Advanced search
Start date
Betweenand

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 researcher: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
Principal researchers: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 ; Kandice Suane Barros Ribeiro ; Marcelo Bertolete Carneiro ; Moysés Leite de Lima ; 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):20/07692-9 - Fabrication and characterization of Fe-based bulk metallic glass composites produced by additive manufacturing, BP.DR
20/05049-1 - Design and evaluation of the mechanical properties of high modulus low-density steel - with formation of TiB2 in situ - processed by additive manufacturing and powder metallurgy, BP.DR
20/08432-0 - Experimental development of gas turbine repair using laser direct energy deposition, BP.DD
+ associated scholarships 20/03119-2 - The study and development of monitoring strategies for hybrid process, BP.IC
20/03110-5 - Characterization of WC-Co deposited through additive manufacturing (AM) using the Direct Energy Deposition (DED) method, 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
20/00035-2 - Evaluation of post processing operations of parts manufactured using hybrid manufacturing (Mfh) for roughness, BP.IC
19/25229-7 - The fabrication of small satellites with use of lasers, BP.PD
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:
Nova tecnologia permitirá fabricar peças de metal por impressão 3D  
Una nueva tecnología permitirá fabricar piezas de metal mediante impresión 3D 
New technology will enable metal parts manufacturing through 3D printing  
Industrias brasileñas están fabricando un modelo de visera de protección desarrollado en la USP 
Face shield developed by the University of São Paulo is produced by industrial firms 
Nova técnica de manufatura é usada para criar réplica da Taça Jules Rimet  
Articles published in Pesquisa FAPESP Magazine about the research grant:
El avance de la impresión 3D 
The advancement of 3D printing 
Articles published in other media outlets (57 total):
More itemsLess items
CNN (Brasil): Estudantes e indústrias produzem máscaras de proteção para doação a hospitais (09/Apr/2020)
O Estado de S. Paulo: Tecnologia dá vida ao místico troféu (01/Jan/2020)
Estadão.com: Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri (01/Jan/2020)
Portal R7: Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet (01/Jan/2020)
IstoÉ online: Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet (01/Jan/2020)
Diário da Região (São José do Rio Preto, SP) online: Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet (31/Dec/2019)
G1: Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço (13/Dec/2019)
UOL: Professor da USP usa nova técnica para imprimir taça Jules Rimet em metais (06/Dec/2019)
BOL: Professor da USP usa nova técnica para imprimir taça Jules Rimet em metais (06/Dec/2019)
Veja online: Impressão 3D está sendo usada para criar nova Taça Jules Rimet (04/Dec/2019)
Saense: Nova técnica de manufatura é usada para criar réplica da Taça Jules Rimet (16/Jun/2021)
Novo Cantu Notícias: Nova técnica de manufatura é usada para criar réplica da Taça Jules Rimet (15/Jun/2021)
Quimiweb: Nova técnica de manufatura é usada para criar réplica da Taça Jules Rimet (15/Jun/2021)
Nas Notícias: Universidades mobilizar para produzir EPI (27/Apr/2020)
Vida & Ação: Protetores faciais nascem nas universidades públicas (10/Apr/2020)
2A+ Farma: Modelo de viseira de proteção desenvolvido pela USP está sendo produzido por indústrias (10/Apr/2020)
Portal do Governo do Estado de São Paulo: USP: Modelo de viseira de proteção é produzido por indústrias no combate à COVID-19 (09/Apr/2020)
Galileu online: Contra Covid-19, USP projeta viseira para milhares de agentes de saúde (09/Apr/2020)
Notícias de Campinas: USP: Modelo de viseira de proteção é produzido por indústrias no combate à COVID-19 (09/Apr/2020)
Mix Vale: USP: Modelo de viseira de proteção é produzido por indústrias no combate à COVID-19 (09/Apr/2020)
Casa dos Médicos: Contra Covid-19, USP projeta viseira para milhares de agentes de saúde (09/Apr/2020)
Notícias de Indaiatuba: USP: Modelo de viseira de proteção é produzido por indústrias no combate à COVID-19 (08/Apr/2020)
Portal Varada: Impressão 3D está sendo usada para criar nova Taça Jules Rimet (28/Feb/2020)
Printnews: Impressão 3D vai reconstruir a taça Jules Rimet em metal (13/Jan/2020)
Band: Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet (02/Jan/2020)
Terra: Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri (01/Jan/2020)
Futebol Interior: Pesquisadores da EESC-USP criam réplica da taça Jules Rimet (01/Jan/2020)
Bem Paraná online: Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet (01/Jan/2020)
