
Alfredo R. de Faria
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Publications (77)
Effect of loading rate, viscosity, and binder activation on the bending response of an infiltrated UD-NCF
Portela, Renan Miranda , Schäfer, Bastian , Kärger, Luise , de Faria, Alfredo Rocha , Montesano, John
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© 2025 The Author(s)Assessing the bending response of infiltrated reinforcement fabrics is crucial in wet compression molding (WCM) as it affects macroscopic wrinkling. Binder-stabilized fabrics may be used in WCM to improve handleability and reduce defects, necessitating their characterization. This study examines the bending behavior of an infiltrated binder-stabilized carbon fiber unidirectional non-crimp fabric (UD-NCF), focusing on the effects of viscosity, loading rate, and binder pre-activation. Infiltration reduces bending stiffness compared to dry fabric owing to lubrication and lower tow-stitch friction, while higher loading rates increase bending stiffness for all considered conditions. Moreover, binder pre-activation increases fabric stiffness by enhancing tow-stitch cohesion and friction. As the first investigation on infiltrated binder-stabilized UD-NCF bending, this work advances understanding of the complex bending response.
A device for testing high strength metallic sheets undergoing cyclic forward and reverse tension–compression loads under plastic strain
da Silva, Fernando Carlos Magalhães Carneiro , de Faria, Alfredo Rocha
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© The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2025.A device apparatus was designed and built to enable the testing of sheet metal undergoing cyclic forward and reverse tension–compression loads under plastic deformation, while preventing the specimen from buckling. This test allows the identification of parameters for the characterization of the material according to advanced hardening models, that are of utmost interest to the automotive industry, for accurate representation of the physical phenomena occurring during mechanical forming, which enables for tighter manufacturing tolerances. The test specimens were manufactured from steel sheets made of materials BH220 and DP600, with thicknesses of 0.65 mm and 1.00 mm respectively. For each specimen tested, three tension–compression cycles were performed, at a strain rate of 0.5 mm/min. The maximum displacements were 0.6 mm in tension and 0.6 mm in compression. A fork configuration was used in which the device has four main plate blocks to transmit the longitudinal displacement of the machine to the sheet metal and to restrict the plane transverse displacement. The results show that the device is capable of creating the cyclic stress–strain curve of which accurate parameters of Yoshida-Uemori model can be extracted.
Integrated analysis strategy for detecting gear contact fatigue before reaching failure interruption criterion
da Silva, Rodrigo Metzger , Rego, Ronnie Rodrigo , de Faria, Alfredo Rocha
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© 2024Identifying the occurrence of gear contact fatigue failure as early as possible is essential for condition-based maintenance (CBM). Vibration signals can be used to identify gear contact fatigue. However, the use of vibration signals can be challenging due to its complexity, compounded by lower levels of vibration during the initial stages of contact fatigue. The present study details a new algorithm that integrates stand-alone features to correlate the vibrational signal with early failure occurrence. The study aim is to identify the failure in the early stages, before reaching the ISO 6336–5 stopping criterion of 4 % damaged area. A damage induction on the flank of helical gears is applied to simulate and characterize the failure occurrence. Damping characteristics with impact evaluation, Kurtosis analysis and the monitoring of the Gear Meshing Frequency are applied to characterize the failure signature. This strategy stands out by the integration of these stand-alone features and their behavior. The algorithm's capacity is verified through durability tests, promoting the natural evolution of this failure mode. Results show a success rate of above 80 % at identifying the failure presence before the stopping criterion limit.
Geometrically nonlinear analysis of composite beams based on global–local superposition
de Faria, Alfredo R. , Baier-Saip, Jürgen A. , de Lima, André S.
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© 2024 Elsevier LtdA composite beam finite element is designed to capture through-thickness effects, specifically normal stress and strain and transverse shear, in the context of geometrically nonlinear analyses. The starting point for the formulation is a similar element already proposed for linear analyzes based on a global–local superposition approach, where local functions are defined in each layer of the laminate, and global functions are defined along the thickness. The consistency of the kinematic hypotheses is guaranteed by imposing the continuity equations of displacements through the thickness, the force balance equations along the thickness, directly or indirectly, by imposing the continuity of transverse stresses, and by applying the boundary conditions on the lower and upper surfaces of the elements. In the context of nonlinear analyzes, the imposition of continuity of displacements is straightforward. However, the continuity of the transverse stresses needs to be carefully imposed, as the relevant stresses are the second order Piola-Kirchhoff stresses and the strains are the Green-Lagrange strains, consistent with the total Lagrangian approach used. The constitutive equations are written in incremental form and a detailed analysis is conducted to ensure that the stresses and strains involved are physically consistent across the different reference frames employed. In order to assess the accuracy of the numerical model implemented, a unique semi-analytical technique is developed to obtain the response of asymmetrical laminated beams under compression.
