Numerical modeling and assessment of the thermal environment in an industrial premise of automotive components

Dissertação de mestrado em Engenharia Industrial

Development and application of a computer-based methodology for design for additive manufacturing of automotive components

The research project aims to improve the Design for Additive Manufacturing of metal components. Firstly, the scenario of Additive Manufacturing is depicted, describing its role in Industry 4.0 and in particular focusing on Metal Additive Manufacturing technologies and the Automotive sector applications. Secondly, the state of the art in Design for Additive Manufacturing is described, contextualizing the methodologies, and classifying guidelines, rules, and approaches. The key phases of product design and process design to achieve lightweight functional designs and reliable processes are deepened together with the Computer-Aided Technologies to support the approaches implementation. Therefore, a general Design for Additive Manufacturing workflow based on product and process optimization has been systematically defined. From the analysis of the state of the art, the use of a holistic approach has been considered fundamental and thus the use of integrated product-process design platforms has been evaluated as a key element for its development. Indeed, a computer-based methodology exploiting integrated tools and numerical simulations to drive the product and process optimization has been proposed. A validation of CAD platform-based approaches has been performed, as well as potentials offered by integrated tools have been evaluated. Concerning product optimization, systematic approaches to integrate topology optimization in the design have been proposed and validated through product optimization of an automotive case study. Concerning process optimization, the use of process simulation techniques to prevent manufacturing flaws related to the high thermal gradients of metal processes is developed, providing case studies to validate results compared to experimental data, and application to process optimization of an automotive case study. Finally, an example of the product and process design through the proposed simulation-driven integrated approach is provided to prove the method's suitability for effective redesigns of Additive Manufacturing based high-performance metal products. The results are then outlined, and further developments are discussed.

Light alloy castings for automotive applications: The case of Al vs Mg

The economical and environmental effects of mass reduction through Al and Mg primary alloys substitutions for cast iron and steel in automotive components are discussed using MF. Ashby's penalty functions method The viability of Mg alloy substitutions for existing Al alloy cast components is also considered. The cost analysis shows that direct, equal-volume, Al alloy substitutions for cast iron and steel are the most feasible in terms of the CAFE liability, followed by substitutions involving flat panels of prescribed stiffness. When the creation of CO2 associated to the production of Al and Mg is considered, the potential gasoline savings over the lifespan of the car compensate for the intrinsic environmental burden of Al in all applications, while electrolytic Mg substitutions for cast iron and steel are feasible for equal volume and panels only. Magnesium produced by the Pidgeon thermal process appears to be too primary energy intensive to be competitive in structural applications. Magnesium substitutions for existing Al alloy beams and panels are generally unviable. The current higher recycling efficiency of Al casting alloys confers Al a significant advantage over Mg alloys.

The Philippines in the Automotive Global Value Chain

This report uses the Duke CGGC Global Value Chain (GVC) framework to examine the role of the Philippines in the global automotive industry and identify opportunities for upgrading. The country’s strength in the sector is in electrical and electronic automotive components, with approximately two-thirds of its US$3.98 billion exports in 2014 falling in one of these categories. The Philippines has a particularly strong foothold in wire harnesses, exports of which increased by 129% from 2007 to 2014 to allow it to become the world’s fourth largest global exporter. The prominence of the cluster affords the country a number of upgrading opportunities moving forward. Otherwise, the relatively small size of the domestic market has constrained the development of the industry, with local companies unable to generate the economies of scale necessary to compete in an increasingly consolidated global environment.

