Herein, the applicability and performance of 22MnB5 steel sheets as protective masks over hot forging dies has been analyzed. Two masks were obtained following two different approaches; by heat treatment of flat sheets in cooling conditions similar to the process of hot stamping and hot stamping on the axial geometry of a cylindrical part. In both processes the sheets were austenitized at 1100° C for 7 min and to obtain bainite microstructure, they were maintained at temperatures higher than 700°C. The flat and axial masks have been subjected to 100 forging cycles for each geometry and positioned on the lower surface of hot forging dies. Surface integrity has been analyzed from microhardness profiles, roughness tests, thickness measurements, optical and electron microscopy. Wear mechanisms have been observed in both masks which was more expressive in the axial mask. Abrasive wear and plastic deformation have been actively observed in both masks; however, they have shown firmness for application as masks.

RESUMO Neste trabalho foi avaliada a influência do raio da ferramenta, do incremento vertical e da velocidade de avanço na estampagem incremental de alumínio AA1100-H14 com espessura inicial 0,5 mm. Foram realizados dezoito experimentos para conformação de formatos de hiperboloide até que ocorresse a fratura do material. Todos experimentos foram realizados por meio de um braço robótico, que conduziu a ferramenta por uma trajetória pré-determinada. Após a realização dos experimentos foram gerados gráficos de superfície de resposta e foi conduzida análise de regressão múltipla, a fim de determinar uma equação para estimar a máxima deformação no processo em função dos parâmetros selecionados. Foi verificado que a maior estampabilidade no processo é obtida pela associação dos menores valores do raio da ferramenta, do incremento vertical e da velocidade de avanço. Sendo que o raio da ferramenta foi o parâmetro que apresentou maior influência na estampabilidade.

ABSTRACT In this work it was evaluated the influence of the tool radius, step-down and feed rate in the incremental sheet forming of aluminum AA1100-H14 with initial thickness 0.5 mm. Eighteen experiments were performed to form hyperboloid shapes until the material fractured. All experiments were performed using a robotic arm, which guided the tool along a predetermined path. After conducting the experiments, response surface graphics were generated and multiple regression analysis was conducted in order to determine an equation to estimate the maximum strain in the process as a function of the selected parameters. It was found that the highest formability in the process is obtained by the association of the lowest values of the tool radius, step-down and feed rate. The tool radius was the parameter that had the greatest influence on the formability.

Knowing the importance of predicting acting forces during the formation process, our research has conducted 27 Single Point Incremental Forming (SPIF) experiments in hyperboloid format, followed by Finite Element Method (FEM) simulations and regression equations were determined to estimate the maximum axial force in the process. ANOVA analysis of variance was used to determine the significance of material parameters in the maximum axial force response. A multiple linear regression model was constructed to estimate the maximum axial force in the SPIF process. After the experiments, we were able to identify that the maximum axial force increases according to an increase in tool radius, sheet initial thickness, and strength coefficient values, as well as according to the decrease in the strain-hardening exponent. The FEM simulations are in agreement with the experimental values found, and the linear regression model has proven to be efficient to describe results, with R2 of 98.85% and a maximum percentage error of 11.5%.

Abstract This study aimed to analyze the wettability characteristics applied to the surface of heat-treated pure titanium grade 2. Titanium is widely used for applications in implants produced by incremental sheet forming (ISF), where the 3D model resulting from tomography was used to produce the part. Since the ISF process creates residual stresses in the sheet, heat treatments were applied to relieve them. Also analyzed were roughness, researching what the literature recommends to enable surface wettability. Tests were conducted to assess geometric discrepancy using 3D scanning. The results obtained prove the efficacy of the experiment in assessing wettability as a characteristic of bioactivity, which is necessary for applications involving the human body. In addition, geometric discrepancy analysis enables the prosthesis to be used with the best esthetic and functional comfort possible.

ABSTRACT Friction between the interface workpiece and tooling has considerable importance in sheet metal forming operations; an accurate description of the friction is necessary to analyze and design new workpieces and tooling. This work suggests a methodology to determine and evaluate the mean coefficient of friction (COF) using the Finite Element Method (FEM) through Dynaform for the aluminum alloy AA1100. The results indicate that this methodology is consistent with reality. It is also observed that the software tends to diverge from the measured results because the software considers the COF to be constant along the process. Despite this trend, the greatest distance between the maximum drawing force given by the measurement and the numeric simulation was not high: it was approximately 6%. Workpiece strain measurements were collected to compare with the numerical simulation results, and it was observed that they are generally in agreement.

