Mecanizado por torneado en duro

[ES]Los objetivos del siguiente trabajo consisten en analizar e optimizar el proceso del torneado en duro del acero ASP-23 indagando de especial manera en la realización de diferentes soluciones para brochas. En este caso, este proyecto nace de la importancia de reducir así como los costes económicos y los costes temporales de fabricación de elementos basados en el acero ASP-23 mediante el torneado en duro; proceso de mecanizado, cuya importancia cada vez es mayor como en las industrias de automoción o aeronáutica. El desarrollo del proyecto es fruto de la necesidad de EKIN S. Coop, uno de los líderes en los procesos de máquina-herramienta de alta precisión para el brochado, de desarrollar un proceso de mecanizado más eficaz de las brochas que produce. Así en el aula máquina-herramienta (ETSIB) se han intentado demostrar los beneficios que tiene el torneado en duro en el mecanizado del ASP-23. Hoy en día, con el rápido desarrollo de nuevos materiales, los procesos de fabricación se están haciendo cada vez más complejos, por la amplia variedad de maquinas con las que se realizan los procesos, por la variedad de geometría/material de las herramientas empleadas, por las propiedades del material de la pieza a mecanizar, por los parámetros de corte tan variados con los que podemos implementar el proceso (profundidad de corte, velocidad, alimentación...) y por la diversidad de elementos de sujeción utilizados. Además debemos ser conscientes de que tal variedad implica grandes magnitudes de deformaciones, velocidades y temperaturas. He aquí la justificación y el gran interés en el proyecto a realizar. Por ello, en este proyecto intentamos dar un pequeño paso en el conocimiento del proceso del torneado en duro de aceros con poca maquinabilidad, siendo conscientes de la amplia variedad y dificultad del avance en la ingeniería de fabricación y del mucho trabajo que queda por hacer.

Multilayer Active Shell Mirrors

This thesis presents a novel active mirror technology based on carbon fiber composites and replication manufacturing processes. Multiple additional layers are implemented into the structure in order to provide the reflective layer, actuation capabilities and electrode routing. The mirror is thin, lightweight, and has large actuation capabilities. These features, along with the associated manufacturing processes, represent a significant change in design compared to traditional optics. Structural redundancy in the form of added material or support structures is replaced by thin, unsupported lightweight substrates with large actuation capabilities.

Several studies motivated by the desire to improve as-manufactured figure quality are performed. Firstly, imperfections in thin CFRP laminates and their effect on post-cure shape errors are studied. Numerical models are developed and compared to experimental measurements on flat laminates. Techniques to mitigate figure errors for thicker laminates are also identified. A method of properly integrating the reflective facesheet onto the front surface of the CFRP substrate is also presented. Finally, the effect of bonding multiple initially flat active plates to the backside of a curved CFRP substrate is studied. Figure deformations along with local surface defects are predicted and characterized experimentally. By understanding the mechanics behind these processes, significant improvements to the overall figure quality have been made.

Studies related to the actuation response of the mirror are also performed. The active properties of two materials are characterized and compared. Optimal active layer thicknesses for thin surface-parallel schemes are determined. Finite element simulations are used to make predictions on shape correction capabilities, demonstrating high correctabiliity and stroke over low-order modes. The effect of actuator saturation is studied and shown to significantly degrade shape correction performance.

The initial figure as well as actuation capabilities of a fully-integrated active mirror prototype are characterized experimentally using a Projected Hartmann test. A description of the test apparatus is presented along with two verification measurements. The apparatus is shown to accurately capture both high-amplitude low spatial-frequency figure errors as well as those at lower amplitudes but higher spatial frequencies. A closed-loop figure correction is performed, reducing figure errors by 94%.

