| Name: | Description: | Size: | Format: | |
|---|---|---|---|---|
| 9.08 MB | Adobe PDF |
Authors
Advisor(s)
Abstract(s)
Esta dissertação teve como objectivo principal o desenvolvimento de uma solução em material compósito para a produção de um componente da suspensão automóvel, o braço de suspensão, que se situasse num patamar intermédio na relação peso/custo relativamente às soluções já existentes em mercado, tipicamente em aço. Como valores alvo e tendo como referência um braço de suspensão em aço, era esperada uma redução em massa de cerca de 40% sem exceder o dobro dos custos de produção do mesmo.
Todo o trabalho desenvolvido foi orientado no sentido da exploração de tecnologias como a estampagem a quente de compósitos de matriz termoplástica combinada com a injecção (one-shot process). Na selecção de materiais a adoptar procuraram-se matérias-primas que apresentassem uma boa relação desempenho/custo, tendo sempre em vista o tipo de aplicação final.
A determinação de uma solução que desse resposta aos requisitos definidos foi obtida recorrendo-se à análise por elementos finitos (FEA). O estudo compreendeu várias análises de um processo iterativo, nas quais se fez variar factores como a geometria, os materiais e a configuração dos laminados, até se obter uma solução que cumprisse os objectivos de forma optimizada.
O trabalho desenvolvido permitiu alcançar uma solução em compósito, constituída por um laminado em matriz de PA6 e reforço de fibra de carbono contínua, onde posteriormente são sobre-injectadas ribs de PA6 carregadas com 60% de fibras de vidro curtas.
A solução encontrada garantiu uma redução de 45% do peso em relação ao componente em aço e num acréscimo de cerca de 1,65 vezes ao custo de produção.
The main objective of this thesis was the development of a composite material solution to produce a component of the car suspension, the suspension arm, which would be at an intermediate level in terms of weight/cost with regard to solutions already on the market, typically in steel. As target values and having as reference a steel suspension arm, a mass reduction of about 40% was expected without exceeding twice the production cost thereof. All the work developed was oriented towards the development of technologies such as hot stamping of thermoplastic matrix composites combined with injection (one-shot process). In the selection of materials to be adopted, raw materials were searched that presented a good performance/cost ratio, always considering the type of finalapplication. The determination of a solution that met the defined requirements was obtained by using finite element analysis (FEA). The study comprised several analyzes of an iterative process, in which factors such as geometry, materials and the configuration of the laminates were varied, until a solution was achieved that optimally fulfilled the objectives. The developed work allowed to reach a composite solution consisting of a PA6 matrix laminate and continuous carbon fiber reinforcement, where PA6 ribs loaded with 60% short glass fibers are subsequently over-injected. The solution found a reduction of 45% of the weight in relation to the steel componente and an increase of about 1.65 times the cost of production.
The main objective of this thesis was the development of a composite material solution to produce a component of the car suspension, the suspension arm, which would be at an intermediate level in terms of weight/cost with regard to solutions already on the market, typically in steel. As target values and having as reference a steel suspension arm, a mass reduction of about 40% was expected without exceeding twice the production cost thereof. All the work developed was oriented towards the development of technologies such as hot stamping of thermoplastic matrix composites combined with injection (one-shot process). In the selection of materials to be adopted, raw materials were searched that presented a good performance/cost ratio, always considering the type of finalapplication. The determination of a solution that met the defined requirements was obtained by using finite element analysis (FEA). The study comprised several analyzes of an iterative process, in which factors such as geometry, materials and the configuration of the laminates were varied, until a solution was achieved that optimally fulfilled the objectives. The developed work allowed to reach a composite solution consisting of a PA6 matrix laminate and continuous carbon fiber reinforcement, where PA6 ribs loaded with 60% short glass fibers are subsequently over-injected. The solution found a reduction of 45% of the weight in relation to the steel componente and an increase of about 1.65 times the cost of production.
Description
Keywords
Braço de suspensão One-shot process Fibra de Carbono PA6 Análise elementos finitos Suspension Arm One-shot process Carbon Fiber Finite Element Analysis