Terminal defect analysis and classification methodology for automotive industry

The impact of end customer quality complaints with direct relationship with automotive components has presented negative trend at European level for the entire automotive industry. Thus, this research proposal is to concentrate efforts on the most important items of Pareto chart and understand the failure type and the mechanism involved, link and impact of the project and parameters on the process, ending it with the development of one of the company’s most desired tool, that hosted this project – European methodology of terminals defects classification, and listing real opportunities for improvement based on measurement and analysis of actual data. Through the development of terminals defects classification methodology, which is considered a valuable asset to the company, all the other companies of the YAZAKI’s group will be able to characterize terminals as brittle or ductile, in order to put in motion, more efficiently, all the other different existing internal procedures for the safeguarding of the components, improving manufacturing efficiency. Based on a brief observation, nothing can be said in absolute sense, concerning the failure causes. Base materials, project, handling during manufacture and storage, as well as the cold work performed by plastic deformation, all play an important role. However, it was expected that this failure has been due to a combination of factors, in detriment of the existence of a single cause. In order to acquire greater knowledge about this problem, unexplored by the company up to the date of commencement of this study, was conducted a thorough review of existing literature on the subject, real production sites were visited and, of course, the actual parts were tested in lab environment. To answer to many of the major issues raised throughout the investigation, were used extensively some theoretical concepts focused on the literature review, with a view to realizing the relationship existing between the different parameters concerned. Should here be stated that finding technical studies on copper and its alloys is really hard, not being given all the desirable information. This investigation has been performed as a YAZAKI Europe Limited Company project and as a Master Thesis for Instituto Superior de Engenharia do Porto, conducted during 9 months between 2012/2013.

Development of a Computer-Based methodology for tolerance selection and optimization applied to the automotive sector

The design optimization of industrial products has always been an essential activity to improve product quality while reducing time-to-market and production costs. Although cost management is very complex and comprises all phases of the product life cycle, the control of geometrical and dimensional variations, known as Dimensional Management (DM), allows compliance with product and process requirements. Hence, the tolerance-cost optimization becomes the main practice to provide an effective application of Design for Tolerancing (DfT) and Design to Cost (DtC) approaches by enabling a connection between product tolerances and associated manufacturing costs. However, despite the growing interest in this topic, a profitable application in the industry of these techniques is hampered by their complexity: the definition of a systematic framework is the key element to improving design optimization, enhancing the concurrent use of Computer-Aided tools and Model-Based Definition (MBD) practices. The present doctorate research aims to define and develop an integrated methodology for product/process design optimization, to better exploit the new capabilities of advanced simulations and tools. By implementing predictive models and multi-disciplinary optimization, a Computer-Aided Integrated framework for tolerance-cost optimization has been proposed to allow the integration of DfT and DtC approaches and their direct application for the design of automotive components. Several case studies have been considered, with the final application of the integrated framework on a high-performance V12 engine assembly, to achieve both functional targets and cost reduction. From a scientific point of view, the proposed methodology provides an improvement for the tolerance-cost optimization of industrial components. The integration of theoretical approaches and Computer-Aided tools allows to analyse the influence of tolerances on both product performance and manufacturing costs. The case studies proved the suitability of the methodology for its application in the industrial field, providing the identification of further areas for improvement and refinement.

Effect of the Impact Conditions on the Mechanical Properties of Injection-Molded Parts

This work focused on the study of the impact event on molded parts in the framework of automotive components. The influence of the impact conditions and processing parameters on the mechanical behavior of talc-filled polypropylene specimens was analyzed. The specimens were lateral-gate discs produced by injection molding, and the mechanical characterization was performed through instrumented falling weight impact tests concomitantly assisted with high-speed videography. Results analyzed using the analysis of variance (ANOVA) method have shown that from the considered parameters, only the dart diameter and test temperature have significant influence on the falling weight impact properties. Higher dart diameter leads to higher peak force and peak energy results. Conversely, higher levels of test temperatures lead to lower values of peak force and peak energy. By means of high-speed videography, a more brittle fracture was observed for experiments with higher levels of test velocity and dart diameter and lower levels of test temperature. The injection-molding process conditions assessed in this study have an influence on the impact response of moldings, mainly on the deformation capabilities of the moldings.