MSN: Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri (01/Jan/2020)
Dom Total: Pesquisadores criam réplica da Jules Rimet usando impressão 3D em metal (01/Jan/2020)
Folha Vitória online: Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet (01/Jan/2020)
Press From Brasil (EUA): Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri (01/Jan/2020)
Central das Notícias: Pesquisadores produzem réplica da taça Jules Rimet para celebrar 50 anos do tri (01/Jan/2020)
Blog da Luciana Mello: Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet (01/Jan/2020)
Superesportes MG: Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet (01/Jan/2020)
Correio do Povo (Porto Alegre, RS) online: Com técnica de impressão 3D em metal, pesquisadores criam réplica da Jules Rimet (31/Dec/2019)
Antena 1: Brasil comemora 50 anos de tricampeonato com nova Taça Jules Rimet (27/Dec/2019)
O Jornal (Palmas, TO): Impressão 3D vai Reconstruir Taça Jules Rimet em Metal (18/Dec/2019)
Globo Esporte online: Taça Jules Rimet será reproduzida em impressora 3D na USP de São Carlos (13/Dec/2019)
Notícias Legais: Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço (13/Dec/2019)
Portal G1 News: Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço (13/Dec/2019)
Silvani Notícias (G1 Notícias): Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço (13/Dec/2019)
Plantão dos Lagos: Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço (13/Dec/2019)
Head Topics (Brasil): Pesquisadores da USP produzem réplica da taça Jules Rimet em impressora 3D que funde aço (12/Dec/2019)
Ipesi: Réplica da Taça Jules Rimet em aço inox será construída com uso de impressão 3D (10/Dec/2019)
Nossa São Carlos: Nova tecnologia de impressão 3D vai reconstruir taça Jules Rimet em metal (09/Dec/2019)
Blog do BG: Impressão 3D está sendo usada para criar nova Taça Jules Rimet (07/Dec/2019)
São Miguel para Todos: Impressão 3D está sendo usada para criar nova Taça Jules Rimet (07/Dec/2019)
Informativo Wildes Brito: Impressão 3D está sendo usada para criar nova Taça Jules Rimet (07/Dec/2019)
A Cidade On (São Carlos, SP): Nova tecnologia de impressão 3D vai reconstruir taça Jules Rimet em metal (06/Dec/2019)
PCWorld Brasil: Nova tecnologia de impressão 3D vai reconstruir taça Jules Rimet em metal (06/Dec/2019)
Jornal da USP online: Nova tecnologia de impressão 3D vai reconstruir taça Jules Rimet em metal (05/Dec/2019)
Notícias Legais: Impressão 3D está sendo usada para criar nova Taça Jules Rimet (05/Dec/2019)
Portal Varada: Impressão 3D está sendo usada para criar nova Taça Jules Rimet (05/Dec/2019)
Head Topics (Brasil): Impressão 3D está sendo usada para criar nova Taça Jules Rimet (04/Dec/2019)
Plantão dos Lagos: Impressão 3D está sendo usada para criar nova Taça Jules Rimet (04/Dec/2019)
Instituto Lado a Lado pela Vida: Modelo de viseira de proteção desenvolvido pela USP está sendo produzido por indústrias (09/Apr/2020)

Scientific publications (9)
(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)
MARTINS BARCELOS GONCALVES, KARINA APARECIDA; DE FARIA, GERALDO LUCIO; MOTA DE SIQUEIRA, RAFAEL HUMBERTO; DE OLIVEIRA, TARCISIO REIS; FERNANDES DE LIMA, MILTON SERGIO. Heat treatment effects on the hardness and wear behavior of laser-welded AISI40 martensitic steel plates. INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, v. 114, n. 3-4 MAR 2021. Web of Science Citations: 0.
DAVILA, JOSE LUIS; INFORCATTI NETO, PAULO; NORITOMI, PEDRO YOSHITO; COELHO, REGINALDO TEIXEIRA; LOPES DA SILVA, JORGE VICENTE. Algorithms-aided design applied to the tool-paths generation for hybrid manufacturing. MANUFACTURING LETTERS, v. 27, p. 53-57, JAN 2021. Web of Science Citations: 0.
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.
RICCARDO AUGUSTO MOREIRA MONTUORI; GUSTAVO FIGUEIRA; THIAGO PACAGNAN CATALDI; NELSON GUEDES DE ALCÂNTARA; CLAUDEMIRO BOLFARINI; REGINALDO TEIXEIRA COELHO; PITER GARGARELLA. Manufatura Aditiva de Aço Inoxidável 316L por Fusão Seletiva a Laser. Soldagem & Inspeção, v. 25, p. -, 2020.
GIULIANA SARDI VENTER; MAÍRA MARTINS DA SILVA. Vibration Control Using Multilayer Piezoelectric Actuators: Towards Chatter Supression in Turning Operations. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 23, n. 4, p. -, 2020. Web of Science Citations: 0.
RAQUEL ALVIM DE FIGUEIREDO MANSUR; CAROLINE CRISTINE DE ANDRADE FERREIRA; ISABELA ATÍLIO; SHEILA MEDEIROS DE CARVALHO; VAGNER BRAGA; RAFAEL HUMBERTO DE MOTA SIQUEIRA; MILTON SERGIO FERNANDES DE LIMA. A Comparative Study of Abbreviated Heat Treatments for SAE 4130 Steel After Laser Welding. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 23, n. 4, p. -, 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.