Faculdade de Engenharia da Universidade do Porto Departamento de Engenharia Mecânica e Gestão Industrial FABRICO RÁPIDO INDIRECTO DE FERRAMENTAS COMPÓSITAS A PARTIR DE MODELOS DE PROTOTIPAGEM RÁPIDA PEDRO VASCO DA SILVA MAGALHÃES E VASCONCELOS Dissertação apresentada à Faculdade de Engenharia da Universidade do Porto para a obtenção do grau de Doutor em Engenharia Mecânica Realizada sob a supervisão do Professor Doutor Fernando Jorge Lino Alves da Faculdade de Engenharia da Universidade do Porto, Departamento de Engenharia Mecânica e Gestão Industrial Porto, Outubro de 2004
Faculdade de Engenharia da Universidade do Porto Departamento de Engenharia Mecânica e Gestão Industrial Financiamento: Fundo Social Europeu no âmbito do concurso Público 4/5.3/PRODEP/2000, pedido de financiamento nº 1012.004, da medida 5/acção 5.3 Formação Avançada de Docentes do Ensino Superior submetido pela Escola Superior de Tecnologia e Gestão do Instituto Politécnico de Viana do Castelo. Programa Operacional Ciência, Tecnologia, Inovação da Fundação para a Ciência e a Tecnologia (POCTI/EME/41199/2001). União Europeia Fundo Social Europeu
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Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida Lista de Abreviaturas # ); %1 @E > ;0 ) ;/%> F%;1 * 3 3.)3;1 &.3 3 &..3 3) 3.3./1 &(.0 A)...; 0 1 = % )%// 1 = A%3.)%//;.3;1 *(?A 2 2 )/ ; ; /1 &. ).. % /1 (?A. ).. ; /1 A 4 * > % E > B0)0/> F%;1 B0 B0? B0? ;: B0B0 @. B0% @. * 0?).%1 (. ;. ).. /1 =..3 )%.3./1 =& %. % )% ; % ;/1 @* B );%;1 @ ' );%;%;1 =& %. % )% ; % ;/1 * BA) 1 '. ). ; %;1 8*( %. 3 ) /. %;%/1 8*. 33C ) 3C. %1 x Pedro Vasco da Silva Magalhães e Vasconcelos
Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida 8Z( 2? ) 3...1 *E ) F%;1 < )/ /1 X )/;;M1 )/;1..)/;/ ;1 Z. );/ 1 ] )/; 1 * C ) C%1 (*.' ). %1 (Z : K 3) :%1 8 %. );% ;/1 * B ) 1 * C ) C%1 (8..;%. );% ;/1 (=?A % A );% / /1 (=* % )(=*1 ((( %. ]Z Z.3 H.D H)H /;/1 Pedro Vasco da Silva Magalhães e Vasconcelos xi
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Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida Capítulo 3 - PROCEDIMENTO EXPERIMENTAL$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,_c #$, <(]ab$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,_- #$ *( $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,c, #$ $, 0$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,c, #$ $ & %? $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,c# #$ $# 3 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,c+ #$# (8@ H*<($$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,c5 #$#$, % 3 % $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,c5 #$#$ * B :0 $$$$$$$$$$$$$$$$$$$$$$$$$,c5 #$#$# &B..3 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,cc #$#$+ %A% A $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,c- #$#$+$, % * $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,c- #$#$+$ * %. > %$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,c- #$#$+$#? H$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,f #$#$5 (A 2 B :0 $$$$$$$$$$$$$$,f #$#$5$, &A $ & $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,f5 #$#$5$ % $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,ff #$#$5$# $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,ff #$#$5$+ & $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,-! #$#$_ & %A$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,-! #$#$_$, *A > $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,-! #$#$c 2$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,-, #$#$c$,.0$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,- #$#$c$ ' &; /$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,- #$#$c$# % $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$,-+ #$#$c$+? $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$!! #$#$f A2 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$!! #$#$f$, & A $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$!! #$#$f$,$, (A.