Browsing by Author "Silva, Francisco J. G."
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- 3D finite element analysis and optimization of cap ply production system in the tire industryPublication . Silva, André; Silva, Francisco J. G.; Campilho, R.D.S.G.; Neves, Pedro M.P.F.In automotive industry, tires play a key role. They are a composite structure formed by multiple layers of different materials such as rubber compounds, steel and polyamide cords. Between the tread and steel belts, a cap ply layer is used to restrict the growth of the tire, due to centrifugal forces. Cap ply is produced by using a pultrusion process that impregnates polyamide cords with rubber, resulting in a rubberized strip. When the controlling of the process is incorrect, premature vulcanization or lack of impregnation is often observed. To optimize the production process, CFD (Computational Fluid Dynamics) simulations were performed to study the flow of rubber inside the extrusion head channels by modelling the fluid properties and the domain. Laboratory tests were also conducted to determine the physical and cure properties of the rubber compound used. Crossing the results of the simulations with the laboratory tests was found that the temperature control used was inadequate. Simulations were also supported with the results provided by a temperature sensor controlled by an external device (Arduino). By using a proportional integral derivative controller and changing the setpoints for the thermal resistance, the amount of scrap generated by vulcanized rubber and lack of rubber in the cap ply strips was reduced by 100%.
- Acrylic adhesives in the polyolefins joiningPublication . Pinto, A. M. G.; Magalhães, A. G.; Silva, Francisco J. G.; Baptista, A. P. M.The mechanical behaviour of single lap adhesive joints was characterized, using two commercial acrylic adhesives. For this purpose the surfaces were cleaned and abraded using fine grit abrasives. The effect of temperature and moisture in the mechanical strength was, also, evaluated. For this characterization, mechanical tests were carried out according procedure and geometry foreseen by ASTM D3163-01 [1] and ASTM D4501-01 [2] standards. The results show that it is possible to get good strengths without great surface preparation. The temperature and moisture effect observed don’t seem to be relevant for the mechanical behaviour.
- Adherend effect on the peel strength of a brittle adhesivePublication . Pereira, J.P.O.; Campilho, R.D.S.G.; Nóvoa, P.J.R.O.; Silva, Francisco J. G.; Gonçalves, D.C.Peel tests are widely used to characterize the peel strength of bonded joints and control adhesion quality. There are various configurations of peel test, such as the T-peel test, peel testing at 180°, the floating roller peel test, and the climbing drum peel test. These methods have been widely used mainly in the aeronautical industry, as a way of assessing the peel strength of metallic joints. However, with the growing use of composite materials in industry, it is necessary to characterize bonded joints with these materials when subjected to peeling loads. In this research, the adherend effect on the peel strength of a brittle adhesive is experimentally studied using the floating roller peel test with the aim of evaluating how adherend changes affect adhesion properties of brittle adhesives and also to assess the viability of using the floating roller peel test in composite-to-composite and composite-to-aluminum joints, as well as make a comparison with aluminum-aluminum joint performance. It is also intended to prove the applicability of this test for quality control of adhesion and determination of peel strength in joints with composite materials. The results show the Araldite® AV138 performance falls within the characteristic values of peel strength of other structural adhesives, particularly when composite adherends are concerned, and with reasonable repeatability considering it is a brittle adhesive.
