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- Lean Six Sigma Approach to Improve the Production Process in the Mould Industry: a Case StudyPublication . Pereira, António M.H.; Silva, Miguel R.; Domingues, Mercedes A.G.; Sá, José C.Purpose: The purpose of this article is to explore the optimization of internal process is assumed as a critical factor to be capable of answering to the moulds industries. Consequently, it has been considered essential to adopt high-valued methodologies to support tooling industry in order to achieve global competitive advantages. For that purpose, this work aims to apply LEAN principles and techniques to support mould design and manufacturing processes. Methodology/Approach: The methodology used was based on PDCA/DMAIC, with the following stages: Define, Measure, Analyze, Improve and Control. For each stages was taken some of Lean Six Sigma techniques, such as Continuous Improvement, Value Stream Mapping, Pareto analysis and Overall Equipment Effectiveness. Findings: This study results was revealed that there are many areas on the organizations in the Mould Industry, when they utilize otimizations tools obtain hugt successes. With the Pareto analysis was carried out to show that events that contributes the most to the stops. The results were: unavailability of the operator (16.4%), programming the machine (14.4%) and tool exchange (12.4%) In the case of this Mould Industry study was obtained for the CNC machines studies, with the implementation of Lean Six Sigma tools as obtained a improvement about 20% of global OEE. Research Limitation/implication: This research was revealed that there the moulds are Project unique and difficult to analyze. Moreover, this paper reports that the approach LEAN Six Sigma is very interesting for the continuous improvement of processes and profitability of moulds industry. Originality/Value of paper: This research highlight areas of future research using of quality management methods and Lean Six Sigma tools to analyse and optimize production in the moulds industry. Therefore this research It is considered to promote and adopt high-valued methodologies to support tooling industry in order to achieve global competitive advantages.
- Development of an Additive Manufacturing System for the Deposition of Thermoplastics Impregnated with Carbon FibersPublication . Reis Silva, Miguel; Pereira, António M.; Alves, Nuno; Mateus, Gonçalo; Mateus, Artur; Malça, C.This work presents an innovative system that allows the oriented deposition of continuous fibers or long fibers, pre-impregnated or not, in a thermoplastic matrix. This system is used in an integrated way with the filamentary fusion additive manufacturing technology and allows a localized and oriented reinforcement of polymer components for advanced engineering applications at a low cost. To demonstrate the capabilities of the developed system, composite components of thermoplastic matrix (polyamide) reinforced with pre-impregnated long carbon fiber (carbon + polyamide), 1 K and 3 K, were processed and their tensile and flexural strength evaluated. It was demonstrated that the tensile strength value depends on the density of carbon fibers present in the composite, and that with the passage of 2 to 4 layers of fibers, an increase in breaking strength was obtained of about 366% and 325% for the 3 K and 1 K yarns, respectively. The increase of the fiber yarn diameter leads to higher values of tensile strength of the composite. The obtained standard deviation reveals that the deposition process gives rise to components with anisotropic mechanical properties and the need to optimize the processing parameters, especially those that lead to an increase in adhesion between deposited layers.
- Design of Kinematic Connectors for Microstructured Materials Produced by Additive ManufacturingPublication . Silva, Miguel R.; Dias-de-Oliveira, João A.; Pereira, António; Alves, Nuno M.; Sampaio, Álvaro M.; Pontes, António J.The main characteristic of materials with a functional gradient is the progressive composition or the structure variation across its geometry. This results in the properties variation in one or more specific directions, according to the functional application requirements. Cellular structure flexibility in tailoring properties is employed frequently to design functionally-graded materials. Topology optimisation methods are powerful tools to functionally graded materials design with cellular structure geometry, although continuity between adjacent unit-cells in gradient directions remains a restriction. It is mandatory to attain a manufacturable part to guarantee the connectedness between adjoining microstructures, namely by ensuring that the solid regions on the microstructure’s borders i.e., kinematic connectors) match the neighboring cells that share the same boundary. This study assesses the kinematic connectors generated by imposing local density restrictions in the initial design domain (i.e., nucleation) between topologically optimised representative unit-cells. Several kinematic connector examples are presented for two representatives unit-cells topology optimised for maximum bulk and shear moduli with different volume fractions restrictions and graduated Young’s modulus. Experimental mechanical tests (compression) were performed, and comparison studies were carried out between experimental and numerical Young’s modulus. The results for the single maximum bulk for the mean values for experimental compressive Young’s modulus (Ex¯ ) with 60%Vf show a deviation of 9.15% . The single maximum shear for the experimental compressive Young’s modulus mean values (Ex¯ ) with 60%Vf , exhibit a deviation of 11.73% . For graded structures, the experimental mean values of compressive Young’s moduli (Ex¯ ), compared with predicted total Young’s moduli (ESe ), show a deviation of 6.96 for the bulk graded structure. The main results show that the single type representative unit-cell experimental Young’s modulus with higher volume fraction presents a minor deviation compared with homogenized data. Both (i.e., bulk and shear moduli) graded microstructures show continuity between adjacent cells. The proposed method proved to be suitable for generating kinematic connections for the design of shear and bulk graduated microstructured materials.
