Smart manufacturing oriented to surface integrity

• Grant number: 20/13798-4
• Support Opportunities: Research Grants - Innovative Research in Small Business - PIPE
• Start date: September 01, 2022
• End date: July 31, 2023
• Field of knowledge: Engineering - Mechanical Engineering - Mechanics of Solids
• Principal Investigator: Andre Luiz Rocha D. Oliveira
• Grantee: Andre Luiz Rocha D. Oliveira
• Company: Engendauer Serviços de Engenharia Ltda
• CNAE: Serviços de engenharia
• Associated scholarship(s): 23/04446-5 - Technical training in the development of numerical models of manufacturing processes., BP.TT; 22/12501-3 - Smart manufacturing oriented to surface integrity, BP.TT; 22/11003-0 - Smart manufacturing directed to surface integrity, BP.PIPE

Abstract

With German's leadership, the world takes another step forward in its industrial development: Industry 4.0. The heart of this new revolution is the smart decision-making to reduce/eliminate the human actions on the process' control. The demand for performance increasing of the final product, besides the needs of manufacturing industry to mitigate the rework/discard converge in engineering solutions in the industry 4.0 context. Thus, the origin of Eigendauer comes to supply this demand: integrating the manufacturing process intelligently through surface integrity for autonomous decision making. Its proposal is to consolidate control data of the manufacturing processes in numerical models of surface integrity considering the fine application of the component. The overall objective of this proposal is the development of a Computational Integrated Manufacturing, converging numerical models of manufacturing processes with process control data to obtain an ideal state of residual stresses. This approach will enable the intelligent control of the surface integrity along the manufacturing chain. Shot peening and grinding processes will be covered. First, the Integrated Simulation will be carried out, where the numerical models of the shot blasting and grinding processes will be developed and integrated for application in the industrial environment. As a result, a digital twin of the final residual stress state will be developed after the process chain is completed. In the final stage, reaching the maturity of the Integrated Manufacturing, the procedure for the integration between the Integrated Simulation, control data and operational parameters will be elaborated for the finishing processes. The gap filled by this complete solution was detected by the founding members of the startup Eigendauer, based on the experience and network developed over years of work at their respective institutes. Most of the founding members of Eigendauer have links with the renowned national and international institutions Instituto Tecnológico de Aeronáutica (ITA) in São José dos Campos, and the Werkzeugmaschinenlabor (WZL), of the RWTH University in Aachen, Germany. These institutions are known for their innovative bias and incentive to research along with the industry, especially in the topics of manufacturing and concepts for Industry 4.0. Above all, both ITA and WZL are great promoters of startup's creation not only in the technical scientific sense, but especially in the transmission of information in their networks. Even though the themes "surface integrity" and "residual stresses" are research topics in the academic world, there is no convergence of these concepts integrated into the industry as a way of making decisions and adjusting them in real time. Considering the new requirements demanded by the industry and the Industry4.0, the time has come to make the use of these variables, crucial for durability, as a key part in the active definition of component manufacturing. (AU)