Browsing by Author "Costa, C."
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- Calibration of the numerical model of a freight railway vehicle based on experimental modal parametersPublication . Ribeiro, Diogo; Bragança, C.; Costa, C.; Jorge, P.; Silva, R.; Arêde, A.; Calçada, R.The simulation of the dynamic behavior of the train-track system is strongly dependent on the accuracy of the numerical models of the train and track subsystems. The use of calibrated numerical models of the railway vehicles, based on experimental data, enhances their ability to correctly reproduce the dynamic responses of the train under operational conditions. In this scope, studies involving the experimental calibration of freight wagon models are still scarce. This article aims to fill this gap by presenting an efficient methodology for the calibration of a numerical model of a freight railway wagon based on experimental modal parameters. A dynamic test was performed during the unloading operation of the train, adopting a dedicated approach which does not interfere with its tight operational schedule. From data collected during the dynamic test, five natural frequencies and mode shapes associated with rigid-body and flexural movements of the wagon platform were identified through the Enhanced Frequency-Domain Decomposition (EFDD) method. A detailed 3D finite-element (FE) model of the loaded freight wagon was developed, requiring precise knowledge of the vehicle design details which, in most situations, are difficult to obtain due to confidentiality reasons of the manufacturers. The model calibration was performed through an iterative method based on a genetic algorithm and allowed to obtain optimal values for seven numerical parameters related to the suspension’s stiffnesses and mass distribution. The stability of the parameters considering different initial populations demonstrated the robustness of the optimization algorithm. The average error of the natural frequencies decreased from 8.5% before calibration to 3.2% after calibration, and the average MAC values improved from 0.911 to 0.950, revealing a significant improvement of the initial numerical model.
- Calibration of the numerical model of a freight railway vehicle based on experimental modal parametersPublication . Ribeiro, Diogo; Bragança, C.; Costa, C.; Jorge, P.; Silva, R.; Arêde, A.; Calçada, R.The simulation of the dynamic behavior of the train-track system is strongly dependent on the accuracy of the numerical models of the train and track subsystems. The use of calibrated numerical models of the railway vehicles, based on experimental data, enhances their ability to correctly reproduce the dynamic responses of the train under operational conditions. In this scope, studies involving the experimental calibration of freight wagon models are still scarce. This article aims to fill this gap by presenting an efficient methodology for the calibration of a numerical model of a freight railway wagon based on experimental modal parameters. A dynamic test was performed during the unloading operation of the train, adopting a dedicated approach which does not interfere with its tight operational schedule. From data collected during the dynamic test, five natural frequencies and mode shapes associated with rigid-body and flexural movements of the wagon platform were identified through the Enhanced Frequency-Domain Decomposition (EFDD) method. A detailed 3D finite-element (FE) model of the loaded freight wagon was developed, requiring precise knowledge of the vehicle design details which, in most situations, are difficult to obtain due to confidentiality reasons of the manufacturers. The model calibration was performed through an iterative method based on a genetic algorithm and allowed to obtain optimal values for seven numerical parameters related to the suspension’s stiffnesses and mass distribution. The stability of the parameters considering different initial populations demonstrated the robustness of the optimization algorithm. The average error of the natural frequencies decreased from 8.5% before calibration to 3.2% after calibration, and the average MAC values improved from 0.911 to 0.950, revealing a significant improvement of the initial numerical model.