- Study of Metal/Polymer Interface of Parts Produced by a Hybrid Additive Manufacturing ApproachPublication . Silva, M. R.; Domingues, J.; Costa, J.; Mateus, A.; Malça, C.The additive manufacturing of multimaterial parts, e.g. metal/plastic, with functional gradients represents for current market demands a great potential of applications [1]. Metal Polymer parts combine the good mechanical properties of the metals with the low weight characteristics, good impact strength, good vibration and sound absorption of the polymers. Nevertheless, the coupling between metal and polymers is a great challenge since the processing factors for each one of them are very different. In addition, a system that makes the hybrid processing - metal/polymer - using only one operation is unknown [2, 3]. To overcome this drawback, a hybrid additive manufacturing system based on the additive technologies of SLM and SL was recently developed by the authors. The SLM and SL techniques joined enabling the production of a photopolymerization of the polymer in the voids of a 3D metal mesh previously produced by SLM [4]. The purpose of this work is the study on the metal/polymer interface of hybrid parts manufactured from the hybrid additive manufacturing system [5]. For this, a core of tool steel (H13) and two different types of photopolymers: one elastomeric (BR3D-DL-Flex) and another one rigid (BR3D-DL-Hard) are considered. A set of six samples for each one of metal core/polymer combination was manufactured and submitted to tensile tests.
- Assessment of the dimensional and geometric precision of micro-details produced by material jettingPublication . Silva, Miguel R.; Pereira, António; Sampaio, Álvaro M.; Pontes, António J.Additive Manufacturing (AM) technology has been increasing its penetration not only for the production of prototypes and validation models, but also for final parts. This technology allows producing parts with almost no geometry restrictions, even on a micro-scale. However, the micro-Detail (mD) measurement of complex parts remains an open field of investigation. To be able to develop all the potential that this technology offers, it is necessary to quantify a process’s precision limitations, repeatability, and reproducibility. New design methodologies focus on optimization, designing microstructured parts with a complex material distribution. These methodologies are based on mathematical formulations, whose numerical models assume the model discretization through volumetric unitary elements (voxels) with explicit dimensions and geometries. The accuracy of these models in predicting the behavior of the pieces is influenced by the fidelity of the object’s physical reproduction. Despite that the Material Jetting (MJ) process makes it possible to produce complex parts, it is crucial to experimentally establish the minimum dimensional and geometric limits to produce parts with mDs. This work aims to support designers and engineers in selecting the most appropriate scale to produce parts discretized by hexahedral meshes (cubes). This study evaluated the dimensional and geometric precision of MJ equipment in the production of mDs (cubes) comparing the nominal design dimensions. A Sample Test (ST) with different sizes of mDs was modeled and produced. The dimensional and geometric precision of the mDs were quantified concerning the nominal value and the calculated deviations. From the tests performed, it was possible to conclude that: (i) more than 90% of all analyzed mDs exhibit three dimensions (xyz) higher than the nominal ones; (ii) for micro-details smaller than 423 μm, they show a distorted geometry, and below 212 μm, printing fails.
- Study on the aerodynamic behavior of a UAV with an applied seeder for agricultural practicesPublication . Felismina, Raimundo; Reis Silva, Miguel; Mateus, Artur; Malça , CândidaIt is irrefutable that the use of Unmanned Airborne Vehicle Systems (UAVs) in agricultural tasks and on the analysis of health and vegetative conditions represents a powerful tool in modern agriculture. To contribute to the growth of the agriculture economic sector a seeder to be coupled to any type of UAV was previously developed and designed by the authors. This seeder allows for the deposition of seeds with positional accuracy, i.e., seeds are accurately deposited at pre-established distances between plants [1]. This work aims at analyzing the aerodynamic behavior of UAV/Seeder assembly to determine the suitable inclination - among 0°, 15° and 30° - for its takeoff and for its motion during the seeding operation and, in turn, to define the suitable flight plan that increases the batteries autonomy. For this the ANSYS® FLUENT computational tool was used to simulate a wind tunnel which has as principle the Navier-Stokes differential equations, that designates the fluid flow around the UAV/Seeder assembly. The aerodynamic results demonstrated that for take-off the UAV inclination of 30° is the aerodynamically most favorable position due to the lower aerodynamic drag during the climb. Concerning flying motion during the seeding procedure the UAV inclination of 0° is that which leads to lower UAV/Seeder frontal area and drag coefficient.