>$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$!! #$#$f$,$ (A.0 % 3 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$! #$#$f$ ( $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$! #$#$f$# &.0 A $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$!# #$#$f$+? A 2 2 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$!# #$#$-. $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$!# #$#$-$,. " :$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$!+ #$#$-$,$, d. )?> %1 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$!5 Pedro Vasco da Silva Magalhães e Vasconcelos xv
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Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida +$ $+$ (3B $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 5f +$ $+$ $, & K. $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ 5f +$ $+$ $ % %..% $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ _! +$ $+$# &D$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ _- +$ $5?. $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ c, +$ $_ * > 3 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ c+ +$ $c & 22A $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ c_ +$ $f & A $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ cf +$ $- ( $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ f! +$ $-$, % $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ f! +$ $-$ &.0 A $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ f# +$ $,! *? B?$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ f+ +$ $,!$, * $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ f5 +$ $,!,$. $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ f_ +$ $,!$#..3 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ f- +$ $,!$+ &D$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ -, +$# <&&(`ab<(& $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ -# +$#$, & : " :$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ -# +$#$,$, '. C 3 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ -+ +$#$,$ $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ -_ +$#$,$# 0. )* %. > 1$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ -c +$#$,$+ =. $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ -- +$#$ D.3 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#!! +$#$# & :.3 $. $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#!, +$#$+ & :.3 [ :$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#!c +$#$+$, 2. % $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#!c +$#$+$ ' $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#,, +$#$+$# & 3 0.3 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#, +$#$5 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#,# +$#$_ &D$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#,f +$+ h<& $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#,- Capítulo 5 - PRODUÇÃO DE MOLDES E ENSAIOS$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$# # 5$, =<*8*<H^&$$$$$$$$$$$$$$$$$$$$$$$$$$$$# 5 5$ H&]ab*8*<8&*&*e(Z$$$$$$$$# c Pedro Vasco da Silva Magalhães e Vasconcelos xvii
Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida 5$ $, C $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$# - 5$ $ G C $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$##, 5$ $# G $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$### 5$ $+ $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$### 5$ $+$,. $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$### 5$ $+$ C$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$##+ 5$ $+$# G C $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$##_ 5$ $+$+ G $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$##c 5$ $+$5 & $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#+! 5$ $5 &D$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#+ 5$# h<&$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#+# Capítulo 6 CONCLUSÕES E TRABALHOS FUTUROS$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#+5 _$, &<&8]i $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ $$#+c _$ (8@ ](] $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ $$#5, ANEXOS $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#5# 4 % $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#55 & : : $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#5c?> % B 3 A&: $$$$$$$$#_! Z : $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#_+ Z K.0 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$# Z % $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#c# Z A $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#c_ Z ;: $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#cc H.3 E3$$$$$$$$$#cf H (X%)X1$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#f_ H *B0 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#ff H 3 0 $$$$$$$$$$$$$$$$$$$$$$$$$$#-, H *?3 D2 ). %1$$$$#- HZ 8 23 $$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$#-5 xviii Pedro Vasco da Silva Magalhães e Vasconcelos
Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida Capítulo 1 Introdução Capítulo 1 INTRODUÇÃO Pedro Vasco da Silva Magalhães e Vasconcelos 1
Capítulo 1 Introdução Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida 2 Pedro Vasco da Silva Magalhães e Vasconcelos
Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida Capítulo 1 Introdução 1.1 ENQUADRAMENTO Entre os desafios que caracterizam o mercado actual, destacam-se a existência de mais nichos de mercado, mais variações de produtos e ciclos de vida mais curtos. Para se sobreviver nesta economia de mercado marcada pela concorrência e pela globalidade, procurase envolver no processo de desenvolvimento do produto, os departamentos de design, engenharia, marketing e produção, o que constitui uma conhecida metodologia industrial designada por engenharia concorrente ou simultânea. A prototipagem rápida (RP) consiste numa família de modernas tecnologias que geram objectos sólidos tridimensionais sob o controlo de um computador. Apesar da designação se referir ao maior campo de aplicação que é a prototipagem industrial, os equipamentos de RP permitem também o fabrico de ferramentas e o fabrico directo de produtos unitários ou em pequenas séries. No processo de desenvolvimento de produto são frequentemente exigidos protótipos funcionais geométricos, funcionais e tecnológicos para simulação e testes. Neste caso, devem ser produzidas algumas dezenas ou centenas de protótipos. Como estas tecnologias são baseadas em modelos virtuais de CAD, é possível produzir uma ferramenta, por exemplo, um molde de injecção, através do qual se possam produzir pequenas séries de protótipos. Nestes casos particulares, as tecnologias RP são conhecidas por Fabrico Rápido de Ferramentas (RT-Rapid Tooling). A popularidade da RP relativamente aos métodos tradicionais de fabricação manual de modelos baseia-se na capacidade de produzir com rigor e rapidamente peças complexas. Os tradicionais longos períodos de vários meses gastos na concepção e desenvolvimento de um novo produto, anteriores à decisão da sua aceitação pela empresa, podem agora ser substituídos por semanas, por vezes, mesmo dias, poupando muito tempo e dinheiro. Infelizmente, só uma gama relativamente restrita de materiais é que podem ser usados para produzir protótipos com as técnicas de RP. Consequentemente, embora a visualização e a