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Abstract(s)
A redução do consumo de combustíveis fósseis nos automóveis surge, nos dias de hoje, como uma meta fundamental, definida pela União Europeia. Surge então, neste contexto, a utilização de materiais que ofereçam a diminuição do peso integral do automóvel. Os materiais compósitos colocam-se, portanto, na linha da frente com a capacidade de alcançar este objetivo, visto serem capazes de oferecer excelentes propriedades mecânicas e, ao mesmo tempo, serem materiais mais leves. Os materiais compósitos termoplásticos apresentam como vantagem a vertente ambiental de serem materiais recicláveis e, do ponto de vista industrial, possuírem tempos de processamentos mais curtos. O processo de estampagem a quente revela-se um excelente processo de fabrico associado aos materiais compósitos de matriz termoplástica por apresentar tempos de ciclos curtos, peças com elevados rendimentos, poucos custos em mão de obra e preços finais atrativos. Este processo é muitas vezes utilizado na obtenção de peças para o setor automóvel. O principal objetivo deste trabalho centra-se na otimização da janela de processamento quando aplicado à obtenção de componentes compósitos de matriz termoplástica, através da correlação dos seus parâmetros de processamento com foco na qualidade do componente e por recurso a diversos indicadores de qualidade. Este processo de otimização leva a cabo a análise de componentes fabricados segundo diferentes condições, que envolvem a realização de um desenho de experiências e posterior análise de variância ANOVA implementada no software Design Expert V13®. Para este estudo demonstrou ser crucial a correta seleção e discretização das variáveis de processo de estampagem a quente. A análise realizada permitiu, não só, compreender de forma isolada o impacto de cada variável do processo na qualidade do produto final, mas também, por correlação, definir a respetiva janela ótima de processamento.
In the present day, the reduction of consumption of fossil fuels in automobiles arises as a goal of the utmost importance, set by the European Union. Thus, in this context emerges the usage of materials that ensure the reduction of the automobile overall weight. Composite materials are the optimal choice to reach the established goal since they are capable of offering excellent mechanical properties in addition to having less weight. Thermoplastic composite materials have the environmental advantage of being recyclable and also, from the industrial standpoint, they are materials with short processing time. The hot stamping process reveals itself as an optimum manufacturing process associated to thermoplastic matrix composite materials mainly due to short cycle times, high performance, few labor costs and pleasing final prices. This process is widely used for obtaining parts for the automotive sector. The main goal of this project focuses on the optimization of the processing window when applied to obtain thermoplastic matrix composite components by correlating its processing parameters with an emphasis on component quality and by using various quality indicators. This optimization executes the analysis of components manufactured under different conditions, which involve the realization of a design of experiments and subsequent ANOVA analysis of variance implemented in Design Expert V13® software. The accurate selection and discretization of the hot stamping process variables was crucial for this study. The performed analysis allowed not only to understand, in an isolated way, the impact of each process variable on the quality of the final product, but also, by correlation, to define the respective optimal processing window.
In the present day, the reduction of consumption of fossil fuels in automobiles arises as a goal of the utmost importance, set by the European Union. Thus, in this context emerges the usage of materials that ensure the reduction of the automobile overall weight. Composite materials are the optimal choice to reach the established goal since they are capable of offering excellent mechanical properties in addition to having less weight. Thermoplastic composite materials have the environmental advantage of being recyclable and also, from the industrial standpoint, they are materials with short processing time. The hot stamping process reveals itself as an optimum manufacturing process associated to thermoplastic matrix composite materials mainly due to short cycle times, high performance, few labor costs and pleasing final prices. This process is widely used for obtaining parts for the automotive sector. The main goal of this project focuses on the optimization of the processing window when applied to obtain thermoplastic matrix composite components by correlating its processing parameters with an emphasis on component quality and by using various quality indicators. This optimization executes the analysis of components manufactured under different conditions, which involve the realization of a design of experiments and subsequent ANOVA analysis of variance implemented in Design Expert V13® software. The accurate selection and discretization of the hot stamping process variables was crucial for this study. The performed analysis allowed not only to understand, in an isolated way, the impact of each process variable on the quality of the final product, but also, by correlation, to define the respective optimal processing window.
Description
Keywords
Indústria automóvel Materiais compósitos Estampagem a quente Termoplásticos CFRTP Método Taguchi Otimização de processo ANOVA DOE Automotive industry Composite materials Hot stamping Thermoplastics Taguchi’s method Process optimization