- Adhesion and wear behaviour of NCD coatings on Si3N4 by micro-abrasion testsPublication . Silva, Francisco J. G.; Neto, M. A.; Fernandes, A. J. S.; Costa, F. M.; Oliveira, F. J.; Silva, R. F.Nanocrystalline diamond (NCD) coatings offer an excellent alternative for tribological applications, preserving most of the intrinsic mechanical properties of polycrystalline CVD diamond and adding to it an extreme surface smoothness. Silicon nitride (Si3N4) ceramics are reported to guarantee high adhesion levels to CVD microcrystalline diamond coatings, but the NCD adhesion to Si3N4 is not yet well established. Micro-abrasion tests are appropriate for evaluating the abrasive wear resistance of a given surface, but they also provide information on thin film/substrate interfacial resistance, i.e., film adhesion. In this study, a comparison is made between the behaviour of NCD films deposited by hot-filament chemical vapour deposition (HFCVD) and microwave plasma assisted chemical vapour deposition (MPCVD) techniques. Silicon nitride (Si3N4) ceramic discs were selected as substrates. The NCD depositions by HFCVD and MPCVD were carried out using H2–CH4 and H2–CH4–N2 gas mixtures, respectively. An adequate set of growth parameters was chosen for each CVD technique, resulting in NCD films having a final thickness of 5 m. A micro-abrasion tribometer was used, with 3 m diamond grit as the abrasive slurry element. Experiments were carried out at a constant rotational speed (80 r.p.m.) and by varying the applied load in the range of 0.25–0.75 N. The wear rate for MPCVD NCD (3.7±0.8 × 10−5 m3N−1m−1) is compatible with those reported for microcrystalline CVD diamond. The HFCVD films displayed poorer adhesion to the Si3N4 ceramic substrates than the MPCVD ones. However, the HFCVD films show better wear resistance as a result of their higher crystallinity according to the UV Raman data, despite evidencing premature adhesion failure.
- After sales service: key settings for improving profitability and customer satisfactionPublication . Rebelo, C.G.S.; Pereira, Maria Teresa; Silva, Francisco J. G.; Pinto Ferreira, Luís; Sá, José Carlos; Mota, A.M.This paper presents a performed study to develop and improve the process of after sales of a Latvian company specialized in manufacturing fish processing equipment. The project was developed based on an action- research methodology. During the first stage of the study, the current after sales process was analysed to identify the issues and possible improvement opportunities that could be implemented later on. Data were collected through surveys and analysed, resulting in a series of improvement proposals discussed with the board of the company. At a later stage of the study, improvements were implemented such as the introduction of new services, development of new process diagrams and improvements of the spare parts management strategy. To conclude the study, the new services were offered and presented to customers and the trial period for the new after sales methodology was started.
- An integrated recycling approach for GFRP pultrusion wastes: recycling and reuse assessment into new composite materials using Fuzzy Boolean NetsPublication . Meira Castro, Ana C.; Carvalho, João P.; Ribeiro, M. C. S.; Meixedo, João Paulo; Silva, Francisco J. G.; Fiúza, António; Dinis, M. L.In this study, efforts were made in order to put forward an integrated recycling approach for the thermoset based glass fibre reinforced polymer (GPRP) rejects derived from the pultrusion manufacturing industry. Both the recycling process and the development of a new cost-effective end-use application for the recyclates were considered. For this purpose, i) among the several available recycling techniques for thermoset based composite materials, the most suitable one for the envisaged application was selected (mechanical recycling); and ii) an experimental work was carried out in order to assess the added-value of the obtained recyclates as aggregates and reinforcement replacements into concrete-polymer composite materials. Potential recycling solution was assessed by mechanical behaviour of resultant GFRP waste modified concrete-polymer composites with regard to unmodified materials. In the mix design process of the new GFRP waste based composite material, the recyclate content and size grade, and the effect of the incorporation of an adhesion promoter were considered as material factors and systematically tested between reasonable ranges. The optimization process of the modified formulations was supported by the Fuzzy Boolean Nets methodology, which allowed finding the best balance between material parameters that maximizes both flexural and compressive strengths of final composite. Comparing to related end-use applications of GFRP wastes in cementitious based concrete materials, the proposed solution overcome some of the problems found, namely the possible incompatibilities arisen from alkalis-silica reaction and the decrease in the mechanical properties due to high water-cement ratio required to achieve the desirable workability. Obtained results were very promising towards a global cost-effective waste management solution for GFRP industrial wastes and end-of-life products that will lead to a more sustainable composite materials industry.
- Analysis and Improvement of the Packaging Sector of an Industrial CompanyPublication . Alves, Diogo; Ferreira, Luís Pinto; Pereira, Maria Teresa; Sá, José Carlos; Silva, Francisco J. G.; Fernandes, N.O.Manual operations in manufacturing companies are still a common practice. This often results in high costs, high cycle times and therefore in lower productivity, particularly for companies operating in western countries. This is why many manufacturing companies relocated their production facilities in low age countries. This study was developed at a leading Portuguese material construction manufacturing company. The objective was to improve the packaging and labeling processes, that were identified as main bottlenecks in the factory. Lean was used to streamline these processes before being automated. This allowed for annual savings of 12432 €, with human operators being reallocated to other departments where they are more useful. Furthermore, cycle times were reduced by 42,9%, non-value-added activities were minimized, and operations with potentially high ergonomic risks were eliminated. In addition, a reduction of 84,3% in lithographed packaging was achieved, with a cost reduction of around 36 000 €/year, which is expected to continue in the forthcoming years.
