Evolving Material Porosity on an Additive Manufacturing Simulation with the Generalized Method of Cells

The effect of material porosity on final part distortion and residual stresses in a selective laser sintering manufacturing simulation is presented here. A time-dependent thermomechanical model is used with the open-source FEA software CalculiX. Effective homogenized material properties for Inconel 625 are precomputed using NASAs Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC). The evolving porosity of the material is estimated with each pass of the laser beam during simulation runtime. A comparison with a homogenous model and the evolving model shows that the evolving porous model predicts larger distortions with greater residual stresses

Duration of Low Wage Employment: A Study Based on a Survival Model

This paper includes a survival analysis which attempts to explain the duration, as in the number of years a worker remains in a low wage situation. Explanatory variables take into account the characteristics of the employee, such as education, age, tenure with the company, gender and nationality, and the characteristics of the job and the company such as industry affiliation, number of employees, age of the company and location.low wage, survival, Portugal

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

The milling process is one of the most used processes in the manufacturing industry. Milling, as a process, as evolved, with new machines and methods being employed, in order to obtain the best results consistently. Milling tools have also seen quite an evolution, from the uncoated high-speed steel tool, to the now vastly used, coated tools. Information on the use of these coated tools in recent scientific researches was collected. The coatings that are currently being researched are going to be presented, highlighting some novel advances in the nanocomposite and diamond coatings area, as these coatings are seeing a growing use in the industry, with very satisfactory results, with performance and tool-life increase. Wear mechanism of various types of coatings are also a popular topic on recent research, as the cutting behavior of these coated tools provides valuable information on the tool’s-life. Furthermore, analysis of these mechanisms enables for the selection of the best coating type for the correct application. Recently, the employment of coated tools paired with sustainable lubrication methods as seen some use. As this presents the opportunity to enhance the coated tool’s and the process’s performance, obtaining better results, in terms of better tool-life and better surface finish quality, in a more sustainable fashionThis research was funded by ON-SURF Project, grant number NUP POCI-01-0247-FEDER-024521.info:eu-repo/semantics/publishedVersio

Recent Advances in Turning Processes Using Coated Tools—A Comprehensive Review

Turning continues to be the largest segment of the machining industry, which highlights the continued demand for turned parts and the overall improvement of the process. The turning process has seen quite an evolution, from basic lathes using solid tools, to complex CNC (Computer Numerical Control) multi-process machines, using, for the most part, coated inserts and coated tools. These coatings have proven to be a significant step in the production of high-quality parts and a higher tool life that have captivated the industry. Continuous improvement to turning coated tools has been made, with many researches focusing on the optimization of turning processes that use coated tools. In the present paper, a presentation of various recently published papers on this subject is going to be made, mentioning the various types of coatings that have recently been used in the turning process, the turning of hard to machine materials, such as titanium alloys and Inconel, as well as the interaction of these coatings with the turned surfaces, the wear patterns that these coatings suffer during the turning of materials and relating these wear mechanisms to the coated tool’s life expectancy. Some lubrication conditions present a more sustainable alternative to current methods used in the turning process; the employment of coated tool inserts under these conditions is a current popular research topic, as there is a focus on opting for more eco-friendly machining options.info:eu-repo/semantics/publishedVersio

Development of a suitable project management approach for projects with parallel planning and execution

30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2021) -15-18 June 2021, Athens, GreeceIn a big company, project management (PM) is always present. Traditional predictive PM approach is concerned with planning everything in advance and then controlling and adjusting if necessary, throughout the project timeline. This may work well when the requirements are well established, but for maintenance projects brings inherent uncertainty. When the subject is aircraft maintenance, it is almost impossible to plan everything at the beginning and expect that it will occur as planned because however a scheduled maintenance plan exists, according to statistics 60% of the aircraft total failure can only be found with ground inspection which means, that even if a plan is established before receiving the aircraft, it will most certainly need to be significantly changed. This requires a big effort from the planning team to plan everything right and ensure that all tools and resources are available to perform the required tasks. To solve this issue, in this paper we propose a hybrid project management approach developed to a case study company from the aircraft repair sector, to enable a faster planning while taking into account the priorities and dependencies of the inherent project tasks with the available resources.The authors would like to acknowledge financial support from Fundação para a Ciência e Tecnologia (Grants: UID/EMS/00667/2019 and UID/UIDB/CPO/04058/2020).info:eu-repo/semantics/publishedVersio