verificação geométrica/dimensional seja possível, os testes funcionais de protótipos por vezes não são possíveis devido às diferentes propriedades físicas (mecânicas e térmicas) exibidas pelo protótipo e pelo produto fabricado. Entretanto, há a necessidade posterior de reduzir o tempo de colocação do produto no mercado, encurtando não só a fase de desenvolvimento, mas também a fase de industrialização. Por estas razões, as tecnologias de RP estão agora a evoluir para o RT. Apesar de no nosso País ainda existirem muitas empresas que desconhecem as potencialidades da RP, a verdade é que, a nível mundial, o estádio de evolução destas tecnologias é tão grande que, Pedro Vasco da Silva Magalhães e Vasconcelos 3
Capítulo 1 Introdução Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida actualmente, as empresas pretendem a conjugação da RP com as tecnologias de RT no sentido de acelerar todo o circuito de produção industrial. Testando precocemente e simultaneamente em várias fases de desenvolvimento do produto, modelos de conceito, protótipos funcionais, protótipos técnicos e pré-séries, é possível agrupar sinergias que incrementam a concretização do conceito de engenharia concorrente. As ferramentas metálicas são as que garantem maior durabilidade (vazamento, projecção metálica, electrodeposição, etc.) e asseguram ciclos térmicos de processamento mais curtos devido à sua elevada condutividade térmica. No entanto, a produção de ferramentas metálicas envolve elevados custos e complexas operações, tais como processamento a altas temperaturas e maquinagem de precisão. Torna-se, assim, premente recorrer a processos menos onerosos, com tempos de colocação no mercado mais curtos e permitindo também a validação da ferramenta. Esta necessidade pode ser colmatada por processos indirectos simples e económicos de RT, como as resinas com cargas metálicas ou baseadas em projecção metálica (Fig. 1.1). Antes dos anos 90, a principal limitação destas tecnologias baseadas em resinas e projecção metálica era a produção do modelo que, caso fosse trabalhado por corte, tinha custos e tempos de execução semelhantes aos gerados pela maquinagem de um molde em aço convencional. O aparecimento das tecnologias de RP, permitindo a produção de modelos com tempos e custos reduzidos, veio estimular a produção de moldes por estas técnicas, convertendo-as assim em alternativas mais competitivas. (a) (b) Figura 1.1 (a) Molde de terminal Multibanco em compósito de base epoxídica; (b) Molde de sola de sapato obtido pela técnica de pulverização metálica. O CETECOFF (Unidade de Fundição e Novas Tecnologias), onde o trabalho de investigação foi realizado, é uma unidade do INEGI (Instituto de Engenharia Mecânica e Gestão Industrial) cuja 4 Pedro Vasco da Silva Magalhães e Vasconcelos
Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida Capítulo 1 Introdução actividade envolve estudos de inovação técnica e de transferência de novas tecnologias para a indústria de fundição. Desde 1997 que o Centro tem dedicado um grande esforço de investigação nas novas tecnologias de RP e RT, no sentido de as aplicar no fabrico de modelos, protótipos, pre -séries de peças e ferramentas. Tem dado apoio a um elevado número de empresas portuguesas, contribuindo para o aumento da sua competitividade, pela redução de custos e tempos de colocação no mercado de novos produtos e melhoria do respectivo design. Esta actividade tem ainda sido acompanhada por um esforço notável de divulgação destas tecnologias junto às empresas, institutos, associações profissionais e instituições de ensino com as quais tem estabelecido frequentemente acordos de cooperação. O presente trabalho de investigação insere-se nestes objectivos de inovação tecnológica que o INEGI se propõe concretizar com vista a apoiar o desempenho e a competitividade das empresas industriais. Pedro Vasco da Silva Magalhães e Vasconcelos 5
