deformation length increases when the yield strength increases. The studies described in paper 4 and 5 measured roll load, roll torque, springback and strain history during the U-profile forming process. The measurement results were used to validate the finite element model in paper 1. The results presented in paper 6 shows that the formability of stainless steel (e.g. AISI 301), that in the cold rolled condition has a large martensite fraction, can be substantially increased by heating the bending zone. The heated area will then become austenitic and ductile before the roll forming. Thanks to the phenomenon of strain induced martensite formation, the steel will regain the martensite content and its strength during the subsequent plastic straining. Finally, a new tooling concept for profiles with variable cross-sections is presented in paper 7. The overall conclusions of the present work are that today, it is possible to successfully develop profiles of complex geometries (3D roll forming) in high strength steels and that finite element simulation can be a useful tool in the design of the roll forming process.

e-Pontos: Uma solução embarcada de automação comercial aplicada a clubes de fidelidade baseado em tecnologia RFID e esmart card

In practically all vertical markets and in every region of the planet, loyalty marketers have adopted the tactic of recognition and reward to identify, maintain and increase the yield of their customers. Several strategies have been adopted by companies, and the most popular among them is the loyalty program, which displays a loyalty club to manage these rewards. But the problem with loyalty programs is that customer identification and transfer of loyalty points are made in a semiautomatic. Aiming at this, this paper presents a master's embedded business automation solution called e-Points. The goal of e-Points is munir clubs allegiances with fully automated tooling technology to identify customers directly at the point of sales, ensuring greater control over the loyalty of associate members. For this, we developed a hardware platform with embedded system and RFID technology to be used in PCs tenant, a smart card to accumulate points with every purchase and a web server, which will provide services of interest to retailers and customers membership to the club

Uma abordagem sistemática para implementação, gerenciamento e customização de testes de linhas de produto de software

Through the adoption of the software product line (SPL) approach, several benefits are achieved when compared to the conventional development processes that are based on creating a single software system at a time. The process of developing a SPL differs from traditional software construction, since it has two essential phases: the domain engineering - when common and variables elements of the SPL are defined and implemented; and the application engineering - when one or more applications (specific products) are derived from the reuse of artifacts created in the domain engineering. The test activity is also fundamental and aims to detect defects in the artifacts produced in SPL development. However, the characteristics of an SPL bring new challenges to this activity that must be considered. Several approaches have been recently proposed for the testing process of product lines, but they have been shown limited and have only provided general guidelines. In addition, there is also a lack of tools to support the variability management and customization of automated case tests for SPLs. In this context, this dissertation has the goal of proposing a systematic approach to software product line testing. The approach offers: (i) automated SPL test strategies to be applied in the domain and application engineering, (ii) explicit guidelines to support the implementation and reuse of automated test cases at the unit, integration and system levels in domain and application engineering; and (iii) tooling support for automating the variability management and customization of test cases. The approach is evaluated through its application in a software product line for web systems. The results of this work have shown that the proposed approach can help the developers to deal with the challenges imposed by the characteristics of SPLs during the testing process

Sequenciamento de lotes em prensas de alta capacidade com tempo de setup dependente da sequência

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)