Investigations on the oxidation of Zn-coated steel cables

The automotive component industry has been constantly being studying to improve its performance. Bowden cables are present in opening doors, moving windows and others. In braided cables formed by galvanized wires with Zn steel exposed to the usual environmental conditions, the generation of ZnO appears, a phenomenon known as "white corrosion". The investigation consisted of mitigating the causes of the ZnO formation. Scanning electron microscopy (SEM) and Electron Probe Micro-Analyzer (EPMA) technology, allowed to detect that the generation of ZnO was induced by the presence of nucleating elements of ZnO on the surface of the steel cable before galvanizing with Zn. The S, Cl and O became visible in the interface between coating and substrate. This allowed concluding, under the coating, there were harmful products capable of triggering the ZnO nucleation reaction. So, the storage and cleaning of the steel wire before galvanizing is essential to prevent the ZnO formation.The Authors would like to thank to Mr. Rui Rocha from CEMUP due to is proactive collaboration in seeking the best images through SEM equipment. The strong cooperation of FicoCables company is also deeply acknowledge. Moreover, the support of CETRIB (Prof. Jorge Seabra) is also strongly appreciatedinfo:eu-repo/semantics/publishedVersio

Hybrid Manufacturing Processes Used in the Production of Complex Parts: A Comprehensive Review

Additive manufacturing is defined as a process based on the superposition of layers of materials in order to obtain 3D parts; however, the process does not allow achieve the adequate and necessary surface finishing. In addition, with the development of new materials with superior properties, some of them acquire high hardness and strength, consequently decreasing their ability to be machined. To overcome this shortcoming, a new technology assembling additive and subtractive processes, was developed and implemented. In this process, the additive methods are integrated into a single machine with subtractive processes, often called hybrid manufacturing. The additive manufacturing process is used to produce the part with high efficiency and flexibility, whilst machining is then triggered to give a good surface finishing and dimensional accuracy. With this, and without the need to transport the part from one machine to another, the manufacturing time of the part is reduced, as well as the production costs, since the waste of material is minimized, with the additive–subtractive integration. This work aimed to carry out an extensive literature review regarding additive manufacturing methods, such as binder blasting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet laminating and vat polymerization, as well as machining processes, studying the additive-subtractive integration, in order to analyze recent developments in this area, the techniques used, and the results obtained. To perform this review, ScienceDirect, Web of Knowledge and Google Scholar were used as the main source of information because they are powerful search engines in science information. Specialized books have been also used, as well as several websites. The main keywords used in searching information were: “CNC machining”, “hybrid machining”, “hybrid manufacturing”, “additive manufacturing”, “high-speed machining” and “post-processing”. The conjunction of these keywords was crucial to filter the huge information currently available about additive manufacturing. The search was mainly focused on publications of the current century. The work intends to provide structured information on the research carried out about each one of the two considered processes (additive manufacturing and machining), and on how these developments can be taken into consideration in studies about hybrid machining, helping researchers to increase their knowledge in this field in a faster way. An outlook about the integration of these processes is also performed. Additionally, a SWOT analysis is also provided for additive manufacturing, machining and hybrid manufacturing processes, observing the aspects inherent to these technologies.The present work was done and funded under the scope of the projects ON-SURF (ANI | P2020 | POCI-01-0247-FEDER-024521 and MCTool21 “Manufacturing of cutting tools for the 21st century: from nano-scale material design to numerical process simulation” (ref.: “POCI-01-0247- FEDER-045940”) co-funded by Portugal 2020 and FEDER, through COMPETE 2020-Operational Programme for Competitiveness and Internationalisation. This work is also sponsored by FEDER National funds FCT under the project CEMMPRE ref. “UIDB/00285/2020”. F.J.G. Silva also thanks INEGI-Instituto de Ciência e Inovação em Engenharia Mecânica e Engenharia Indústria due to its support.info:eu-repo/semantics/publishedVersio