ABSTRACT Friction between the interface workpiece and tooling has considerable importance in sheet metal forming operations; an accurate description of the friction is necessary to analyze and design new workpieces and tooling. This work suggests a methodology to determine and evaluate the mean coefficient of friction (COF) using the Finite Element Method (FEM) through Dynaform for the aluminum alloy AA1100. The results indicate that this methodology is consistent with reality. It is also observed that the software tends to diverge from the measured results because the software considers the COF to be constant along the process. Despite this trend, the greatest distance between the maximum drawing force given by the measurement and the numeric simulation was not high: it was approximately 6%. Workpiece strain measurements were collected to compare with the numerical simulation results, and it was observed that they are generally in agreement.

RESUMO A lubrificação em estampagem de peças tem um papel importante no processo de produção, auxiliando na redução do enrugamento, fratura prematura e afinamentos muito localizados da espessura da chapa. Para tal, o lubrificante deve ser capaz de reduzir o atrito a níveis baixos mas não tão baixos a ponto de promover outros tipos de defeitos como o enrugamento da chapa. Uma boa lubrificação também reduz o desgaste prematuro das ferramentas de estampagem que são utilizadas para produção de peças, assim como é essencial para se ter sucesso no processo desenvolvimento de novas peças. Neste trabalho, 4 condições de lubrificações foram avaliadas (3 lubrificantes líquidos e a ausência de lubrificantes) através do ensaio DST (Dobramento Sob Tensão) e ensaio Swift (deep drawing test). A atuação benéfica (redução do atrito) ao processo de estampagem, dos lubrificantes, foi testada através da medição da força máxima de embutimento no ensaio Swift, da força em cada lado da chapa, torque e força vertical no pino do ensaio DST. O material de estudo foi o alumínio comercialmente puro AA1100. As conclusões indicam que o lubrificante que minimiza o atrito sempre fica evidente, não importando o tipo do ensaio a que a chapa foi submetida, porém a medição do torque facilita a identificação do mesmo. É observado também que a medição da força vertical gerada no pino é menor quanto mais ineficiente for o lubrificante.

ABSTRACT The lubrication in sheet metal forming plays an important role in the production process, helping to reduce the wrinkling, premature fracture and very localized thinning of the sheet thickness. To this end, the lubricant should be able to reduce friction at low levels but not so low that promote other kinds of defects such as wrinkling of the sheet. A good lubrication also reduces premature wear of the stamping tools used to produce parts, as it is essential for success in the process of developing new parts. In this work, four lubrication conditions were evaluated (3 liquid lubricants and the absence of lubricants) by the bending under tension test (BUT) and deep drawing test. The performance of the lubricants were evaluated by measuring the maximum force of deep drawing test, the forces on each side of the sheet, torque and vertical force on the pin of the BUT test. The material used was the commercially pure aluminum AISI AA1100 alloy. The results indicate that the best lubricant always show the best performance no matter what type of test, but the measurement of torque facilitates the identification of it. It was also observed that the measurement of vertical force generated at the pin is smaller the more inefficient is the lubricant.

The objective of this work is to optimize and scale a bioreactor. The design and choice of materials are essential aspects to ensure proper operation and performance of the plant for biogas generation. Computational tools can assist in the design and sizing of biogas plants. Computer simulations were performed to determine the minimum plate thickness of the bioreactor considering three types of steels: AISI 318, AISI 316 L y ASTM A36. The simulation of bioreactors for the design and for the choice of materials is done using the software CAE FEMAP NASTRAN 10.0.2. The results show that the optimum material is steel AISI 318 while the steels AISI 316 L y ASTM A36 presented a similar behavior during simulation.