- Analyzing the Implementation of Lean Methodologies and Practices in the Portuguese Industry: A SurveyPublication . Pinto, Carla; Mendonça, Jorge; Babo, Lurdes; Silva, Francisco J. G.; Fernandes, José L. R.The mass production paradigm on which much of the industry was based has changed. The market is increasingly demanding, requesting diversity and products that are more and more adapted to personal wishes and requirements. This implies producing a greater diversity of products in smaller quantities. Competitiveness is enormous, which forces most companies to be truly effective and efficient, taking care of product quality, delivery time, and final cost. Lean methodologies have been a valuable aid in this field. The diversity of Lean tools has been shown to have answers to the most diverse challenges, and companies are aware of this, increasingly adopting methodologies and processes that aim to progressively reduce waste and adapting their production paradigm to what the market requires. This work intends to provide a vision, as global as possible, of the pathway of Lean implementation in the Portuguese industry. For this purpose, a survey was carried out with a significant sample of Portuguese industrial companies from a wide range of activity sectors. The data collected through the survey were treated statistically, and then a SWOT analysis of the results was performed, which provided a collection of precious information on the evolution of industrial companies in Portugal
- Analyzing the Implementation of Lean Methodologies and Practices in the Portuguese Industry: A SurveyPublication . Pinto, Carla M. A.; Mendonça, Jorge; Babo, Lurdes; Silva, Francisco J. G.; Fernandes, José L. R.The mass production paradigm on which much of the industry was based has changed. The market is increasingly demanding, requesting diversity and products that are more and more adapted to personal wishes and requirements. This implies producing a greater diversity of products in smaller quantities. Competitiveness is enormous, which forces most companies to be truly effective and efficient, taking care of product quality, delivery time, and final cost. Lean methodologies have been a valuable aid in this field. The diversity of Lean tools has been shown to have answers to the most diverse challenges, and companies are aware of this, increasingly adopting methodologies and processes that aim to progressively reduce waste and adapting their production paradigm to what the market requires. This work intends to provide a vision, as global as possible, of the pathway of Lean implementation in the Portuguese industry. For this purpose, a survey was carried out with a significant sample of Portuguese industrial companies from a wide range of activity sectors. The data collected through the survey were treated statistically, and then a SWOT analysis of the results was performed, which provided a collection of precious information on the evolution of industrial companies in Portugal.
- Applying the SMED Methodology to Tire Calibration ProceduresPublication . Santos, Vítor; Sousa, Vitor F. C.; Silva, Francisco J. G.; Matias, João C. O.; Costa, Rúben D.; Pinto, Arnaldo; Campilho, RaulDue to the automotive industry’s strict demands, customers submit constant production pressure, leading to the adoption of new methodologies, techniques, and management ideas. The goal is always to minimise losses and waste. These demands also affect the maintenance department, which has to keep the balance between machines’ availability for production and ensuring that the machines’ proper running conditions translate into excellent-quality products. Thus, continuous improvement and correct management of maintenance activities are crucial for a company to maintain effective production, without defects, breakdowns, and accidents. Nevertheless, some maintenance activities should also prevent the degradation of equipment conditions in order to produce high-quality products. This paper presents an improvement of maintenance activities conducted on equipment that produces large tires. The main problems and technical difficulties of Machine Tolerance Check (MTC) activities are explored by analysing existing documents, internal knowledge, and changes to working methods. We discuss the implementation of the SMED (Single-Minute Exchange of Die) methodology in calibration procedures, as this method is commonly applied to machines’ setups to reduce downtime. At the end of the study, a 31% decrease in the duration of machine tolerance check activities was achieved, which led to a significant increase in the equipment’s availability