INEGI Science & Innovation in Mechanical and Industrial Engineering

Transcription

1 AUTOMOBILE AND TRANSPORT AERONAUTICS, SPACE AND DEFENCE HEALTH INEGI Science & Innovation in Mechanical and Industrial Engineering SEA ECONOMY ENERGY EQUIPMENT AND DURABLE GOODS 2015 SERVICES ENVIRONMENT 1

2 1. FACTS & FIGURES 2

3 1. FACTS & FIGURES INEGI Research and Technology Organization (RTO) Industry-oriented RD & Innovation Advanced Engineering Services in Mechanical and Industrial Engineering. Created in 1986 as an Interface Institution between the Department of Mechanical Engineering and Industrial Management of the Faculty of Engineering of University of Porto (PT) and the global industry. Private Organization (Owned by University, industrial associations, regional authorities and 70 private companies as associates) Non-Profit and recognised as being of Public Utility Financial and Administrative Autonomy 3

4 1. FACTS & FIGURES BUSINESS DOMAIN Knowledge creation and development of new technologies, usually 100% funded by FCT (National Foundation for Science and Technology) and EC. ~ 80% of total Revenues R&D projects with industry, co-funded by Portuguese and European funds. R&D and Innovation projects with industry, funded by customers. Technical Consulting and Advanced Engineering Services. 4

5 ORGANISATIONAL STRUCTURE 1. FACTS & FIGURES 5

6 1. FACTS & FIGURES PEOPLE Permanent staff 100 Research Grant 48 TOTAL % 34% Faculty Researchers 70 Other (MSc and PhD Students and Internship) 66 27% 16% Permanent staff Research Grant Faculty researchers Other 6

7 Million Euros 1. FACTS & FIGURES TURNOVER 7,00 6,00 5,00 4,89 5,47 5,93 5,89 6,41 4,00 3,00 2,00 1,00 0,

8 1. ABOUT INEGI MARKETS AERONAUTICS, SPACE AND DEFENCE AUTOMOBILE AND TRANSPORT ENVIRONMENT SEA ECONOMY ENERGY EQUIPMENT AND DURABLE GOODS HEALTH CARE METALLOMECHANIC SERVICES 8

9 2. COMPETENCES & OFFER 9

10 2. COMPETENCES & OFFER BASIC COMPETENCES Product & Systems Development NDT & Experimental Mechanics Instrumentation Automation & Control Composite Materials & Structures Casting, Rapid Prototyping & Rapid Tooling Sheet Metal Forming Industrial Engineering, Technology & Innovation Management Tribology & Dynamics Renewable Energy & Efficiency 10

11 2. COMPETENCES & OFFER LABORATORIES Metrology & reverse engineering Mechanical testing of metallic and composites materials and structures Polymer & composite materials Rapid prototyping & rapid tooling Advanced sheet metal forming technologies Tribology and Vibration NDT, Optics and Experimental Mechanics Materialography Combustion Aerodynamics Material s Smoke and fire behaviour (accredited by IPAC) 11

12 2. COMPETENCES & OFFER ENGINEERING TOOLS 3D Computer Aided Design: Solidworks, CATIA Computer Aided Engineering: linear and non-linear simulation, Cosmos, ABAQUS Simulation of production processes: casting, injection, metal forming and composite production processes. Life-Cycle/Eco-Efficiency Assessment 12

13 2. COMPETENCES & OFFER PRODUCTION PROCESSES Composite Materials Advanced Casting Sheet metal forming Machining 13

14 2. COMPETENCES & OFFER 14

15 COMPOSITES Development of novel concepts for advanced materials Material Prototyping and Characterization R&D in the development of semi-products for the composites production value-chain 15

16 CARBON FIBRES AND PRE- IMPREGNATED-BASED MATERIALS Development of carbon fibers and pre-impregnated materials for Aerospace applications. Improved electrical and thermal conductivity by using CNT doped resins. Integrating Medium-scale Collaborative Projects FP7-SPA Space Critical Technologies 16

17 DEVELOPMENT OF CNT-DOPED CFRP Improved thermal/electrical conductivity of CFRP composites (thermal management, electrostatic discharges, structural health monitoring, etc). Inter- and intra-laminar reinforcement of CFRP composites. Inter and intralaminar reinforcement From: Tsu-Wei Chou, Limin Gao, Erik T. Thostenson, Zuoguang Zhang, Joon-Hyung Byun, An assessment of the science and technology of carbon nanotube-based fibers and composites, Composites Science and Technology, 2010 Activities on Materials and Structures for Space 17