Capítulo 1 Introdução Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida 1.2 OBJECTIVOS Com este trabalho pretende-se fabricar rápida e economicamente, utilizando métodos indirectos, ferramentas inovadoras em resinas compósitas, a partir de modelos CAD. As ferramentas obtidas poderão ser utilizadas em processos tais como a injecção e termoformação de diferentes tipos de termoplásticos. Para atingir estes objectivos, o trabalho foi conduzido segundo as seguintes linhas gerais: - Incorporação de aditivos e reforços nas matrizes epoxídicas para obter propriedades específicas, visando melhorar a resposta aos requisitos técnicos destes materiais compósitos destinados à produção de moldes de injecção. Investigando e caracterizando o binómio processos/materiais, melhorar as características mecânicas e térmicas, reprodutibilidade, estabilidade dimensional e durabilidade da ferramenta compósita; - Estudo profundo das relações existentes entre as propriedades macroestruturais e microestruturais, tendo em conta os resultados obtidos com diferentes tipos de ensaios. - Ensaio, avaliação e caracterização de moldes produzidos em compósitos de matriz epoxídica testados máquina industrial de injecção de termoplásticos. As ferramentas produzidas neste projecto não permitirão realizar o mesmo número de ciclos das ferramentas metálicas convencionais, de custo mais elevado, mas serão adequadas para produzir protótipos funcionais, pré-séries, etc., em plástico, em tempos muito mais curtos do que com os obtidos com processos convencionais. Pretende-se, assim, dar às empresas poder de antecipação na colocação de produtos no mercado, o que permitirá maior agressividade e competitividade nos diferentes mercados internacionais. 6 Pedro Vasco da Silva Magalhães e Vasconcelos
Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida Capítulo 1 Introdução 1.3 ORGANIZAÇÃO DA DISSERTAÇÃO A parte introdutória da dissertação consta de um capítulo de introdução e de uma revisão bibliográfica. No capítulo 1 faz-se a introdução da investigação desenvolvida na presente tese, apresentando-se o enquadramento, objectivos e plano de actividades e o presente tópico (organização da dissertação). A revisão bibliográfica, incluída no capítulo 2, está organizada partindo do geral para o particular, de modo a dar uma perspectiva lógica, alargada e compreensível do enquadramento da investigação. Parte-se de conceitos e estado da arte das tecnologias de RP e RT, abordando-se seguidamente os compósitos poliméricos utilizados em RT. Em relação a estes últimos, apresenta-se a selecção da matriz (propriedades, o processo de cura e a relação da estrutura física com as propriedades mecânicas), das partículas de alumínio e das fibras, os requisitos exigidos para um molde de injecção e os ensaios de caracterização termomecânica e térmica. A problemática das interfaces é apresentada no capítulo 2.6 (Ciência da superfície e adesão). Por fim, são apresentados os ensaios de caracterização da interface reforço-matriz e o método usado para o tratamento estatístico dos resultados. Numa segunda parte aborda-se o trabalho experimental realizado. No capítulo 3 descrevem-se os materiais utilizados, as resinas epoxídicas, pó de alumínio e fibras de carbono e vidro e os detalhes experimentais. No capítulo 4 são apresentados os resultados relativos ao processamento dos materiais, ensaios mecânicos, ensaios térmicos e termomecânicos, ensaios de caracterização de interfaces e propõe-se um modelo semi-empírico para o módulo de elasticidade dos compósitos reforçados com partículas e fibras moídas. Nesta fase, discutem-se os resultados, na tentativa de obter relações que permitam ampliar o conhecimento do comportamento dos materiais estudados. A finalizar o estudo experimental apresenta-se o capítulo 5 relativo à produção de moldes e aos ensaios de injecção de polímeros. No capítulo 6 apresentam-se as conclusões deste trabalho, bem como as perspectivas futuras de investigação nesta área. Pedro Vasco da Silva Magalhães e Vasconcelos 7