Comparación de la rugosidad media y máxima obtenida mediante diferentes instrumentos: análisis del filtro y Lc empleados

[ES]Este trabajo pretende analizar la influencia que tiene la longitud de corte elegida y el filtro empleado en la medida de la rugosidad. Se realizan medidas de rugosidad en tres probetas que han sido sometidas a diferentes procesos de fabricación (fresado, rectificado y electroerosión). Además, se utilizan tres instrumentos diferentes para la medición. Tras realizar las medidas, se comparan los resultados y se extraen las conclusiones

Bizikletako aurreko abatzaren mekanizaziorako cam bidezko programazioa

[EU]Lan honek bizikletako aurreko gurpileko abatz baten CAM edo CNC programazioa egitean datza, honen bidez erremintaren ibilbidea deskribatuz piezaren CAD eredutik abiatuz. Hasteko, zenbakizko kontrolak izan duen eboluzioa eta garrantzia azaltzen da. Ondoren, abatzaren funtzionamenduaren deskribapena egin da, bere osagaiak eta izan behar dituen ezaugarriak aztertuz. Gainera, fabrikazio prozesu ezberdinen analisia egin da, bakoitzaren abantaila eta desabantailak azpimarratuz. Azkenik, zenbakizko kontrolaren inguruan bereganatutako ezagutzak aplikatu dira CAM programa batean abatz baten mekanizazioa programatuz. Honez gain, erabilitako CAM programaren erabilera azaltzen da.

Reciclado de polvo inconel 718 y evolución de las propiedades de los componentes fabricados con los mismos.

[ES]El objetivo de este trabajo ha sido la determinación de un proceso para la reutilización del polvo metálico desperdiciado durante el proceso de aporte por láser. El polvo necesita ser inyectado para ser fundido directamente sobre el aporte pero un alto porcentaje de las partículas golpean el área no fundida y directamente rebotan fuera de la zona de aporte. La eficiencia de las partículas depositadas puede bajar hasta el 40 % dependiendo de la configuración y del tamaño del punto de aporte. El material utilizado ha sido la superaleación de níquel Inconel 718 debido a su potencial aplicación en procesos de fabricación aditiva. Después del primer uso, el polvo es recolectado y tamizado. La fracción indeseada es magnéticamente segregada y la parte limpia es nuevamente tamizada para obtener datos y de nuevo mezclada para estar lista para la reutilización. No ha sido añadido polvo nuevo a la fracción recuperada y este procedimiento ha sido repetido 5 veces. Los test experimentales muestran que el material depositado presenta resultados similares a aquellos obtenidos con polvo nuevo. La implementación de este proceso permite la mejora de la eficiencia final reduciendo tanto costes como residuos materiales.

A questão da autoria na produção de filmes em duas oficinas de formação audiovisual

É na intersecção entre o campo do audiovisual e o da educação que se localiza o interesse desta pesquisa. Ela parte da premissa que o meu objeto é aquilo que é passível de ser mapeado, um dispositivo de subjetivação que se dá no entrecruzamento de elementos presentes, de maneira mais ou menos direta, nos processos de fabricação de filmes em duas oficinas de formação audiovisual: oficina Cinemaneiro e oficina de video do Núcleo Arte Grécia. Apoiando-se metodologicamente na Teoria Ator Rede, de Bruno Latour, esta pesquisa irá apresentar um rastreamento da rede sóciotécnica a partir das figuras discursivas presentes nos créditos dos filmes produzidos nessas oficinas: "No Limite do Horizonte, Complexo de Juninho e Kurú, o valor da amizade. Esta pesquisa considera que a investigação sobre a autoria desses filmes revela muito sobre os modos de construção de visões de mundo implicados nos processos de formação em questão.

