Microsoft word - nbayreport2008.doc

Report on IDMEC Institute of Mechanical Engineering visit 7.-8. August 2008
by Niels Bay

1. Introduction
The undersigned, Professor Niels Bay, who has acted as member of the International
Scientific Advisory Council of IDMEC in the period 2003-2005 and again in 2008 visited
this year IDMEC’s Center of Advanced Production Technologies August 7-8, 2008. On
the 7th of August personal discussions were held with Professor Paulo Martins on the
general organisation and performance of his Center of Manufacturing and Industrial
Management, CMIM, and on collaborative projects, whereas the next day was dedicated
to meetings with about 10 members of his staff. In the following a review is given of the
center activities based on these personal discussions and the annual reports of 2005, 2006
and 2007 provided before the visit.
2. Organisation and activities
The CMIM, which is headed by Professor Paulo Martins, is organized in five thematic
research groups:
1. Metal Forming Group headed by Professor Paulo Martins 2. Metal Cutting Group headed by Assistant Professor Pedro Rosa 3. Joining Technologies Group headed by Associate Professor Luisa Quintino 4. Rapid Prototyping Group headed by Assistant Professor Inês Pires 5. Industrial Management Group headed by Associate Professor Elsa Henriques The CMIM facilities include research and training laboratories equipped with machine tools for metal forming, metal cutting and welding as well as equipment for materials testing and geometrical metrology. The staff includes 17 researchers, 1 facility engineer, 1 technician and approximately 30 students. Activities includes teaching, fundamental theoretical and experimental research and technology transfer to industry. 2.1 Metal Forming Group
The Metal Forming Group was formed at the end of the 1970-es. During the later years
an impressive amount of new equipment has been purchased or built implying that the
laboratory is now very well equipped for R&D.
Ongoing research activities include theoretical and experimental analysis of Single Point
Incremental Forming, a rather new process especially suited for prototype and small
quantity production. A unique theoretical model has been established proving the much
larger formability in SPIF than in conventional sheet forming operation. The work is
carried out in collaboration with the Technical University of Denmark.
SPIF has been extended to forming of polymers and a theoretical model for SPIF in
polymers including the special characteristics of these materials has been developed.
A mini-press for microforming of metals has been developed and equipment for
electromagnetic forming has been obtained through collaborative work with the
Technical University of Dortmund in Germany.
The group’s strong involvement in development of FE programs is ongoing, supporting
the above mentioned activites. As such 2D and 3D FE programs for cold forming of
polymers has been developed.
2.2 Metal Cutting Group
The Metal Cutting Group was formed in 2003. Fundamental research is carried out on the
mechanics in metal cutting studying the mechanisms of material separation at the tool tip.
A special purpose FE program modelling the metal cutting process based on ductile
fracture mechanics has been developed. The work is carried out in collaboration with
Professor Atkins at the University of Reading and presents a new very promising
interpretation of modelling the mechanics of metal cutting.
In order to obtain materials data for metal cutting analysis two high speed material
characterisation facilities have been designed and constructed, i.e. an electromagnetic,
split Hopkinson’s bar for high strain rates and a drop hammer for medium ones.
Furthermore a special tribo-tester based on the pin-on-disk principle has been developed
for measurements of friction of freshly cut workpiece surface towards a tool surface.
Equipment for micro-EDM has been constructed for production of tools for the earlier
mentioned microforming.
For teaching purposes an industrial machine tools training laboratory and CAM teaining
software has been established.
2.3 Joining Technologies Group
The Joining Technologies Group was formed in the 1980-ies. The group is involved in
R&D on new variants of MIG/MAG welding, health and ergonomics in welding, friction
stir welding and laser welding, which is carried out at the Welding Institute in Portugal,
as well as in UK at Cranfield Univ., where they have access to laser equipment due to
long term collaboration in EU projects, visitng professorship etc. Topics of research are
micro-laser welding and fiber laser welding of Ti, Al and steel.
The group on friction stir welding is very active studying new assembly geometries, new
materials and combinations (welding of metal foam, Cu-Al), welding and forming of
tailored blanks, optimisation of pin tool geometry etc. The recent purchase of an ESAB
friction stir welding equipment has implied new possibilities for research.
2.4 Rapid Prototyping Group
The Rapid Prototyping Group was established in the early 1990-ies and restructered in
2008. It is primarily involved in rapid tooling, rapid manufacturing, virtual prototyping
and reverse engineering. An interesting development is the patent on polymer tool inserts
for sheet metal forming, which are removed after forming by melting or dissolving. This
patented technique has been used in an industrial project to produce hollow spheres from
thin Al-tubes.

2.5 Industrial Management Group
The Industrial Management Group was formed in the 1990-ies. R&D is focussed on
development of new business models for the tooling industry, lean manufacturing
strategies for SME’s, technology management and life cycle cost assessment for
sustainable decisions, impact assessment of emergent technologies based on systematic
analysis and technological cost models and stochastic models in operational research.
Collaboration with the life cycle group at MIT has been established.
3. Concluding remarks

The Center of Manufacturing and Industrial Management is now established as a group
of relatively young, very enthusiastic and competent researchers headed by a few senior
researchers with outstanding international recognition.
It is the strategy of the Center of Manufacturing and Industrial Management to possess
mastership in key areas and good craftsmanship in others. This is a good strategy based
on the fact, that the group with its limits of human resources wish to educate students
with the competences required in industry.
Key areas where the group reaches mastership of international standard is seen in bulk
metal forming and welding. The research on metal cutting is on its way to reach a similar
level. In general the contact to and collaboration with Portuguese industry is good.


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