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Advisor(s)
Abstract(s)
A indústria automóvel é uma das mais competitivas no mercado mundial. Isto obriga as empresas
deste sector a uma constante necessidade de inovar e adotar novas tecnologias de forma a
conseguirem aumentar a sua produtividade. Existe por parte do consumidor final uma grande
pressão para produzir mais rápido e mais barato. Posto isto, é importante que a qualidade dos
produtos não decresça, pois isso leva à insatisfação do cliente, diminuindo as vendas, que por sua
vez diminui a quota de mercado da empresa.
O presente trabalho foi realizado no âmbito de estágio curricular na empresa Ficocables Lda. e teve
como foco a melhoria do processo de fundição injetada a câmara quente de Zamak, nomeadamente
dos componentes de injeção. O problema que se visa resolver é provocado pela configuração atual
do sistema de injeção da máquina de Zamak utilizada. Devido a algumas ineficiências no processo,
ocorre uma contra saída no gito da peça injetada. Isto provoca dificuldades na extração da peça do
respetivo molde. A consequência mais preocupante neste momento, no ambiente empresarial, é a
diminuição da Eficácia geral da máquina (OEE), devido às paragens causadas por falhas de injeção,
ou à necessidade de remoção manual do gito preso no molde. Ambos os problemas estão
associados à contra saída.
Deste modo, dando uso à metodologia Design Science Research (DSR), foi realizado um estudo no
qual se explorou diversas possibilidades como a alteração do ângulo de admissão do Zamak na
moldação, na qual se realizaram ensaios com um conceito de bico diferente. Foi também efetuado
um estudo dos parâmetros de injeção das máquinas, a sua influência na contra saída do gito e a
possibilidade de utilizar outras famílias de matérias e revestimentos, para além do aço, no fabrico
dos componentes de injeção. Por fim, foi criado um modelo de simulação térmica com os principais
elementos do sistema de injeção. Deste modo, foi possível realizar as alterações necessárias, de
modo a eliminar as ineficiências térmicas do sistema. O novo conceito foi implementado na fábrica
e os resultados observados foram validados, resultando numa diminuição de intervenções não
planeadas na máquina.
The automotive industry is one of the most competitive in the world market. This forces companies in this sector to constantly need to innovate and adopt new technologies to increase their productivity. There is great pressure from the end consumer to produce faster and cheaper. Therefore, it is important that the quality of products does not decline, as this leads to customer dissatisfaction, reducing sales, which in turn reduces market share. The present work was carried out as part of a curricular internship at the company Ficocables Lda. and focused on improving the Zamak hot chamber injection molding process, particularly the injection components. The problem this work aims to solve is caused by the current configuration of the injection system of the Zamak machine used. Due to some inefficiencies in the process, there is a backflow in the sprue of the injected part, which causes difficulties in extracting the part from the respective mold. The most worrying consequence at this moment, in the business environment, is the decrease in the Overall Equipment Effectiveness (OEE), due to stoppages caused by injection failures or the need to manually remove the sprue stuck in the mold. Both problems are associated with the counter exit. In this way, using the Design Science Research (DSR) methodology, a study was carried out in which several possibilities were explored by changing the Zamak admission angle in the mold in which tests were carried out with a different nozzle concept. A study was also carried out on the injection parameters of the machines, their influence on the sprue backflow, and the possibility of using other families of materials and coatings in addition to steel in the manufacture of injection components. Finally, a thermal simulation model was created with the main elements of the injection system, with which it was possible to make the necessary changes to eliminate the system's thermal inefficiencies. The new concept was implemented in the factory and the results observed were validated, resulting in a reduction in unplanned interventions on the machine.
The automotive industry is one of the most competitive in the world market. This forces companies in this sector to constantly need to innovate and adopt new technologies to increase their productivity. There is great pressure from the end consumer to produce faster and cheaper. Therefore, it is important that the quality of products does not decline, as this leads to customer dissatisfaction, reducing sales, which in turn reduces market share. The present work was carried out as part of a curricular internship at the company Ficocables Lda. and focused on improving the Zamak hot chamber injection molding process, particularly the injection components. The problem this work aims to solve is caused by the current configuration of the injection system of the Zamak machine used. Due to some inefficiencies in the process, there is a backflow in the sprue of the injected part, which causes difficulties in extracting the part from the respective mold. The most worrying consequence at this moment, in the business environment, is the decrease in the Overall Equipment Effectiveness (OEE), due to stoppages caused by injection failures or the need to manually remove the sprue stuck in the mold. Both problems are associated with the counter exit. In this way, using the Design Science Research (DSR) methodology, a study was carried out in which several possibilities were explored by changing the Zamak admission angle in the mold in which tests were carried out with a different nozzle concept. A study was also carried out on the injection parameters of the machines, their influence on the sprue backflow, and the possibility of using other families of materials and coatings in addition to steel in the manufacture of injection components. Finally, a thermal simulation model was created with the main elements of the injection system, with which it was possible to make the necessary changes to eliminate the system's thermal inefficiencies. The new concept was implemented in the factory and the results observed were validated, resulting in a reduction in unplanned interventions on the machine.
Description
Keywords
Automobile industry Bowden cables Zamak Injection Foundry