Este trabajo tiene el objetivo de dimensionar un biorreactor de forma optimizada. El dimensionamiento correcto y la elección de materiales son ítems imprescindibles para garantizar un buen funcionamiento y rendimiento de la planta para la generación de biogás. Las herramientas computacionales pueden ayudar en el proyecto y dimensionamiento de plantas de biogás. En este trabajo se han ejecutado simulaciones computacionales para conocer el espesor mínimo de las paredes del biorreactor, considerando tres aceros: AISI 318, AISI 316 L y ASTM A36. La simulación de los biorreactores para dimensionamiento y la elección de los materiales se han desarrollado con el uso de software de CAE FEMAP NASTRAN 10.0.2. Los resultados muestran que el material óptimo es el acero AISI 318 mientras que los aceros AISI 316 L y ASTM A36 tuvieron un comportamiento semejante en la simulación.

Os aplicativos de software usados na area comercial, em sua grande maioria, nao sao desenvolvidos com o objetivo de trocar informacoes com dispositivos industriais. Seus recursos nativos nao permitem o intercambio de dados na maioria dos casos. A comunicacao entre diferentes aplicativos pode auxiliar a automacao e controle de determinados processos. Este trabalho esta relacionado a area de automacao industrial, foi executado com o objetivo de desenvolver um aplicativo para agregar recursos ao Office Excel, integrando a este os protocolos de comunicacao usados em redes industriais. O aplicativo foi desenvolvido com a finalidade de realizar a conversao entre padroes de comunicacao, gerenciando as informacoes entre dispositivos industriais e planilhas do Office Excel, criando uma nova opcao para monitorar processos na industria.

Software applications used in the commercial area are mostly not developed with the aim of exchanging information with industrial devices. Native resources do not allow the exchange of data in most cases. The communication between different applications can help control and automation of certain processes. This work is related to the industrial automation area. It was executed with the goal of developing an application to add features to Office Excel, integrating those communication protocols used in industrial networks. The application was developed in order to perform the conversion between standard communications, managing information between industrial devices and Office Excel spreadsheets, creating a new option to monitor processes in the industry.

Las aplicaciones de software usadas en el area comercial no son desarrolladas, en su mayoria, con el objetivo de cambiar informaciones con dispositivos industriales. Sus recursos nativos no permiten el intercambio de datos en la mayor parte de los casos. La comunicacion entre diferentes aplicaciones puede ayudar en la automatizacion y en el control de determinados procesos. Este trabajo se relaciona con el area de automatizacion industrial y se ejecuto con el objetivo de desarrollar una aplicacion para anadir recursos al Office Excel, integrando al mismo los protocolos de comunicacion usados en redes industriales. Se desarrollo la aplicacion con el fin de realizar la conversion entre estandares de comunicacion, administrando las informaciones entre dispositivos industriales y plantillas del Office Excel, creando una nueva opcion para monitorear procesos en la industria.

INTRODUCTION: This work aims to pre-operatively manufacture custom-made low-cost implants and physical models (‘biomodels’) of fractured skulls. The pre-DOI: operative manufacturing of biomodels and implants allows physicians to study and plan surgery with a greater possibility of achieving the expected result. Customization contributes to both the esthetic and functional outcome of the implant because it considers the anatomy of each patient, while the low cost allows a greater number of people to potentially benefit. METHODS: From CT images of a fractured skull, a CAD model of the skull (biomodel) and a restorative implant were constructed digitally. The biomodel was then physically constructed with 3D Printing, and Incremental Sheet Forming (ISF) was used to manufacture the implant from a sheet of pure grade 2 titanium. Before cutting the implant’s final shape from a pre-formed sheet, heat treatment was performed to avoid deformations caused by residual stresses generated during the ISF process. RESULTS: A comparison of the dimensions of the implant and its respective CAD biomodel revealed geometric discrepancies that can affect both functional and aesthetic efficiency. Nevertheless, the final shape preserved symmetry between the right and left sides of the skull. Electron microscopy analysis did not indicate the presence of elements other than pure titanium. CONCLUSION: Dimensional variability can be decreased with changes in the manufacturing process (i.e., forming and cutting) and the heating ramp. Despite biomedical characteristics, there was no contamination of the implant by harmful chemical elements. 3D Printing was effective in making the biomodel, enabling pre-operative planning and improving physician-patient communication. Current results indicate that ISF is a process that can be used to obtain custom-made implants.