- A case study on the improvement of eco-efficiency ratios: application to a composite processing industryPublication . Ribeiro, M. C. S.; Meira Castro, Ana C.; Silva, Francisco J. G.; Alvim, Mário Rui; Costa, C.; Fiúza, António; Dinis, M. L.; Meixedo, João PauloThe World Business Council for Sustainable Development (WBCSD) defines Eco-Efficiency as follows: ‘Eco- Efficiency is achieved by the delivery of competitively priced-goods and services that satisfy human needs and bring quality of life, while progressively reducing ecological impacts and resource intensity throughout the life-cycle to a level at least in line with the earth’s estimated carrying capacity’. Eco-Efficiency is under this point of view a key concept for sustainable development, bringing together economic and ecological progress. Measuring the Eco-Efficiency of a company, factory or business, is a complex process that involves the measurement and control of several and relevant parameters or indicators, globally applied to all companies in general, or specific according to the nature and specificities of the business itself. In this study, an attempt was made in order to measure and evaluate the eco-efficiency of a pultruded composite processing company. For this purpose the recommendations of WBCSD [1] and the directives of ISO 14301 standard [2] were followed and applied. The analysis was restricted to the main business branch of the company: the production and sale of standard GFRP pultrusion profiles. The main general indicators of eco-efficiency, as well as the specific indicators, were defined and determined according to ISO 14031 recommendations. With basis on indicators’ figures, the value profile, the environmental profile, and the pertinent eco-efficiency’s ratios were established and analyzed. In order to evaluate potential improvements on company eco-performance, new indicators values and ecoefficiency ratios were estimated taking into account the implementation of new proceedings and procedures, both in upstream and downstream of the production process, namely: a) Adoption of new heating system for pultrusion die in the manufacturing process, more effective and with minor heat losses; b) Implementation of new software for stock management (raw materials and final products) that minimize production failures and delivery delays to final consumer; c) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. In particular, the last approach seems to significantly improve the eco-efficient performance of the company. Currently, by-products and wastes generated in the manufacturing process of GFRP profiles are landfilled, with supplementary added costs to this company traduced by transport of scrap, landfill taxes and required test analysis to waste materials. However, mechanical recycling of GFRP waste materials, with reduction to powdered and fibrous particulates, constitutes a recycling process that can be easily attained on heavy-duty cutting mills. The posterior reuse of obtained recyclates, either into a close-looping process, as filler replacement of resin matrix of GFRP profiles, or as reinforcement of other composite materials produced by the company, will drive to both costs reduction in raw materials and landfill process, and minimization of waste landfill. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.
- Comparative study about heating systems for pultrusion processPublication . Silva, Francisco J. G.; Ferreira, F.; Costa, C.; Ribeiro, M. C. S.; Meira Castro, Ana C.Different heating systems have been used in pultrusion, where the most widely used heaters are planar resistances. The primary objective of this study was to develop an improved heating system and compare its performance with that of a system with planar resistances. In this study, thermography was used to better understand the temperature profile along the die. Finite element analysis was performed to determine the amount of energy consumed by the heating systems. Improvements were made to the die to test the new heating system, and it was found that the new system reduced the setup time and energy consumption by approximately 57%.
- Development of a meso-microscale coupling procedure for site assessment in complex terrainPublication . Castro, Fernando Aristides; Santos, Carlos Silva; Costa, C.A procedure for coupling mesoscale and CFD codes is presented, enabling the inclusion of realistic stratification flow regimes and boundary conditions in CFD simulations of relevance to site and resource assessment studies in complex terrain. Two distinct techniques are derived: (i) in the first one, boundary conditions are extracted from mesoscale results to produce time-varying CFD solutions; (ii) in the second case, a statistical treatment of mesoscale data leads to steady-state flow boundary conditions believed to be more representative than the idealised profiles which are current industry practice. Results are compared with measured data and traditional CFD approaches.
- Finite Element Analysis (FEA) applied to heat transfer optimization process of pultrusion die systemsPublication . Silva, Francisco J. G.; Ferreira, F.; Costa, C.; Meira Castro, Ana C.; Meixedo, João Paulo; Alvim, Mário Rui; Santos, R. P. C.; Ribeiro, M. C. S.; Fiúza, António; Dinis, M. L.The aim of this study is to optimize the heat flow through the pultrusion die assembly system on the manufacturing process of a specific glass-fiber reinforced polymer (GFRP) pultrusion profile. The control of heat flow and its distribution through whole die assembly system is of vital importance in optimizing the actual GFRP pultrusion process. Through mathematical modeling of heating-die process, by means of Finite Element Analysis (FEA) program, an optimum heater selection, die position and temperature control was achieved. The thermal environment within the die was critically modeled relative not only to the applied heat sources, but also to the conductive and convective losses, as well as the thermal contribution arising from the exothermic reaction of resin matrix as it cures or polymerizes from the liquid to solid condition. Numerical simulation was validated with basis on thermographic measurements carried out on key points along the die during pultrusion process.
