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Desenvolvimento de ferramentas para prensa hidrofórmica/borracha com recurso ao fabrico aditivo metálico
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Este projeto propõe a implementação do fabrico aditivo metálico, utilizando o processo de Fusão em Camada de Pó (PBF), para produzir ferramentas de moldagem aplicadas em prensas de borracha e hidrofórmica, destinadas à moldagem de peças em chapa de alumínio para a indústria aeronáutica. O objetivo é avaliar a viabilidade desta tecnologia como alternativa aos métodos convencionais, visando reduzir significativamente o tempo de fabrico, simplificar a cadeia de produção e diminuir custos. Inicialmente, foram desenvolvidos artefactos para validar tolerâncias dimensionais, geométricas e testar tratamentos de superfície. Paralelamente, estudaram-se estruturas à compressão, como reticulares, TPMS e ISOGRID, com o intuito de reduzir a densidade e aproveitar as vantagens do fabrico aditivo, economizando matéria-prima e tempo de produção. Como caso de estudo, adaptou-se uma ferramenta com estrutura interna ISOGRID (50% de densidade), tendo sido tratada superficialmente por pedras vibratórias. Após controlo dimensional e ensaios de moldagem, verificou-se que, apesar de algumas tolerâncias não terem sido cumpridas, devido a problemas de produção, foi possível moldar algumas peças dentro dos requisitos. Os resultados confirmam que, com um desenho adequado ao fabrico aditivo e tratamentos corretos, é viável produzir este tipo de ferramentas por fabrico aditivo, obtendo-se uma expressiva redução no tempo de ciclo e custos competitivos, comprovando a aplicabilidade técnica desta tecnologia.
This project proposes the implementation of metal additive manufacturing using the Powder Bed Fusion (PBF) process to produce moulding tools applied in rubber and hydroforming presses, for shaping aluminium sheet parts for the aerospace industry. The goal is to assess the feasibility of this technology as an alternative to conventional methods, aiming to significantly reduce manufacturing time, simplify the production chain, and lower costs. Initially, artifacts were developed to validate dimensional and geometrical tolerances, and test surface treatments. In parallel, structures such as lattice, TPMS, and ISOGRID were studied under compression to reduce density and leverage the advantages of additive manufacturing, saving raw material and production time. As a case study, a tool was adapted with an internal ISOGRID structure (50% density) and treated with vibratory stones. After dimensional control and moulding tests, it was found that, despite some tolerances not being met due to production issues, it was possible to mould some parts within the required specifications. The results confirm that, with a design tailored for additive manufacturing and proper treatments, it is feasible to produce this type of tool using additive processes, achieving a significant reduction in cycle time and competitive costs, thus proving the technical applicability of this technology.
This project proposes the implementation of metal additive manufacturing using the Powder Bed Fusion (PBF) process to produce moulding tools applied in rubber and hydroforming presses, for shaping aluminium sheet parts for the aerospace industry. The goal is to assess the feasibility of this technology as an alternative to conventional methods, aiming to significantly reduce manufacturing time, simplify the production chain, and lower costs. Initially, artifacts were developed to validate dimensional and geometrical tolerances, and test surface treatments. In parallel, structures such as lattice, TPMS, and ISOGRID were studied under compression to reduce density and leverage the advantages of additive manufacturing, saving raw material and production time. As a case study, a tool was adapted with an internal ISOGRID structure (50% density) and treated with vibratory stones. After dimensional control and moulding tests, it was found that, despite some tolerances not being met due to production issues, it was possible to mould some parts within the required specifications. The results confirm that, with a design tailored for additive manufacturing and proper treatments, it is feasible to produce this type of tool using additive processes, achieving a significant reduction in cycle time and competitive costs, thus proving the technical applicability of this technology.
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Palavras-chave
Fabrico aditivo metálico Fusão em camada de pó Ferramenta de moldagem Prensa borracha/hidrofórmica TPMS Metal additive manufacturing Powder bed fusion Forming tool Rubber/hydroform press