A linha de Materiais e Manufatura Avançada dedica-se a realizar pesquisas científicas e de desenvolvimento tecnológico que abrangem a caracterização de novos materiais, o aprimoramento dos processos de fabricação e a integração entre sistemas de produção e tecnologias emergentes com foco no desenvolvimento da manufatura digital. Neste contexto, busca-se tanto explorar e compreender aspectos tribológicos dos materiais e particularidades dos processos de fabricação, como desenvolver métodos e ferramentas computacionais que possibilitem a integração de tecnologias emergentes aos sistemas clássicos de manufatura, possibilitando novas investigações quanto a melhorias e aperfeiçoamentos de produtos e processos produtivos.

 

Research Project

1) Application of protective coatings, by laser methods, in agricultural implements

Abstract:This project aims to apply protective coatings on agricultural implement parts deposited via laser cladding. The demand for better equipment, such as subsoiler tips, is increasing as they are widely used in the sector. Parts coated with a material of high hardness and low friction coefficient are ideal, as they enhance wear resistance properties. Another important factor is the reduction of the part's friction coefficient, thus ensuring a decrease in traction force, resulting in reduced fuel consumption. The use of a protective coating not only allows for an increase in the part's lifespan but also significant increases in machine operation speed. In this project, a powder layer will be deposited on the surface of agricultural parts, acting as a protective coating. Carbon black and WC-Co (tungsten carbide - cobalt) powders will be used. The technique for creating this intermediate barrier will be the laser cladding process. In this process, a thin layer of powder previously deposited on the part's surface will be irradiated by a laser beam, creating a dense coating strongly bonded to the substrate. This technology is innovative, fast, versatile, and cost-effective, making it interesting for potential transfer to the industry in terms of industrial scaling.

2) Research Project: Applications of Additive Manufacturing by Arc Welding (AMAW) in Metal Parts

Abstract: Additive Manufacturing (AM) processes enhance the individualized production of parts and are increasingly widespread for applications in polymers, which already have well-structured equipment and usage procedures. However, metal AM, despite having significant application potential, enabling the manufacture of complex parts from various types of metals, still has several limitations related to equipment costs and/or the need for refinement of techniques to promote the diffusion of this application in the Industry. Among the various existing processes for metal AM, Additive Manufacturing by Arc Welding (AMAW), which consists of manufacturing metal preforms by depositing multiple layers of weld beads on a substrate, has great potential due to its relative simplicity and lower equipment costs, but still requires studies for the consolidation of the technique and potential for improvement and development of new procedures. Therefore, the objective of this project is to strengthen a research line in the Graduate Program in Mechanical Engineering (PPGMEC-UFG) that covers AMAW processes, seeking the development and improvement of processes, simulations, studies on the implementation of the Internet of Things in AMAW processes, as well as analyses of microstructures, wear resistance, corrosion resistance, and mechanical behaviors of parts produced by AMAW. To achieve the objective, the project aims to start the AMAW project with equipment already existing in LAMAF, such as GMAW, FCAW, and GTAW, and seek resources for the modernization and implementation of the AMAW process.

3) Temperature Control of Interpass in the Overlay of Layers of Metal 3D Printing Performed by the Arc Welding Additive Manufacturing Method

Abstract: Additive manufacturing processes are currently being studied due to their ability to produce complex elements through material addition. These processes have become widespread due to the use of polymer printers (3D printers) because of their cost and ease of operation. However, when it comes to printing metal parts, the problem becomes more complex. One way to carry out the metal 3D printing process is through the Arc Welding Additive Manufacturing (AWAM) process. In this process, layers of weld beads are deposited to build the elements. However, this process still faces challenges such as temperature control between one layer and another; interpass temperature control. The objective of the present proposal is to optimize the interpass time through automatic control of a robotic arm based on knowledge of the critical interpass temperature. The methodology involves monitoring and determining a critical interpass temperature that does not cause deformation of the printed element due to the imposed heat.

4) Influence of the Inductive Effect of the Power Source on the Regularity of Metal Transfer by Short-Circuiting in MIG/MAG Welding

Abstract: Among the possible operating modes used in MIG/MAG welding, the short-circuiting mode is widely used due to its application in conditions where low heat input is required. Examples include welding thin plates, root passes, positional welding, etc. In this mode of operation, correct adjustment of voltage and wire feed speed is crucial for the process to occur smoothly. In addition to the mentioned parameters, since the transfer occurs through short circuits, a parameter sometimes overlooked but of great importance is the inductance of the power source. Its importance lies in its impact on the current rise rate and the peak current value, which in turn influence the pinch effect that acts at the end of the transfer. This study proposes to measure the current rise rate for different settings of the inductive effect and correlate the values with the process regularity for 4 shielding gases with varying carbon dioxide content balanced in argon. The objective is to understand how carbon dioxide influences the relationship between process regularity and current rise rate, and thus determine the best adjustment values for the inductive effect depending on the shielding gas.

