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Desenvolvimento de ferramentas por impressão 3D para estampagem de peças em chapa de alumínio
| Name: | Description: | Size: | Format: | |
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| 4.72 MB | Adobe PDF |
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Abstract(s)
A impressão 3D é um método de produção promissor para a indústria que consiste no fabrico de produtos por adição de material, ao contrário das técnicas tradicionais que são em geral subtrativas. A impressão 3D tem como aplicação principal a prototipagem rápida e a produção de peças funcionais em geral, destacando para a indústria aeroespacial, aeronáutica, automóvel e aplicações médicas.
O presente trabalho inicia-se com uma revisão bibliográfica sobre o modo como o fabrico aditivo se relaciona com os métodos convencionais, os materiais aplicados e as tecnologias já existentes na indústria. É apresentada uma metodologia para a calibração de impressoras e são aferidas duas impressoras de forma a avaliar os limites operacionais destas. É produzida uma ferramenta de estampagem, por impressão 3D, usando-se materiais poliméricos para estampar chapa de alumínio pelo processo de rubber pad forming, tendo sido utilizada na produção de uma série de 20 peças. A ferramenta foi sendo sucessivamente avaliada de forma a detetar-se desgaste ou eventuais pontos de falha durante a produção. Por fim fez-se um estudo de viabilidade económica para a produção de ferramentas poliméricas, tendo em conta vários materiais com potencial de utilização e a dimensão global da ferramenta.
A calibração e o aumento da precisão das impressoras resultaram no ajuste do perfil de impressão associado a cada impressora, podendo reduzir consideravelmente as tolerâncias. Dos ensaios de estampagem realizados com uma ferramenta impressa a 3D, concluiu-se que pelo menos ao fim de 20 ciclos que a deformação era muito baixa, perfeitamente dentro dos limites aceitáveis para este tipo de aplicação.
O estudo da viabilidade económica permitiu concluir que a implementação da impressão 3D no processo produtivo das ferramentas é uma alternativa muito vantajosa, comparativamente com processos tradicionais, tanto na redução da complexidade do processo de fabrico como em termos de tempo de produção, não comprometendo a qualidade das peças produzidas. Em termos de custos, depende do material utilizado e da dimensão da ferramenta.
3D printing is a promising production method for industry that consists of manufacturing products by adding material, as opposed to traditional techniques that are generally subtractive. 3D printing has as main application the rapid prototyping and the production of functional parts in general, highlighting for the aerospace industry, aeronautics, automotive and medical applications. The present work begins with a literature review on how additive manufacturing relates to conventional methods, the materials applied, and the technologies already existing in the industry. A methodology for calibrating printers is presented and two printers are calibrated in order to evaluate their operational limits. A 3D printed stamping tool is produced using polymeric materials to stamp aluminum plates using the rubber pad forming process and was used in the production of a series of 20 parts. The tool was successively evaluated to detect wear or possible failure points during production. Finally, an economic feasibility study was done to produce polymeric tools, considering several potential materials and the overall size of the tool. The calibration and the increase in precision of the printers resulted in the adjustment of the printing profile associated with each printer, being able to considerably reduced tolerances. From the stamping tests performed with a 3D printed tool, it was concluded that at least after 20 cycles the deformation was very low, perfectly within acceptable limits for this type of application. The economic feasibility study concluded that the implementation of 3D printing in the tool production process is a very advantageous alternative, compared to traditional processes, both in reducing the complexity of the manufacturing process and in terms of production time, without compromising the quality of the parts produced. In terms of costs, it depends on the material used and the size of the tool.
3D printing is a promising production method for industry that consists of manufacturing products by adding material, as opposed to traditional techniques that are generally subtractive. 3D printing has as main application the rapid prototyping and the production of functional parts in general, highlighting for the aerospace industry, aeronautics, automotive and medical applications. The present work begins with a literature review on how additive manufacturing relates to conventional methods, the materials applied, and the technologies already existing in the industry. A methodology for calibrating printers is presented and two printers are calibrated in order to evaluate their operational limits. A 3D printed stamping tool is produced using polymeric materials to stamp aluminum plates using the rubber pad forming process and was used in the production of a series of 20 parts. The tool was successively evaluated to detect wear or possible failure points during production. Finally, an economic feasibility study was done to produce polymeric tools, considering several potential materials and the overall size of the tool. The calibration and the increase in precision of the printers resulted in the adjustment of the printing profile associated with each printer, being able to considerably reduced tolerances. From the stamping tests performed with a 3D printed tool, it was concluded that at least after 20 cycles the deformation was very low, perfectly within acceptable limits for this type of application. The economic feasibility study concluded that the implementation of 3D printing in the tool production process is a very advantageous alternative, compared to traditional processes, both in reducing the complexity of the manufacturing process and in terms of production time, without compromising the quality of the parts produced. In terms of costs, it depends on the material used and the size of the tool.
Description
Keywords
Impressão 3D Precisão Dimensional Rubber Pad Forming Viabilidade Económica 3D Printing Dimensional Accuracy Rubber Pad Forming and Economic Viability