The mechanical properties of the alloy which has in its composition Fe-Cu-C and fly ash, obtained by conventional powder metallurgy have been studied and analyzed. Fly ashes were added to balance the origin compound (Fe-Cu-C). The apparent density and the compressibility graph were determined and the samples of the composites with different percentages of ash. Sintering of the three composites generated was performed in a controlled atmosphere with argon at a temperature of 1150 °C. Tests of density, hardness and micrographic analysis after sintering were also performed on the samples. Analyses of the results show that fly ash can be used in balance with Fe-Cu-C at the rate of 4.8%.

Este trabajo tiene el objetivo de estudiar y analizar las propiedades mecánicas de la aleación que presenta en su composición Fe-Cu-C-Ceniza ligera obtenida por pulvimetalurgia convencional. Se determinó la densidad aparente, la curva de compresibilidad y se compactaron las muestras de los compuestos con diferentes porcentuales de ceniza. Se realizó la sinterización de las tres aleaciones generadas en atmósfera controlada por argón a temperatura de 1150°C. También se realizó ensayo de densidad, dureza y análisis micrográfico de las muestras. Analizando las propiedades presentadas, los resultados muestran que se puede utilizar la ceniza ligera en balance con la aleación Fe-Cu-C en concentración de 4,8%.

The present work is focused on ferrous powder metallurgy and presents some results of a development of a suitable masteralloy for use as an additive to iron powder for the production of sintered steels. The masteralloy was produced by melting a powder mixture containing approximately Fe + 20% Ni + 20% Mn + 20% Si + 1% C (wt%), in order to obtain a cast billet that was converted into fine powder by crushing and milling. It was observed presence of SiC in the masteralloy after melting that is undesirable in the alloy. Si element should be introduced by using ferrosilicon. Sintered alloys with distinct contents of alloying elements were prepared by mixing the masteralloy powder to plain iron powder. Samples were produced by die compaction of the powder mixtures and sintering at 1200 °C in a differential dilatometer in order to record their linear dimensional behaviour during heating up and isothermal sintering, aiming at studying the sinterability of the compacts. Microstructure development during sintering was studied by SEM, XRD and microprobe analyses.

This work presents research involving a pilot scale biogas compression system. In an attempt to make it easier to use and commercialize this biofuel, the study looks at its treatment, filtration and compression. The process studied enables storage, transport and sale of biogas. Without a compression system, the use of biogas is restricted to the production site. On the other hand, when biogas is filtered and compressed there are several different applications in homes, industry, automotive vehicles, and other cases. The system is composed of a sector for filtration, reduction of noncombustible gases such as carbon dioxide and a compression sector for filling cylinders. The process uses biogas itself as fuel for motors and equipment. Different levels of pressure were established to use in various applications. In the experiment, data on compression, flow and composition of the biogas were obtained.

Se presenta una investigación relacionada con un sistema de compresión para biogás a escala piloto, buscando facilitar la utilización y comercialización de este biocombustible. El estudio considera el tratamiento, filtración y compresión del biogás como también su almacenamiento, transporte y la comercialización. El sistema propuesto está compuesto por la sección de filtración, reducción de gases no combustibles (como dióxido de carbono) y la sección de compresión para ser envasado en cilindros. El proceso utiliza el propio biogás como combustible en los motores y equipos. Se establecieron diferentes niveles de presiones para su utilización en diversas aplicaciones obteniendo datos sobre compresión, flujo y composición del biogás.

This paper shows friction results obtained through compression ring tests for two commercially-available lubricants (i.e., Oildag and Deltaforge) applied in the hot forging of aluminum alloys. The experiments were performed with AA 6061 F aluminum alloy samples with the goal of observing the behavior of each lubricant in several conditions of temperature (200, 300, and 450 °C), strain rates (1, 10 and 50 s-1), and strain (25, 50 and 75%). The friction coefficients for each lubrication condition were established by means of calibration curves determined from finite element calculations with the use of the PEP/Larstran software package. An Analysis-of-Variance approach for the ring's internal diameter was followed in order to evaluate the performance of the lubricants. The results indicated that the Oildag lubricant presents a better stability as well as lower friction coefficients than the Deltaforge lubricant for the range of conditions tested, which translates into a better friction condition at die-part interface.