Analytic solution for two dimensional beam problems: Pure displacement boundary conditions
Baier-Saip, J. A. , Baier, P. A. , de Faria, A. R. , Baier, H.
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© 2024 Elsevier Inc.The present manuscript delineates the derivation of strong solutions for the linear elasticity problem in a two dimensional rectangular beam. The materials under consideration can exhibit either isotropic or orthotropic properties. Additionally, the analysis is not restricted to slender beams because the ratio between the length and the height of the beam can be arbitrary. The boundary conditions fall into the Dirichlet category, implying that both horizontal and vertical displacements are specified on all four surfaces. The sole requirement is that these surface displacements are continuous functions, although they may not necessarily be smooth. Since the displacements at the surfaces can be arbitrary, there is no need to consider approximations, such as those concerning local (small) boundaries in slender beams. Nonetheless, it is demonstrated that an equivalent principle to the Saint-Venant principle exists for pure displacement boundary conditions. The partial differential equations are solved through the separation of variables method, leading to the identification of two solution types, encompassing both cosine and sine Fourier series. Particular emphasis is placed on evaluating the convergence of these solutions. For two distinct and general examples, it is confirmed that the solutions indeed exist.
Surface Integrity of 20MnCr5 Laser Powder Bed Fusion parts subject to contact fatigue test
Guimarães, Guilherme Fernandes , de Faria, Alfredo Rocha , Rego, Ronnie Rodrigo
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© 2024 The Authors. Published by Elsevier B.V.Additive Manufacturing (AM) is vital for industrial innovation, offering high potential for groundbreaking solutions. However, its successful implementation still depends on overcoming several challenges. Particularly, the assessment of surface integrity in AM-generated components, and its degradation when subjected to contact stresses presents an ongoing endeavor. Within this context, the current work delves into the study of the surface integrity of 20MnCr5 case-hardened samples manufactured through laser powder bed fusion (L-PBF), as well as delves into the investigation of surface failure progression when the samples are subjected to cyclic contact stresses. This study encompasses the analysis of residual stresses, hardness, and roughness of specimens manufactured through both additive and conventional production routes. The study's findings show that it is feasible to attain analogous surface quality when proper finishing is applied to L-PBF samples. Although, despite the comparable surface quality, the contact fatigue performance was significative lower on the AM sample when compared to the conventionally manufactured. Additionally, additive manufacturing brings up new challenges to performance by presenting a heterogeneous stress distribution and sub-superficial porosity. In conclusion, to attain a desirable surface integrity for additive manufactured parts, further research should not only focus on improving the process parametrization but should also developing finishing routes especially oriented to additive manufacturing, considering therefore how the interaction between the manufacturing processes will evolve into a desirable surface integrity state.
Shot peening simulation oriented to residual stress interaction with gear grinding
Fernandes Guimarães, Guilherme , Rocha de Faria, Alfredo , Rego, Ronnie Rodrigo , D'Oliveira, André Luiz Rocha
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© 2023 Elsevier B.V.The current study proposes a shot peening model which enables the residual stress interaction with grinding, a typical combination for gear finishing. The effect of the interaction on the stress state development was addressed by comparing the residual stress state from a standalone shot peening procedure, against the residual stress state arising from a manufacturing route where the interaction of shot peening and grinding takes place. In the interaction model, the grinding procedure generates a pre-loaded condition on the material, modifying the internal strain system of the gear tooth. This pre-loaded system, when disturbed by shot peening, reaches a new internal strain equilibrium. In the interaction model, a 24% less compressive stress state was attained when compared with the standalone shot peening process. A significant shift in the depth and magnitude of the peak compressive stress was also observed. On account of the numerical study of the processes’ interaction, the developed model substantially contributed to understanding the residual stress formation during manufacturing chains.