Estudo e Implementação de Ferramentas Lean

Neste documento, apresenta-se o reflexo sobre o trabalho de estágio desenvolvido entre 17 de Fevereiro e 31 de Julho de 2014, nas instalações da Fábrica das Estruturas Metálicas da Faurecia, em São João da Madeira, num Projecto Final no âmbito de Implementação de Ferramentas Lean. O objetivo proposto foi a participação na procura e implementação de soluções, com vista à melhoria contínua do sistema de produção. Foi utilizado, para esse efeito, um vasto conjunto de ferramentas entre as quais os 5S, QRCI, Standardized Work, entre outras e amplamente empregues na indústria automóvel (e nesta empresa em particular), através do Sistema de Excelência Faurecia (FES), aplicado ao ramo de negócio onde está solidamente implantada esta multinacional de origem francesa. O período de tempo em que decorreu o estágio constituiu uma oportunidade única para o estagiário contactar com os problemas existentes no departamento de produção, num mercado tão concorrencial e competitivo como é o da indústria de componentes para automóveis. O presente trabalho de estágio apresenta duas vertentes distintas: uma de caráter interno à empresa e outra relativa aos fornecedores e clientes. Em termos internos, foi visível a batalha pela diminuição das variabilidades que surgem no plano da produção ao absorver grande parte do esforço dos agentes que trabalham na otimização dos processos. Externamente, observou-se a dificuldade em encontrar fornecedores adequados a satisfazer os aprovisionamentos da Faurecia, em quantidade e qualidade, e um elevado grau de exigência imposto por parte dos vários clientes. Por fim, este Projeto possibilitou a aplicação de conhecimentos adquiridos não só ao longo do curso como também durante a realização do estágio, o conhecimento da realidade industrial e o enriquecimento técnico e pessoal.

Desenvolvimento de sistemas automáticos de alimentação e descarga de injectora de plásticos

A indústria de componentes para automóveis necessita de constante inovação, no sentido de manter a elevada competitividade, imprescindível à sobrevivência de qualquer empresa neste sector. A automação e robótica são vias incontornáveis para a prossecução dos objetivos de produtividade desejados. Mesmo dentro da automação, a evolução é constante. Para além disso, a crescente inovação nos produtos fabricados, exige também novas soluções em termos de processos de fabrico. Isto leva a que, soluções válidas até uma determinada altura, passem facilmente a obsoletas, com necessidade premente de se implementarem novos sistemas que correspondam às necessidades atuais. Este trabalho teve por base uma necessidade detetada numa empresa fabricante de acessórios para a indústria automóvel: estruturas para estofo de assento automóvel, entre muitos outros. Atualmente, a estrutura do estofo automóvel assenta numa grelha constituída por um conjunto de arames, que é agregado por uma série de tiras de plástico injetadas em seu redor. As máquinas de injeção responsáveis por este processo têm superfície de apartação horizontal, e necessitam de mão-de-obra adjacente para a colocação dos arames no molde e descarga do conjunto, na razão de uma pessoa para duas máquinas, dependendo do tempo de ciclo da injeção. O trabalho consistiu no desenvolvimento de um sistema automático de alimentação e descarga da máquina de injeção, que tivesse por base um sistema já existente, mas que passasse a comportar outras funções até agora não desempenhadas pelos sistemas antigos, ou seja, que fossem capazes de ultrapassar os problemas colocados pela complexidade atual dos produtos em fabricação. O projeto foi concluído com sucesso, tendo sido validado pela empresa FicoCables, através da construção, teste e colocação em funcionamento de vários protótipos.

Estudo e Avaliação de Plataformas de Business Intelligence em contexto empresarial

O crescente interesse pela área de Business Intelligence (BI) tem origem no reconhecimento da sua importância pelas organizações, como poderoso aliado dos processos de tomada de decisão. O BI é um conceito dinâmico, que se amplia à medida que são integradas novas ferramentas, em resposta a necessidades emergentes dos mercados. O BI não constitui, ainda, uma realidade nas pequenas e médias empresas, sendo, até, desconhecido para muitas. São, essencialmente, as empresas de maior dimensão, com presença em diferentes mercados e/ou áreas de negócio mais abrangentes, que recorrem a estas soluções. A implementação de ferramentas BI nas organizações depende, pois, das especificidades destas, sendo fundamental que a informação sobre as plataformas disponíveis e suas funcionalidades seja objetiva e inequívoca. Só uma escolha correta, que responda às necessidades da área de negócio desenvolvida, permitirá obter dados que resultem em ganhos, potenciando a vantagem competitiva empresarial. Com este propósito, efectua-se, na presente dissertação, uma análise comparativa das funcionalidades existentes em diversas ferramentas BI, que se pretende que venha auxiliar os processos de seleção da plataforma BI mais adaptada a cada organização e/ou negócio. As plataformas BI enquadram-se em duas grandes vertentes, as que implicam custos de aquisição, de índole comercial, e as disponibilizadas de forma livre, ou em código aberto, designadas open source. Neste sentido, equaciona-se se estas últimas podem constituir uma opção válida para as empresas com recursos mais escassos. Num primeiro momento, procede-se à implementação de tecnologias BI numa organização concreta, a operar na indústria de componentes automóveis, a Yazaki Saltano de Ovar Produtos Eléctricos, Ltd., implantada em Portugal há mais de 25 anos. Para esta empresa, o desenvolvimento de soluções com recurso a ferramentas BI afigura-se como um meio adequado de melhorar o acompanhamento aos seus indicadores de performance. Este processo concretizou-se a partir da stack tecnológica pré-existente na organização, a plataforma BI comercial da Microsoft. Com o objetivo de, por um lado, reunir contributos que possibilitem elucidar as organizações na escolha da plataforma BI mais adequada e, por outro, compreender se as plataformas open source podem constituir uma alternativa credível às plataformas comerciais, procedeu-se a uma pesquisa comparativa das funcionalidades das várias plataformas BI open source. Em resultado desta análise, foram selecionadas duas plataformas, a SpagoBI e a PentahoBI, utilizadas na verificação do potencial alternativo das open source face às plataformas comerciais. Com base nessas plataformas, reproduziu-se os processos e procedimentos desenvolvidos no âmbito do projeto de implementação BI realizado na empresa Yazaki Saltano.