- Gluten labeling in non-packaged food sold in catering businesses: the importance of cross contamination and good manufacturing practicesPublication . Freitas, Marisa; Seixas, A.; Costa, N.; Costa, C.The incidence of food allergies has been increasing in recent years and among food allergens, gluten has been identified as a major public health concern. Because there is no cure for gluten allergy, its avoidance is the best strategy to allergic individuals. Recently, non-packaged foods sold in the catering businesses were required by law to declare allergens. However, since gluten can be unintentionally introduced into food due to the cross-contamination and non-compliance of good manufacturing practices, improper label declaration may occur
- How to reduce energy consumption on pultrusionPublication . Ferreira, F.; Costa, C.; Silva, Francisco J. G.; Meira Castro, Ana C.The global warming due to high CO2 emission in the last years has made energy saving a global problem nowadays. However, manufacturing processes such as pultrusion necessarily needs heat for curing the resin. Then, the only option available is to apply all efforts to make the process even more efficient. Different heating systems have been used on pultrusion, however, the most widely used are the planar resistances. The main objective of this study is to develop another heating system and compares it with the former one. Thermography was used in spite of define the temperature profile along the die. FEA (finite element analysis) allows to understand how many energy is spend with the initial heating system. After this first approach, changes were done on the die in order to test the new heating system and to check possible quality problems on the product. Thus, this work allows to conclude that with the new heating system a significant reduction in the setup time is now possible and an energy reduction of about 57% was achieved.
- Influence of textile cord tension in cap ply productionPublication . Costa, C.; Silva, F.J.G.; Campilho, R.D.S.G.; Neves, P.; Godina, R.; Ferreira, S.The deep knowledge about manufacturing processes, as well as their optimization, present themselves as indispensable factors in the search for the best product quality. It is this point of view of continuous improvement that makes companies in profitable and sustainable way. This paper presents a study about unwinding tension of textile cords in the cap ply manufacturing process, using machines called cap-strips for production. In this work, tension can be understood as the tensile force exerted on the cord. This study determines the influence of unwinding tension on the physical and shrinkage properties of the cord, as well as on the properties of cap ply, namely green adhesion and peel adhesion. Furthermore, the impact of cord tension on tire uniformity and the manufacturing process itself was also studied. All conclusions are based on the performed experiments and the execution of statistical tests. This work allows to conclude that the unwinding tension of the textile cords have some impact on the cap ply properties but have no influence on the tire uniformity.
- Insights into corrosion behaviour of uncoated Mg alloys for biomedical applications in different aqueous mediaPublication . Neves, C. S.; Sousa, L.; Freitas, M. A.; Costa, C.; Teixeira, J. P.; Fraga, S.; Pinto, Edgar; Almeida, A.; Scharnagl, N.; Zheludkevich, M. L.; Ferreira, M. G. S.; Tedim, J.MgCa and MgGd series of alloys are often reported as promising candidates for biomedical applications. In the present study, cytotoxicity and corrosion behavior of Mg1Ca and Mg10Gd alloys in different electrolytes (NaCl, PBS, MEM) have been investigated in order to make a direct comparison and understand the mechanisms behind their performance. Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) were employed to analyze corrosion processes depending on media composition, whereas X-Ray diffraction (XRD) and scanning electron microscopy (SEM) were used to evaluate crystalline structure, phase composition and surface morphology of the corroded substrates after immersion in the different electrolytes. Moreover, cytotoxicity of the Mg alloys was assessed using the WST-1 reduction and lactate dehydrogenase (LDH) release assays in L929 mouse fibroblasts. The electrochemical results showed that Mg1Ca has a lower degradation rate when compared to Mg10Gd, due to the lower microgalvanic effects and the presence of Ca as an alloying element. Furthermore, the corrosion activity is reduced in MEM, for both alloys, when compared to NaCl and PBS. The cytotoxicity assays revealed that Mg10Gd was cytotoxic in all the conditions tested, while the toxicity of Mg1Ca was low. Overall, these findings show that Mg1Ca alloy presents a higher corrosion resistance and biocompatibility and is a promising material to be used in biomedical implants.