Avaliação de complexos de inclusão na inibição do aço carbono em meio ácido

A indústria de petróleo e gás apresenta sérios problemas relacionados à corrosão. Nas petroquímicas e nas instalações de refino de petróleo, as falhas em materiais estão relacionadas com a corrosão, além disso, os processos de corrosão de metais são problemas no mundo, causando ônus em processos industriais e gerando situações de risco como a corrosão de pilares metálicos em pontes ou em fuselagens de aviões. Dentre os meios corrosivos, um muito comum é o meio ácido, que será o meio estudado neste trabalho. Com todos os problemas citados, se faz necessário o estudo de inibidores de corrosão com alta eficiência, estabilidade e que, preferencialmente, não agridam o meio ambiente. Alguns inibidores de corrosão apresentam solubilidade limitada em água, sendo necessária a utilização de alguns solventes não tão amigáveis ao meio ambiente. Então, propôs-se formar um complexo de inclusão para tornar possível a solubilização de inibidores convencionais em solução aquosa, como algumas tioureias, que apresentam solubilidade limitada em água. Essa completa solubilização do inibidor de corrosão orgânico em meio aquoso é possível com a utilização de um aditivo (hospedeiro) capaz de encapsular tais moléculas (convidados) via interações não covalentes, de modo a alcançar o máximo desempenho de inibição. Para a formação do complexo de inclusão foi usado como molécula hospedeira, a α e a β hidroxipropilciclodextrina e como molécula convidada a dibenziltioureia. A intenção foi testar a melhora da ação inibidora da corrosão do aço carbono em meio de HCl 1mol.L-1 com ensaios de perda de massa, de impedância, polarização e microscopia eletrônica de varredura (MEV), além de evidenciar a formação destes complexos de inclusão através da espectroscopia de absorção vibracional no infravermelho, espectroscopia de RMN de 1H, espectroscopia de absorção no Ultra-violeta e análise térmica diferencial (DTA)

Assessing the potential of yield improvements, through process scrap reduction, for energy and CO2 abatement in the steel and aluminium sectors

Targets to cut 2050 CO2 emissions in the steel and aluminium sectors by 50%, whilst demand is expected to double, cannot be met by energy efficiency measures alone, so options that reduce total demand for liquid metal production must also be considered. Such reductions could occur through reduced demand for final goods (for instance by life extension), reduced demand for material use in each product (for instance by lightweight design) or reduced demand for material to make existing products. The last option, improving the yield of manufacturing processes from liquid metal to final product, is attractive in being invisible to the final customer, but has had little attention to date. Accordingly this paper aims to provide an estimate of the potential to make existing products with less liquid metal production. Yield ratios have been measured for five case study products, through a series of detailed factory visits, along each supply chain. The results of these studies, presented on graphs of cumulative energy against yield, demonstrate how the embodied energy in final products may be up to 15 times greater than the energy required to make liquid metal, due to yield losses. A top-down evaluation of the global flows of steel and aluminium showed that 26% of liquid steel and 41% of liquid aluminium produced does not make it into final products, but is diverted as process scrap and recycled. Reducing scrap substitutes production by recycling and could reduce total energy use by 17% and 6% and total CO 2 emissions by 16% and 7% for the steel and aluminium industries respectively, using forming and fabrication energy values from the case studies. The abatement potential of process scrap elimination is similar in magnitude to worldwide implementation of best available standards of energy efficiency and demonstrates how decreasing the recycled content may sometimes result in emission reductions. Evidence from the case studies suggests that whilst most companies are aware of their own yield ratios, few, if any, are fully aware of cumulative losses along their whole supply chain. Addressing yield losses requires this awareness to motivate collaborative approaches to improvement. © 2011 Elsevier B.V. All rights reserved.

An evaluation of a new product data model

Engineering companies face many challenges today such as increased competition, higher expectations from consumers and decreasing product lifecycle times. This means that product development times must be reduced to meet these challenges. Concurrent engineering, reuse of engineering knowledge and the use of advanced methods and tools are among the ways of reducing product development times. Concurrent engineering is crucial in making sure that the products are designed with all issues considered simultaneously. The reuse of engineering knowledge allows existing solutions to be reused. It can also help to avoid the mistakes made in previous designs. Computer-based tools are used to store information, automate tasks, distribute work, perform simulation and so forth. This research concerns the evaluation of tools that can be used to support the design process. These tools are evaluated in terms of the capture of information generated during the design process. This information is vital to allow the reuse of knowledge. Present CAD systems store only information on the final definition of the product such as geometry, materials and manufacturing processes. Product Data Management (PDM) systems can manage all this CAD information along with other product related information. The research includes the evaluation of two PDM systems, Windchill and Metaphase, using the design of a single-handed water tap as a case study. The two PDMs were then compared to PROSUS/DDM. PROSUS is the Process-Based Support System proposed by [Blessing 94] using the same case study. The Design Data Model is the product data model that includes PROSUS. The results look promising. PROSUS/DDM is able to capture most design information and structure and present it logically. The design process and product information is related and stored within the DDM structure. The PDMs can capture most design information, but information from early stages of design is stored only as unstructured documentation. Some problems were found with PROSUS/DDM. A proposal is made that may make it possible to resolve these problems, but this will require further research.