Capítulo 1 Introdução Fabrico Rápido Indirecto de Ferramentas Compósitas a Partir de Modelos de Prototipagem Rápida 8 Pedro Vasco da Silva Magalhães e Vasconcelos
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Ú ¾ ½± Î? ¼± ²¼»½ ± ¼» Ú» ³»² ݱ³ - Ð ¼» Ó±¼» ± ¼» Ð ± ± ¹»³ Î? ¼ Ý 3 «± î Š λª =± Þ ¾ ±¹?º ½» ¼± 3 «¼± ±«ª ½± ±» ½±³ «³» ««³±»½«½±² «3¼ ± ³±²-³» ± ±«± ¹-³» ±ø ± 3³» ± º± ³ ¼± ± «³» ²± ²&³» ± ¼» «² ¼ ¼» ¼± ³±²-³» ± ò ß ª7 ¼ ± ³» 9=±» «³ ³ ½ ±³± 7½ ½«¼ ± ¹ 9+» ¼» ² «3³ ½ ±«¼» ª 6²½ ³? ø½±ª»²» ò Û» ««ó¼ ³»² ±² - =± ± 3ª»» ± ³±²-³» ±»»²»³ ³ ¼» ¼± ¹ «± º«²½ ±² ø± ½ ª± ô ½ ± ½±²? ± ± ¹ ² ó»ó ³ ½±²º ¹«9+» ²»» ò Ü»ª ¼± @ ««³±»½«ô ±» ³±»²¼½3ª» =± ¼«±» 3¹ ¼± ò Û»ª ²¼±»³» «ô ±¼«ó» «³ «³»² ± ¼ ¼«½ ¼ ¼» ½±» ±²¼» «³ ¼ ³ ²«9=±»ª» 3ª» ¼± ª ± ¼ ¹ ¼» ¼» ½» ½ ¼» ïð𠪻» ò ß ¹»³ ¼» «³ ½±³ ± ³»² ± 3¹ ¼± «³ ½±³ ± ³»² ± ¼&½ ¼» ¹² ó» ± ±² ¼» ² 9=± ª3» ò ß ½ ³»² ± ³»»ª ¼± ²=±» ³»³ ±¾» «³ ³» ¼»º± ³?ª» ±«º«²¼ ¼±ô ¼»ª ¼± @ ¹ ¼» ¼ ¹ 9+» «3³ ½ »ª ½ ¼» ± ³ ¼»»²» ô ± ¹ ² ²¼±ô ²±»² ² ±ô «¼»¹ ¼ 9=± 7 ³ ½ ª7 ¼ ««¼ ¹ 9+» ½±ª»²» ò Û³¾± ± ³» ± ³7 ½±» ½±³ ±»³ ³«²» ³»²» ½±³±»? ½± ô ª ½± ±» ª ½±»? ½± ô» ««³±»½» ½«¼» ¾»³»¼±³ ² ²»³»²» «³ ½±³ ± ³»² ±»? ½±ò Í»³»²»³ ¹ ²¼» ¼»» ¼»»²¹»² «3³ ½ ± ¹>² ½ » ½»¼»³ ± >³¾ ± ¼» ²ª» ¹ 9=±ô ±¼» ½ ó» ô ¼» «³ º± ³ «³? ô ±»½ ±» ««½±² ¼» ²º ²½ ³ ½ ½» 3 ½ ¼» «³ ± 3³» ± =± ÅÝ»³»² ô ïççéãæ ïò Ò± ²» ± ¼» «³ ³± 7½«Š»»»± ±³» ³±ô ³ º ½ 9=±ô» ± ³±»½»»½ ª ¼ ¾«9=±ô ¹ «±» ³ ² ô»¹«¼ ¼»» « ½± ± ³» 9=±ò îò Û²» ³± 7½«Š» ½«9=±ô ¹ 9+»»½«²¼?» ½ ² ¼ ¼»ò îòîòîòï Ð ±»¼ ¼» 7 ³ ½ ß ±»¼ ¼» 7 ³ ½ ³ ¹² º ½ ª =±æ» ¾ ¼ ¼» ¼ ³»² ±² å ¼»½±³ ± 9=± 7 ³ ½ å» ² =± 7 ³ ½» ½±²¼«ª ¼ ¼» 7 ³ ½ ÅÝ»³»² ô ïççéãò Ò» ¾± ¼ ¹»³ «³?»? ¼ ¼ «³ ³ ±»»ª± ± ± 3³» ±» ³±»²¼½3ª» ô ª ±»»³ ± ±¾»½ ± ¼»»» «¼±ò Û ¾ ¼ ¼» ¼ ³»² ±² ß½ ³ ¼» ¼»» ³ ² ¼»³» «ô ± ± 3³» ±» ¼»³ ¾ ¼ ¼» ¼ ³»² ±² ò Û³ ¹» ô»»³» «½±» ±²¼» @»³» «¼» ² 9=± ª3» ô ̹ ø»³» «@ º± ³ «³ ìî л¼ ± Ê ½± ¼ Í ª Ó ¹ =»» Ê ½±²½» ±
Ú ¾ ½± Î? ¼± ²¼»½ ± ¼» Ú» ³»² ݱ³ - Ð ¼» Ó±¼» ± ¼» Ð ± ± ¹»³ Î? ¼ Ý 3 «± î Š λª =± Þ ¾ ±¹?º ½ - ¼± ¼»» ««ª3» ô»³ ± ½±² ± ± ¼± ±½» ± ¼» ½«¼ ¹ ¼±» ½ ²7 ½ «3³ ½ ¼» ½9+» «³ ½±² ± ± ¼±³ ² ¼±» ¼ º«=±ò ò ß» ¼ ¼» ¹ ¼»» ¼»» ¾ ¼ ¼» ¼ ³»² ±² «²¼±» »³» «7ô»³ ¹» ô ³ ½ ²» ²«³» ³±? ½±ò Ò«³ ± 3³» ±» ³±»²¼½3ª»» ³«¼ ²9 ²=± 7 =±»ª» ô ³?»¹ «³ ¹² º ½ ª» ¼ ² ±»¼ ¼» ³»½>² ½ ò ß º» ¾ ¼ ¼»ô ¼»² ¼ ¼» ¼± ³±²-³» ±»»²» ¹ ¼ ¹ 9+» «²»³ ³± 7½«6³ ¹ ²¼» ²º «6²½»³ ̹ò ±» ½ ± º ½ ± ¼±» ³±»²¼½3ª»»»²»³ ̹ ³»»ª ¼± ¼± ±» ³±? ½± ò л ±¾» «³» ½«9=±»»ª ¼ ô ± 7 «³ ̹»»ª ¼±ô ±» ³±»²¼½3ª» =±» ½«¼± ²=± -»» ² ½±³± ³¾7³» ± ¹»²» ¼» ½«ô» º± ³«9+» =± ½«¼ ¼± ³»²»» «¼ ¼ º ³ ¼»»¹»ª ¼ ¼»² ¼ ¼» ¼»» ½«9=± ½ 9+» ¼»»³» «ò Ì»³» «¼» ¼»½±³ ± 9=± 7 ³ ½ ß»³» «¼» ¼»½±³ ± 9=± 7 ³ ½ 7»»½ ³»²» ³ ± ²» ± 3³» ± ¼»»³» «ò ß ¼»½±³ ± 9=± 7 ³ ½ ² ½ ó» «²¼± ¹ 9+» ³? ½±ª»²» ±º»³ ««ò Û»³» «7 ¼»» ³ ² ¼»» 6²½ ¼ ¹ 9+» ô ¼» ¹² ¼ ³»²» ¼»»²» ¹ ò Û ² =± 7 ³ ½ ß» ² =± 7 ³ ½ ¼»»²¼» ³¾7³ ¼± ¹ «¼»» ½«9=±» ²¼ ¼ ¹ ¼» ¹» ¼± ³±²-³» ± ò Ò±» ³±»²¼½3ª» ¹ 9+»»½«²¼? 6³ ±«½±»º» ± ²» ² =± 7 ³ ½ ô ± ½±²? ± ¼± ½±²»½» ½±³ ±» ³±? ½± Åλ ª» ¼ô ïççéãò ݱ²¼«ª ¼ ¼» 7 ³ ½ ß ½±²¼«ª ¼ ¼» 7 ³ ½ ¼»»²¼» ¼ ¹ 9+» ³?»»½«²¼? ò Ñ» ³±»²¼½3ª» =± ³» ±» ½±²¼«±» 7 ³ ½± ª ± » =± ³ º±»³»²» ¹ ¼± ±» ³±? ½± ò б¼»ó» «³»² ±«¼ ³ ²«½±²¼«ª ¼ ¼» 7 ³ ½ ª7 ¼» ¼ 9=± ¼» ½ ¹ ½±³±ô ±»»³ ±ô «²¼± ³» ±««³ ² ô»»½ ª ³»²»ò îòîòîòî Ð ±»¼ ¼» ³»½>² ½ Î ¹ ¼» ß ¹ ¼» ²«³» ³±? ½± 7 ¼»» ³ ² ¼» ½ ² ¼ ¼»»»» 6²½ ¼ ¹ 9+»»½«²¼? ò Ñ «³»² ± ¼±» ± ³±»½«ô»³ ¹» ô ³» ±» 6²½ ò Ò«³» ³±»²¼½3ª» ¹ ¼» ¼»»²¼» ¼± ²&³» ±» ± ¼»» ½«9+» ò ß» ««¼» «³» ²» ± 3¼ ½ ô 7 º± ³ ¼ л¼ ± Ê ½± ¼ Í ª Ó ¹ =»» Ê ½±²½» ± ìí