Browsing by Author "Pinto, A.G."
Now showing 1 - 2 of 2
Results Per Page
Sort Options
- Designing a Novel System for the Introduction of Lubricant in Control Cables for the Automotive IndustryPublication . Ribeiro, R.; Silva, F.J.G.; Pinto, A.G.; Campilho, R.D.S.G.; Pinto, H.A.The increasing competitiveness installed in the automotive industry implies continuous improvements in all fields of knowledge and action. Thus, it is very important to be aware of the wastes generate across all the productive and logistics operations. In this regard, and considering the production process of command cables for the automotive industry, it was detected that a significant volume of lubricant is wasted during the task of introducing grease into the spiral used in the command cables utilized to drive the doors, windows and brakes of motor vehicles. The industrial operation was carefully followed leading to identify the main causes of the wastes and a brainstorming was carried out allowing the discussion of new ideas on how to overcome the problem. A novel equipment was developed, being also cared all the logistics around the supplying task. The new solution developed, as well as the redefinition of the logistic process of supplying the lubricating grease to the production lines, made it possible to make the process more flexible for the admission of different grease packs, as well as a better utilization of the existing grease in the reservoirs, resulting in a cut of grease waste by more than 70%. It was also produced a prototype of the grease supply system, which allowed validate the previously developed system.
- Improvement and validation of Zamak die casting mouldsPublication . Pinto, H.A.; Silva, F.J.G.; Martinho, R.P.; Campilho, R.D.S.G.; Pinto, A.G.The automotive industry, like many other industries, uses a wide range of parts produced by the die-cast process. Parts like engine blocks, wheel spacers, alternator housings and command cable terminals, are made by die casting with different kinds of materials like aluminium and zinc alloys. Despite being a reliable process both in terms of quantity and quality, it is very important to keep the process parameters controlled, in order to achieve a minimum percentage of defective parts, which may be caused by several factors such as, porosities, segregations, incomplete fill, soldering, cracks, etc. The main goal of the die casting industry is to achieve the zero per cent defects target, a goal that goes along with the automotive industry and its quality system, and to accomplish this objective the stakeholders need to invest in research and development. In the casting industry, for instance, it is very important to have a complete knowledge of the entire process developed inside the casting machine, from the melting pot to the die, in order to obtain data so one can improve the filling parameters, machine parts, and moulds. The focus of the presented study is the improvement of the methodologies used to design moulds for control cable terminals in Zamak alloys. The work starts by characterizing the flow happening inside the mould at the moment of cavity fill by analysing computer fluid dynamics simulations (CFD). The study proceeds by quantifying the porosities detected on cut terminal surfaces, and the ultimate goal is achieved with the modification of molten metal flow systems, like channels and sprues, and the introduction of venting systems, with a resource to mathematical and geometrical calculus developed in MATLAB® specifically for that purpose. The paper ends with the validation of the improvements, by comparing the initial results with the ones obtained through an improved mould, building bases for novel design concepts of moulds for this kind of parts, as well as new studies trying to improve the results now achieved.