18 MODELLING & CHARACTERIZATION Development of non-linear analytic and numerical models for composite laminate design incorporating stress concentration. Prediction of fatigue and fracture mechanics in composite laminates Assessment of laminate damage tolerance; Design of experiments and implementation of model validation tests Production of coupon test samples, tests and specialist assessment of results for model verification 18

19 STRUCTURAL NUMERICAL ANALYSIS & SIMULATION Cohesive Elements Continuum Damage Models 19

20 MODELLING TOOLS 20

21 PRODUCT DEVELOPMENT (PD) TOOLS Mechanical and complex System Design; Structural simulation, dynamics and optimization using Finite Element Methods; Instrumentation, automation & control; Industrial Design. Production of functional or non-functional prototypes, using appropriate technologies, tooling systems and materials; Methodologies and tools for PD: Ecodesign and Eco-Efficiency; Modular Design; Optimization using structured methodologies and Lean principles. 21

22 INTEGRATED STRUCTURAL DESIGN OF COMPOSITE COMPONENTS Load Case Selection Stability Analysis Optimisation Critical Area Selection Failure Analysis Safety Margins Development of integrated methods for the design of composite laminates with tailored stress concentrations (non-linear FEM methods for complex geometries) 22

23 ENGINEERING DESIGN & PROTOTYPING Lighter, Ecofriendly and Efficient Aircraft Cabin Industrial Partners: Alma Design, SET, Amorim, Couro Azul, Embraer 23

24 OTHER PD PROJECTS Mechanical simulation models of actuation cable systems for automobiles Development of a software tool to assess the stresses and the efficiency involved in transmission, with manual or mechanical actuation and its validation through experimental work. Industrial Partner: FICOCABLES, SA Development of new interiors for buses Lighter, more eco-efficient, comfortable and integrated bus interiors, reflect broad technological capabilities and group synergies. Industrial Partners: Caetano Components SA, Amorim, CouroAzul, INEGI and SET.SA, Alma Design 24

25 PROCESS DEVELOPMENT Advanced Manufacturing Processes Online Process Control Tool Design Prototyping and pre-series Simulation and Testing methods for Process Certification 25

26 PROCESS DEVELOPMENT_COMPOSITES Process Simulation Tool Design Prototyping Thermoplasticmatrix Composites Filament Winding 26

27 PROCESS DEVELOPMENT_ ELETROMAGNETIC TECHNOLOGY 1. FORMING Sheet metal or 3D geometries (Tubes) 2. WELDING Solid state welding of metal sheets and tubes 3. CRIMPING Joining of dissimilar materials, metal / metal, metal / polymers, metal / composites, etc. 4. CALIBRATION / Form-fit Joint High strength mechanical joints Lower cost of ownership: Lower energy consumption. Smaller footprint. Lower cost, better quality Process stability eliminates failures and re-working of workpiece Process time is extremely short. Handling is the bottleneck High Repeatability and Cost Efficiency due to generic stability of Bmax s core technology. No Heat, No Smoke, No Sparks, No Oil, No Detergents 27

28 PROCESS DEVELOPMENT_Controlled- Atmosphere Investment Casting 1. Titanium alloys compressor wheels for turbochargers. 2. Turbines of titanium aluminides for turbochargers. 3. Inconel heat shields for turbo-reactors. 28

29 PROCESS DEVELOPMENT_ Die Casting of aluminium alloys 1. Low pressure and tilt die casting of aluminium alloys process development for aesthetical products. 2. High pressure die casting of aluminium alloys over stainless steel tubes process development. 3. Product and die design for improving mechanical and aesthetical quality based on simulation with ProCast. 4. Prototypes and pre series based on Additive manufacturing and Investment Casting. 29

30 CHARACTERIZATION & TESTING Quasi-static Vibration Shock Structural Health Monitoring Shearography Fatigue 30

31 MECHANICAL CHARACTERIZATION_ Lightweight Stiffened Panels Multi-part structure skin stringer stringer welded affected area butt joint T-joint FSW tool Integral structure 31

32 MECHANICAL CHARACTERIZATION_ Adhesive Joints Determination of the strain distribution in adhesive joints using Fibre Bragg Grating (FBG) 32

33 THANK YOU! 33