A practical technique to assess the influence of the misalignment angle of unidirectional composite fibers under compressive load
de Faria, Alfredo Rocha , Arakaki, Francisco Kioshi
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© 2023, The Author(s), under exclusive licence to The Brazilian Society of Mechanical Sciences and Engineering.This work employs a micromechanical theory and kinematic relationships to describe the displacement field in individual unidirectional composite plies. The technique relies on an incremental approach where the misalignment angle of fibers is the main variable in the analysis. Upon convergence at a certain loading level, stresses and strains are evaluated in the fibers and matrix using micromechanics, and a specific failure criterion is applied. The Ramberg–Osgood relations are used to correct degraded mechanical properties of the resin in the nonlinear regime. The use of a 2D finite element model with a 3° initial misalignment angle of fibers, showed a good approach to complement the problem solution. The Hashin-Rotem failure criterion and experimental data obtained by Matsuo (Compos Part A: Appl Sci Manuf, 93:117-125, 2017) are used to validate the technique. It is observed that the numerical and experimental results obtained correlate well.
Layerwise theories for composite beams with continuous and discontinuous stresses
Baier-Saip, J. A. , Baier, P. A. , de Faria, A. R. , Baier, H.
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© 2022 Elsevier Masson SASDue to the unique characteristics of composite materials, the study of composite beams is far more complex than the study of homogeneous beams. The finite element method has proven to be a powerful approach to analyze composites subjected to the most distinctive situations. In the present work, two element solutions using cubic polynomials are considered: with continuous stresses and with discontinuous stresses along the transverse direction. Both converge to the analytical solution as the number of elements increase, i.e. with a finer mesh. Besides satisfying the boundary conditions at the surfaces and interfaces, the first solution gives better outcomes close to the center of the beam. On the other hand, the second solution gives better outcomes close to the borders of the beam, but it has a larger number of nodal parameters. The results are compared to a zig-zag element solution which has a number of nodal parameters independent of the number of layers. An element based on the Reissner mixed variational theorem is also included for additional comparisons. It is concluded that the cubic polynomials used to expand the cross section functions, must be different in each layer in order to achieve a reasonable agreement between the analytical and the calculated transverse normal stress.
Brazilian Engineering Research Center for the Aerial Mobility of the Future
Rade, Domingos A. , Dos Santos, Luciano J.Pedrote , Pomilio, Jose A. , Da Silva, Roberto G.Annes , Ribeiro, Carlos Henrique C. , De Faria, Alfredo Rocha , Villani, Emilia
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© 2023 IEEE.The paper describes the constitution of the Engineering Research Center for the Aerial Mobility of the Future (ERC-AMF) having ITA as the host institution, Embraer as the industrial partner, and researchers from the University of São Paulo and the University of Campinas. The objective of the ERC-AMF is the realization of R&D to contribute to overcoming challenges to the shaping of aerial mobility in the upcoming decades. These challenges arise from the necessity of reducing pollutant and noise emissions, and the need for increased efficiency of manufacturing processes, besides the trend of introducing in the market novel aircraft adapted for operation in urban environments and short-range travels. Five research areas are focused on the first operation phase of the Center: Machine Control for Electric Propulsion; Aeropropulsion Integration in Electric Aircraft; Methods for Decision Making in Autonomous Systems; Advanced Design for Metallic Additive Manufacturing; and Intelligent Aircraft Final Assembly. Each line will be developed by researchers from partner universities and engineers from Embraer. It is expected that the Center will contribute to the appropriation, by the Brazilian aeronautical industry, of scientific and technological knowledge generated, and, as a result, increase its preparedness to face challenges that shall be overcome in the process of shaping the aerial mobility of the upcoming decades.
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Supervisions (15 master's, 9 phd)
Fernando Carlos Magalhăes Carneiro da Silva (2025) PhD
Guilherme Fernandes Guimarăes (2025) PhD
Luiza Emília Vila Nova Mazzoni (2024) Master's
Felipe de Sá Carneiro (2024) Master's
Bruno da Silva Sales (2023) Master's
José Jerônimo Rabelo Faria (2022) PhD
Guilherme Fernandes Guimarães (2021) Master's
André Luiz Rocha D'Oliveira (2021) PhD
André Schwanz de Lima (2020) PhD
Luiz Guilherme Aun Fonseca (2020) PhD