Lean Production e Ergonomia: o impacto de estratégias implementadas nas condições de trabalho numa indústria de componentes para automóveis

Dissertação de mestrado em Engenharia Humana

Desenvolvimento de uma matriz de sensores piezoresistivos baseados em técnicas de impressão

Dissertação de mestrado em Técnicas de Caracterização e Análise Química

Cardiovascular effects in patrol officers are associated with fine particulate matter from brake wear and engine emissions

Background: Exposure to fine particulate matter air pollutants (PM2.5) affects heart rate variability parameters, and levels of serum proteins associated with inflammation, hemostasis and thrombosis. This study investigated sources potentially responsible for cardiovascular and hematological effects in highway patrol troopers. Results: Nine healthy young non-smoking male troopers working from 3 PM to midnight were studied on four consecutive days during their shift and the following night. Sources of in-vehicle PM2.5 were identified with variance-maximizing rotational principal factor analysis of PM2.5-components and associated pollutants. Two source models were calculated. Sources of in-vehicle PM2.5 identified were 1) crustal material, 2) wear of steel automotive components, 3) gasoline combustion, 4) speed-changing traffic with engine emissions and brake wear. In one model, sources 1 and 2 collapsed to a single source. Source factors scores were compared to cardiac and blood parameters measured ten and fifteen hours, respectively, after each shift. The "speed-change" factor was significantly associated with mean heart cycle length (MCL, +7% per standard deviation increase in the factor score), heart rate variability (+16%), supraventricular ectopic beats (+39%), % neutrophils (+7%), % lymphocytes (-10%), red blood cell volume MCV (+1%), von Willebrand Factor (+9%), blood urea nitrogen (+7%), and protein C (-11%). The "crustal" factor (but not the "collapsed" source) was associated with MCL (+3%) and serum uric acid concentrations (+5%). Controlling for potential confounders had little influence on the effect estimates. Conclusion: PM2.5 originating from speed-changing traffic modulates the autonomic control of the heart rhythm, increases the frequency of premature supraventricular beats and elicits proinflammatory and pro-thrombotic responses in healthy young men. [Authors]

Multivalency in healable supramolecular polymers: the effect of supramolecular cross-link density on the mechanical properties and healing of noncovalent polymer networks

Polymers with the ability to heal themselves could provide access to materials with extended lifetimes in a wide range of applications such as surface coatings, automotive components and aerospace composites. Here we describe the synthesis and characterisation of two novel, stimuli-responsive, supramolecular polymer blends based on π-electron-rich pyrenyl residues and π-electron-deficient, chain-folding aromatic diimides that interact through complementary π–π stacking interactions. Different degrees of supramolecular “cross-linking” were achieved by use of divalent or trivalent poly(ethylene glycol)-based polymers featuring pyrenyl end-groups, blended with a known diimide–ether copolymer. The mechanical properties of the resulting polymer blends revealed that higher degrees of supramolecular “cross-link density” yield materials with enhanced mechanical properties, such as increased tensile modulus, modulus of toughness, elasticity and yield point. After a number of break/heal cycles, these materials were found to retain the characteristics of the pristine polymer blend, and this new approach thus offers a simple route to mechanically robust yet healable materials.