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Dimensionamento e ensaio de uma ferramenta produzida por impressão 3D para estampagem de alumínio
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Abstract(s)
A tecnologia de impressão 3D vem revolucionar os métodos de produção e de consumo, dando a
possibilidade de desenvolver produtos de uma forma rápida e com um investimento reduzido, criando
ainda a possibilidade de ser flexível no desenho do produto. A evolução desta tecnologia tem
contribuindo em muito para a 4ª revolução industrial, com cada vez maior interesse de aplicação desta
tecnologia na indústria.
O presente trabalho procura apresentar uma solução de desenvolvimento de ferramentas, fabricadas
por impressão 3D através de técnicas de fabrico por fusão de filamento, que permitam a sua aplicação
em processos de estampagem de chapa de alumínio a baixa pressão, por via do processo de rubber
forming.
Através de técnicas de fabrico rápido de ferramentas, pretende-se evidenciar que é possível a
produção de ferramentas de estampagem por fabrico aditivo, em alternativa aos processos de fabrico
convencionais, com as inerentes vantagens deste processo produtivo, em termos de redução de
tempo de produção e impacto económico de construção de ferramentas, assim como na obtenção de
produtos usando-se materiais e processos mais sustentáveis para o ambiente.
No presente trabalho, foi projetada, desenhada e produzida uma ferramenta, por fabrico aditivo, para
estampagem de um componente aeronáutico em chapa de alumínio. O processo de estampagem foi
simulado pelo método dos elementos finitos, tendo-se estudado o comportamento da chapa em
deformação plástica e da ferramenta durante o processo de conformação. Após produção de um
protótipo da ferramenta por impressão 3D, verificou-se que a ferramenta impressa cumpria requisitos
dimensionais e que estava apta para a realização de ensaios em ambiente industrial.
Concluindo, depois dos ensaios de estampagem realizados a uma amostragem de produção de 3
peças em continuo, e conferindo os resultados dimensionais das peças, foi possível verificar que a
ferramenta resistiu aos esforços sem deformação mensurável, conseguindo-se bons resultados para
aplicação na produção de produtos, pelo menos em quantidade de pré-séries ou de baixo volume de
produção para o tipo de peça estudada durante este trabalho.
The 3D printing technology is revolutionizing the production and consumptions methods, giving the possibility to develop products in a fast way and with a reduced budget, creating also the possibility to be flexible on the product design. The evolution of this technology has contributed greatly to the 4th industrial revolution, having a greater interest in applying this technology in the industry. This thesis seeks to present a solution for the tools development, produced by 3D printing through fused filament fabrication technique, which allow their application in low pressure stamping of aluminum metal sheets, being used the rubber forming process. Through rapid tooling manufacturing techniques, it is intended to clarify that is possible to produce stamping tools by additive manufacturing, as an alternative to conventional manufacturing processes, with the inherent advantages of this production process in terms of reducing time and economic impact on the production by developing these tools, as well as obtaining products using materials and processes that are more sustainable for the environment. In the current work, a tool was designed and produced by addictive manufacturing, for stamping an aeronautical component in aluminum sheet. The stamping process was simulated by the finite element method, studying the behavior of plastic deformation of the sheet plate, and the tool, during the bending process. After producing a prototype of the too by 3D printing, was verified that the printed tool, meets dimensional requirements, and was able to carry out the testes in an industrial environment. In conclusion, after the stamping try-outs carried out on a sample of three continuous parts, and checking the dimensional results of the parts, it was possible to verify that the tool resisted to the tension applied without mensurable deformation, achieving good results to apply in the production of products, at least in quantity of pre-series or low volume production for the part studied throughout this work.
The 3D printing technology is revolutionizing the production and consumptions methods, giving the possibility to develop products in a fast way and with a reduced budget, creating also the possibility to be flexible on the product design. The evolution of this technology has contributed greatly to the 4th industrial revolution, having a greater interest in applying this technology in the industry. This thesis seeks to present a solution for the tools development, produced by 3D printing through fused filament fabrication technique, which allow their application in low pressure stamping of aluminum metal sheets, being used the rubber forming process. Through rapid tooling manufacturing techniques, it is intended to clarify that is possible to produce stamping tools by additive manufacturing, as an alternative to conventional manufacturing processes, with the inherent advantages of this production process in terms of reducing time and economic impact on the production by developing these tools, as well as obtaining products using materials and processes that are more sustainable for the environment. In the current work, a tool was designed and produced by addictive manufacturing, for stamping an aeronautical component in aluminum sheet. The stamping process was simulated by the finite element method, studying the behavior of plastic deformation of the sheet plate, and the tool, during the bending process. After producing a prototype of the too by 3D printing, was verified that the printed tool, meets dimensional requirements, and was able to carry out the testes in an industrial environment. In conclusion, after the stamping try-outs carried out on a sample of three continuous parts, and checking the dimensional results of the parts, it was possible to verify that the tool resisted to the tension applied without mensurable deformation, achieving good results to apply in the production of products, at least in quantity of pre-series or low volume production for the part studied throughout this work.
Description
Keywords
Estampagem Fabrico Rápido de Ferramentas Impressão 3D Processos de Fabrico Não Convencionais Rubber Forming Simulação Numérica Stamping Rapid Tooling Manufacturing 3D printing Non-Conventional Manufacturing Processes Rubber Forming Numerical Simulation