5) Investigation and development of welding equipment, processes, and procedures.

Abstract: Small modifications in a welding process, such as welding voltage and current, contact tip-to-workpiece distance, filler metals, shielding gases, among others, significantly influence the quality of a weld bead, thus altering the properties of the welded structure. For this reason, the welding area constantly lacks studies and innovations to ensure quality, always seeking increased productivity. Several methodologies are used in welding process studies, including the acquisition of welding voltage and current, sound or light emitted by the electric arc, and high-speed filming to monitor metal transfer, typically using automated processes to ensure welding procedure repeatability. There is also an increase in welding process simulations aimed at conducting preliminary analyses of the welding procedure, primarily focusing on preventing possible distortions.

6) Mechanical strength of parts manufactured by additive manufacturing method with different manufacturing parameters

Abstract: This research aims to study the mechanical strength capacity of different materials using additive manufacturing techniques. The growing industry demand for geometrically complex, lighter, and mechanically stronger parts, economically unfeasible or hardly produced solely by traditional machining techniques (subtractive manufacturing), encourages studies and new manufacturing approaches, with additive manufacturing (AM) standing out. The global consumption of AM machines, printing materials, parts, software, and related services totaled over 13 billion dollars in 2016. According to He et al., a significant portion of consumption is concentrated in the method of manufacturing by fused deposition of thermoplastic polymer, a process originally patented by Stratasys as Fused Deposition Modeling® (FDM) (COON, 2017), and more recently, with the end of industrial protection, generically referred to as Fused Filament Fabrication (FFF) (JIANG, 2019). According to SINGH (2015) and BRIAN (2014), the last decade has demonstrated the technical feasibility of AM to manufacture not only prototypes but mainly final parts with project performance. In this regard, there are many challenges to overcome, with standardization of raw materials and static and dynamic mechanical properties of printed materials associated with their geometries standing out. Scientific and technological developments are needed to understand the influences of raw materials and deposition parameters on product performance.

7) Techniques and Architectures Applied to Manufacturing Digitalization

Abstract: The concept of Industry 4.0 points towards the digitization of production processes, interconnection among field devices, data collection and analysis, autonomous diagnostics, and decision-making. However, current industrial environments lack advancements in communication infrastructure resources, evolution of artificial intelligence techniques, and digital data security. In Brazil, the Brazilian Agency for Industrial Development launched the Brazilian agenda for Industry 4.0 in 2017, foreseeing financing programs and partnerships between companies and funding agencies to modernize the country's industrial sector. In this scenario, it is also essential to modernize teaching and learning environments, especially regarding the improvement of engineering education laboratories. This research project aims to develop techniques and architectures applied to manufacturing digitalization in an academic environment. To achieve this, a study is proposed to adapt processes, machines, and equipment present in the laboratories of the undergraduate mechanical engineering course at EMC/UFG to the concepts of Industry 4.0. It is expected that this infrastructure will enable greater integration between strategic and operational levels, facilitating the development of scientific research on computational techniques applied in industrial processes. Furthermore, it is aimed that this research ensures professionals involved greater ease in disseminating the acquired knowledge and provides students with training to work in various areas of the future industrial production sector.

8) Mechanical Lung Ventilator for emergency use in treating patients with Severe Acute Respiratory Syndrome (SARS) to be produced on a large scale with national technology.

Abstract: Recognizing the scarcity of Mechanical Lung Ventilators (MLV) for the urgent treatment of patients with Severe Acute Respiratory Syndromes (SARS), the present proposal aims to design an alternative MLV focusing on this urgent demand while maintaining the mandatory functional characteristics required by national technical standards and capable of being produced on a large scale using equipment, parts, and instruments strictly found and/or manufactured within the national industry and commerce. This research project proposal aims to develop two models of lung ventilators. The first version will limit the use of the largest possible quantity of existing commercial components and the application of discrete pneumatic valves, aiming to reduce dependence on imported components in ventilator manufacturing. This model will have limited and adapted resources to meet the minimum functionality required for patient care during the COVID-19 crisis, while respecting all safety standards and criteria. The second ventilator model will be developed based on continuous control techniques; it will consider the possibility of using imported components - with lower availability in the market; manufacturing component sizing for flow, pressure measurement, etc., will be incorporated into the project. This version will have greater limitations for mass production but will more efficiently meet the needs of patients with acute respiratory syndrome, as it will have a higher capacity to deliver tidal volume and will use functionalities analogous to commercial equipment - minimizing the need for new protocols or reducing the actions required for healthcare workers' training to operate the equipment. Finally, an analysis will be made of the development capacity of a ventilator with exclusively national technology.