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The study, development and application of a hybrid process: Additive Manufacturing (AM) plus High Speed Machining/Grinding (HSM/G)

Grant number: 16/11309-0
Support type:Research Projects - Thematic Grants
Duration: September 01, 2017 - August 31, 2022
Field of knowledge:Engineering - Mechanical Engineering - Manufacturing Processes
Principal Investigator:Reginaldo Teixeira Coelho
Grantee:Reginaldo Teixeira Coelho
Home Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
Co-Principal Investigators:João Fernando Gomes de Oliveira ; Jorge Vicente Lopes da Silva ; Mário Boccalini Júnior ; Milton Sergio Fernandes de Lima ; Nelson Guedes de Alcântara
Assoc. researchers:Alex Camilli Bottene ; Andre Luiz Nunis da Silva ; Claudemiro Bolfarini ; Daniel Leal Bayerlein ; Éder Sócrates Najar Lopes ; Eraldo Jannone da Silva ; Joao Batista Ferreira Neto ; João Ricardo Filipini da Silveira ; Jose Donato Ambrósio ; Marcelo Bertolete Carneiro ; Pablo Aronne Funchal de Barros ; Paulo Inforçatti Neto ; Pedro Yoshito Noritomi ; Piter Gargarella ; Raphael Galdino dos Santos ; Sheila Medeiros de Carvalho
Associated grant(s):19/08926-6 - Advanced post processing for quality enhancement of 3D-printed engineering components, AP.R SPRINT
17/24122-9 - Multi-user equipment approved in grant 16/11309-0: equipment to DED - direct energy deposition, AP.EMU
Associated scholarship(s):20/03119-2 - The study and development of monitoring strategies for hybrid process, BP.IC
19/26362-2 - Study of tungsten carbide (WC) coatings produced by DED Direct Energy Deposition in AISI H13 and 4140 steels, BP.PD
19/25229-7 - The fabrication of small satellites with use of lasers, BP.PD
+ associated scholarships 20/00035-2 - Evaluation of post processing operations of parts manufactured using hybrid manufacturing (Mfh) for roughness, BP.IC
19/13715-4 - Studies of the process variables in the inert gas atomization in the production of metal powders for DED - Direct Energy Deposition and PBD - Powder Bed Deposition, BP.PD
19/10758-4 - Study and development of post-processing in metal parts produced by additive manufacturing: application of high speed machining/grinding and magnetic abrasive finishing process, BP.DR
19/01829-5 - Additive manufacturing through selective laser melting and directed energy deposition of 316L stainless steel: effect of process parameters on mechanical properties, BP.DR
19/02772-7 - Study, development and application of hybrid process: additive manufacturing (AM)+High speed machining/grinding (HSM/G), BP.PD
19/00343-1 - Control of directed energy deposition process for manufacturing complex geometry components by Additive Manufacturing (AM), BP.DR
18/23884-5 - Evaluation of the additive manufacturing process in the microstructural and mechanical performance of repairs for injection molds, BP.DR
18/16898-0 - Selective laser melting of a 316L stainless steel, BP.IC
18/17981-8 - Additive manufacturing of H13 tool steel, BP.IC
18/15659-1 - Selective laser melting of H13 tool steel, BP.DD
18/09999-4 - Laboratory technical support in the metallographic preparation and mechanical testing, BP.TT
18/06691-9 - 316L steel commercial powder characterization, BP.IC
18/05845-2 - H13 steel commercial powder characterization, BP.IC - associated scholarships

Abstract

Economic and sustainable production is among the most recent and enduring challenges being faced by the manufacturing area nowadays. The Additive Manufacturing (AM), capable of producing with flexibility, fully automation and sustainability, arises with a strong appeal to replace traditional processes such as casting, forging and conventional machining. AM technology was addressed in a workshop at IPT in 2015, with the presence of directors, researchers and representatives from industry and FAPESP. Due to the importance of the subject, it was suggested a gathering of main institutions working with AM in the State of São Paulo, in order to align the efforts for further development of such recent and innovative manufacturing technology. After a series of meetings the team put together the present proposal and highlights that future developments using AM technology are, however, marked by a number of technological challenges, some of them addressed in the project proposed herein. The surface finishing of workpieces produced by AM is one of them, since it may not meet some high performance applications. Thus, subtractive processes such as High Speed Machining/Grinding (HSM/G) may be employed, creating a new class of processes known as Hybrid Processes (HPr). Other issues within this almost unknown field are the metallurgical quality and the right amount of stock to machine the workpieces. In order to manage them, the whole powder production route, AM and HSM/G parameters have to be known and controlled, also a subject proposed to be studied by the present project. Regarding AM, two processes are being addressed: the Powder Bed Deposition-PBD and the Direct Energy Deposition-DED. The former uses laser to selectively bonds a tiny layer of metal powder, building the workpiece by adding sequential layers. The latter uses laser to create a fused pool over the substrate, injecting at it powder using a flow of inert gas. Following that, pool material is added creating the 3D shape. Finally, the present proposal aims to organize the researches and knowledge acquired to apply them into two particularly suitable products as a benchmark for a broad field of applications: a mold for injection molding of thermoplastics, and a turbine blade commonly used in energy generation plants. Both products will be obtained by using the HPr developed during the project. The outcome of the present research project will certainly promote scientific and technological advancements in AM, as well as it will contribute to create new resources in this most recent and innovative engineering area. In addition to that, the project intends to go beyond the average research goals by applying the newly acquired knowledge to manufacture real parts, which grants to it a strong innovative feature too. Annual workshops involving the project team and industrial partners are among the planned targets, as well as patent requests for possibly new processes, procedures and products. (AU)