Cost-effective 10 Gb/s polymer-based chip-to-chip optical interconnect

Board-level optical links are an attractive alternative to their electrical counterparts as they provide higher bandwidth and lower power consumption at high data rates. However, on-board optical technology has to be cost-effective to be commercially deployed. This study presents a chip-to-chip optical interconnect formed on an optoelectronic printed circuit board that uses a simple optical coupling scheme, cost-effective materials and is compatible with well-established manufacturing processes common to the electronics industry. Details of the link architecture, modelling studies of the link's frequency response, characterisation of optical coupling efficiencies and dynamic performance studies of this proof-of-concept chip-to-chip optical interconnect are reported. The fully assembled link exhibits a -3 dBe bandwidth of 9 GHz and -3 dBo tolerances to transverse component misalignments of ±25 and ±37 μm at the input and output waveguide interfaces, respectively. The link has a total insertion loss of 6 dBo and achieves error-free transmission at a 10 Gb/s data rate with a power margin of 11.6 dBo for a bit-error-rate of 10 -12. The proposed architecture demonstrates an integration approach for high-speed board-level chip-to-chip optical links that emphasises component simplicity and manufacturability crucial to the migration of such technology into real-world commercial systems. © 2012 The Institution of Engineering and Technology.

Superconducting fault current limiter design using parallel-connected YBCO thin films

Superconducting Fault Current Limiters (SFCLs) are able to reduce fault currents to an acceptable value, reducing potential mechanical and thermal damage to power system apparatus and allowing more flexibility in power system design and operation. The device can also help avoid replacing circuit breakers whose capacity has been exceeded. Due to limitations in current YBCO thin film manufacturing processes, it is not easy to obtain one large thin film that satisfies the specifications for high voltage and large current applications. The combination of standardized thin films has merit to reduce costs and maintain device quality, and it is necessary to connect these thin films in different series and parallel configurations in order to meet these specifications. In this paper, the design of a resistive type SFCL using parallel-connected YBCO thin films is discussed, including the role of a parallel resistor and the influence of individual thin film characteristics, based on both theory and experimental results. © 2009 IEEE.

Bulk forming of sheet metal

Ever increasing demands on functional integration of high strength light weight products leads to the development of a new class of manufacturing processes. The application of bulk forming processes to sheet or plate semi-finished products, sometimes in combination with conventional sheet forming processes creates new products with the requested properties. The paper defines this new class of sheet-bulk metal forming processes, gives an overview of the existing processes belonging to this class, highlights the tooling aspects as well as the resulting product properties and presents a short summary of the relevant work that has been done towards modeling and simulation. © 2012 CIRP.

Low-cost PCB-integrated 10-Gb/s optical transceiver built with a novel integration method

A novel integration method for the production of cost-effective optoelectronic printed circuit boards (OE PCBs) is presented. The proposed integration method allows fabrication of OE PCBs with manufacturing processes common to the electronics industry while enabling direct attachment of electronic components onto the board with solder reflow processes as well as board assembly with automated pick-and-place tools. The OE PCB design is based on the use of polymer multimode waveguides, end-fired optical coupling schemes, and simple electro-optic connectors, eliminating the need for additional optical components in the optical layer, such as micro-mirrors and micro-lenses. A proof-of-concept low-cost optical transceiver produced with the proposed integration method is presented. This transceiver is fabricated on a low-cost FR4 substrate, comprises a polymer Y-splitter together with the electronic circuitry of the transmitter and receiver modules and achieves error-free 10-Gb/s bidirectional data transmission. Theoretical studies on the optical coupling efficiencies and alignment tolerances achieved with the employed end-fired coupling schemes are presented while experimental results on the optical transmission characteristics, frequency response, and data transmission performance of the integrated optical links are reported. The demonstrated optoelectronic unit can be used as a front-end optical network unit in short-reach datacommunication links. © 2011-2012 IEEE.