Avaliação da estabilidade dimensional de ferramentas de hidroconformação fabricadas por manufatura aditiva
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Data
2022-03-07
Autores
Massa, Renan Cesar
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Universidade Estadual Paulista (Unesp)
Resumo
O presente trabalho avalia a estabilidade dimensional de ferramentas de hidroconformação fabricadas por Manufatura Aditiva (MA). Há evidências que a tecnologia de hidroconformação surgiu no final da década de 50, é classificado como um processo de estampagem e é bastante utilizado em setores da indústria como o setor bélico, automobilístico, aeronáutico e de fabricação de quadros de bicicleta. Este trabalho propõe substituir o processo convencional de fabricação das ferramentas de conformação, que é a partir de conceitos subtrativos de manufatura (usinagem), por um conceito de manufatura atualmente ascendente no mercado industrial, que é a Manufatura Aditiva. Entre todas as tecnologias aditivas aplicáveis e disponíveis, a que é empregada na proposta deste estudo é a tecnologia aditiva por extrusão de material, também conhecida como FDM (Modelagem por Fusão e Deposição) ou FFF (Fabricação por Filamento Fundido). Para validação da proposta é necessário que o desempenho mecânico da ferramenta fabricada por MA seja satisfatório tanto quanto o desempenho mecânico da ferramenta fabricada pelo processo convencional, logo, para esta avaliação objetiva a fabricação, simulação (MEF), medição tridimensional e ensaio de dois corpos de provas similares às ferramentas de hidroconformação. Um corpo de prova manteve as características convencionais de fabricação (processo de manufatura e material) e um segundo foi fabricado pelo conceito aditivo e material termoplástico. Em relação aos materiais utilizados para a fabricação dos corpos de prova, respectivamente para o método convencional e aditivo foram: liga de alumínio (AA 7050-T7 451) e liga polimérica (ULTEM 9085) com base no polímero termoplástico poli(éter-imida) (PEI). Características como anisotropia e porosidade também foram avaliadas e discutidas para ambos corpos de provas. Considerando as características mecânicas da liga polimérica utilizada, o corpo de prova fabricado em ULTEM 9085, após a fase de ensaios com mais de 950 ciclos a valores de carga próximos de 40 MPa, apresentou satisfatório desempenho mecânico e baixas deformações (máxima de 0.17 mm). Os valores máximos de deformação apresentados ficaram dentro da tolerância de 0.3 mm utilizada no estudo, desta forma a estabilidade dimensional do corpo de prova em ULTEM 9085 foi validada a partir do bom desempenho apresentado na fase de ensaio utilizando o processo de hidroconformação com diafragma de borracha.
The present work evaluates the dimensional stability of hydroforming tools manufactured by Additive Manufacturing (AM). There is evidence that hydroforming technology emerged in the late 1950s, is classified as a stamping process and is widely used in industry sectors such as the military, automobile, aeronautical and bicycle frame manufacturing sectors. This work proposes to replace the conventional manufacturing process of forming tools, which is based on subtractive manufacturing concepts (machining), for a manufacturing concept currently rising in the industrial market, which is Additive Manufacturing. Among all the applicable and available additive technologies, the one used in the proposal of this study is the material extrusion based additive manufacturing, also known as FDM (Fusion and Deposition Modeling) or FFF (Fused Filament Fabrication). In order to validate the proposal, it is necessary that the mechanical performance of the tool manufactured by AM be satisfactory as much as the mechanical performance of the tool manufactured by the conventional process, so, for this objective evaluation, the fabrication, simulation (MEF), three-dimensional measurement and testing two specimens similar to hydroforming tools. One specimen kept the conventional manufacturing characteristics (manufacturing process and material) and a second one was manufactured by the additive concept and thermoplastic material. Regarding the materials used to manufacture the specimens, respectively for the conventional and additive method, they were: aluminum alloy (AA 7050-T7 451) and polymer alloy (ULTEM 9085) based on the thermoplastic polymer poly(ether-imide) (PEI). Characteristics such as anisotropy and porosity were also evaluated and discussed for both specimens. Considering the mechanical characteristics of the polymeric alloy used, the specimen manufactured in ULTEM 9085, after the testing phase with more than 950 cycles at load values close to 40 MPa, presented satisfactory mechanical performance and low deformations (maximum of 0.17 mm). The maximum values of deformation presented were within the tolerance of 0.3 mm used in the study, in this way the dimensional stability of the specimen in ULTEM 9085 was validated from the good performance presented in the test phase using the hydroforming process with rubber diaphragm.
The present work evaluates the dimensional stability of hydroforming tools manufactured by Additive Manufacturing (AM). There is evidence that hydroforming technology emerged in the late 1950s, is classified as a stamping process and is widely used in industry sectors such as the military, automobile, aeronautical and bicycle frame manufacturing sectors. This work proposes to replace the conventional manufacturing process of forming tools, which is based on subtractive manufacturing concepts (machining), for a manufacturing concept currently rising in the industrial market, which is Additive Manufacturing. Among all the applicable and available additive technologies, the one used in the proposal of this study is the material extrusion based additive manufacturing, also known as FDM (Fusion and Deposition Modeling) or FFF (Fused Filament Fabrication). In order to validate the proposal, it is necessary that the mechanical performance of the tool manufactured by AM be satisfactory as much as the mechanical performance of the tool manufactured by the conventional process, so, for this objective evaluation, the fabrication, simulation (MEF), three-dimensional measurement and testing two specimens similar to hydroforming tools. One specimen kept the conventional manufacturing characteristics (manufacturing process and material) and a second one was manufactured by the additive concept and thermoplastic material. Regarding the materials used to manufacture the specimens, respectively for the conventional and additive method, they were: aluminum alloy (AA 7050-T7 451) and polymer alloy (ULTEM 9085) based on the thermoplastic polymer poly(ether-imide) (PEI). Characteristics such as anisotropy and porosity were also evaluated and discussed for both specimens. Considering the mechanical characteristics of the polymeric alloy used, the specimen manufactured in ULTEM 9085, after the testing phase with more than 950 cycles at load values close to 40 MPa, presented satisfactory mechanical performance and low deformations (maximum of 0.17 mm). The maximum values of deformation presented were within the tolerance of 0.3 mm used in the study, in this way the dimensional stability of the specimen in ULTEM 9085 was validated from the good performance presented in the test phase using the hydroforming process with rubber diaphragm.
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Palavras-chave
Manufatura aditiva, Extrusão de material, FDM, Modelagem por fusão e deposição, FFF, Fabricação por filamento fundido, Impressão 3D, Prototipagem rápida, Ferramental rápido, Processo de conformação, Ferramenta de conformação, PEI, Poli(éter-imida), additive manufacturing, Material extrusion, Fused deposition modeling, Fused filament fabrication, 3D printing, Rapid prototyping, Rapid tooling, Forming process, Forming tool, Poly(ether-imide)