Articles published in Agência FAPESP Newsletter about the research grant
Face shield developed by the University of São Paulo is produced by industrial firms 
New technology will enable metal parts manufacturing through 3D printing  
Articles published in other media outlets (44 total):
More itemsLess items
Universidades mobilizar para produzir EPI 
Modelo de viseira de proteção desenvolvido pela USP está sendo produzido por indústrias 
Contra Covid-19, USP projeta viseira para milhares de agentes de saúde 
Contra Covid-19, USP projeta viseira para milhares de agentes de saúde 
USP: Modelo de viseira de proteção é produzido por indústrias no combate à COVID-19 
Impressão 3D vai reconstruir a taça Jules Rimet em metal 
Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet 
Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet 
Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet 
Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri 
Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet 
Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri 
Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet 
Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet 
Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri 
Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri 
Pesquisadores da EESC-USP criam réplica da taça Jules Rimet 
Tecnologia dá vida ao místico troféu 
Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri 
Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet 
Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet 
Impressão 3D vai Reconstruir Taça Jules Rimet em Metal 
Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço 
Taça Jules Rimet será reproduzida em impressora 3D na USP de São Carlos 
Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço 
Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço 
Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço 
Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço 
Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço 
Réplica da Taça Jules Rimet em aço inox será construída com uso de impressão 3D 
Nova tecnologia de impressão 3D vai reconstruir taça Jules Rimet em metal 
Impressão 3D está sendo usada para criar nova Taça Jules Rimet 
Impressão 3D está sendo usada para criar nova Taça Jules Rimet 
Impressão 3D está sendo usada para criar nova Taça Jules Rimet 
Professor da USP usa nova técnica para imprimir taça Jules Rimet em metais 
Nova tecnologia de impressão 3D vai reconstruir taça Jules Rimet em metal 
Professor da USP usa nova técnica para imprimir taça Jules Rimet em metais 
Nova tecnologia de impressão 3D vai reconstruir taça Jules Rimet em metal 
Nova tecnologia de impressão 3D vai reconstruir taça Jules Rimet em metal 
Impressão 3D está sendo usada para criar nova Taça Jules Rimet 
Impressão 3D está sendo usada para criar nova Taça Jules Rimet 
Impressão 3D está sendo usada para criar nova Taça Jules Rimet 
Impressão 3D está sendo usada para criar nova Taça Jules Rimet 
Impressão 3D está sendo usada para criar nova Taça Jules Rimet 

Scientific publications (4)
(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)
DE ANDRADE FERREIRA, CAROLINE CRISTINE; BRAGA, VAGNER; MOTA DE SIQUEIRA, RAFAEL HUMBERTO; DE CARVALHO, SHEILA MEDEIROS; FERNANDES DE LIMA, MILTON SERGIO. Laser beam welding of DP980 dual phase steel at high temperatures. OPTICS AND LASER TECHNOLOGY, v. 124, APR 2020. Web of Science Citations: 0.
GONCALVES, THAIS SOARES; DE FARIA, GERALDO LUCIO; DE SIQUEIRA, RAFAEL HUMBERTO MOTA; DE LIMA, MILTON SERGIO FERNANDES. Weldability and mechanical behavior of laser-welded TRIP 750 steel sheets. INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, v. 107, n. 5-6 MAR 2020. Web of Science Citations: 0.
SAKAMITI, GUILHERME PENNACHIN; MOTA DE SIQUEIRA, RAFAEL HUMBERTO; DE CARVALHO, SHEILA MEDEIROS; MEIRELES, JOAO BATISTA; FERNANDES DE LIMA, MILTON SERGIO. Weldability of a zirconium alloy comparing resistance and pulsed laser methods. NUCLEAR MATERIALS AND ENERGY, v. 20, AUG 2019. Web of Science Citations: 0.
LIMA, M. S. F.; CARVALHO, S. M.; SIQUEIRA, R. H. M.; CUNHA, M. C.; GONCALVES, C. M.; GODEFROID, L. B. Laser-induced heating for enhanced fatigue life of aerospace aluminum alloys. Journal of the Brazilian Society of Mechanical Sciences and Engineering, v. 40, n. 11 NOV 2018. Web of Science Citations: 0.

Please report errors in scientific publications list by writing to: cdi@fapesp.br.