{"id":22087,"date":"2024-07-22T17:11:30","date_gmt":"2024-07-22T09:11:30","guid":{"rendered":"https:\/\/firstmold.com\/?post_type=case-study&p=22087"},"modified":"2026-01-27T14:29:11","modified_gmt":"2026-01-27T06:29:11","slug":"production-of-automotive-armrest-bases","status":"publish","type":"case-study","link":"https:\/\/firstmold.com\/pt\/case-study\/production-of-automotive-armrest-bases\/","title":{"rendered":"Fabrico de caixas de apoio de bra\u00e7o da consola central para autom\u00f3veis atrav\u00e9s de moldagem por inje\u00e7\u00e3o"},"content":{"rendered":"

A parte do apoio de bra\u00e7o da consola central tem um papel est\u00e9tico e funcional. O design e o acabamento do material contribuem para a beleza geral do habit\u00e1culo. No entanto, serve principalmente os pap\u00e9is funcionais de proporcionar conforto e melhorar a comodidade. Por exemplo, inclui normalmente uma arruma\u00e7\u00e3o secreta para objectos pessoais como telem\u00f3veis, carteiras e chaves.<\/p>\n\n\n\n

O apoio de bra\u00e7os da consola central proporciona um local de descanso para os bra\u00e7os do condutor e do passageiro da frente. Isto reduz o risco de rigidez muscular e fadiga, particularmente durante as viagens longas. Com os bra\u00e7os devidamente descansados, o condutor pode manter uma postura est\u00e1vel e descontra\u00edda, o que \u00e9 vital para um melhor controlo do ve\u00edculo.<\/p>\n\n\n\n

\"Base<\/figure>\n\n\n\n

Componentes do apoio de bra\u00e7o da consola central em ve\u00edculos modernos<\/h2>\n\n\n\n

Os fabricantes da maioria dos ve\u00edculos modernos querem que cada carater\u00edstica aumente o conforto ou traga novas funcionalidades. Os diferentes componentes integrados no fabrico de pe\u00e7as para o apoio de bra\u00e7o da consola central s\u00e3o concebidos para concretizar esta vis\u00e3o.<\/p>\n\n\n\n

Componentes do apoio de bra\u00e7o da consola central<\/th>Fun\u00e7\u00e3o<\/th><\/tr>
Caixa do apoio de bra\u00e7o da consola central<\/td>\u00c9 um inv\u00f3lucro exterior r\u00edgido que protege os componentes internos do apoio de bra\u00e7o. \u00c9 a pe\u00e7a que est\u00e1 fisicamente montada na consola central ou no chassis para proporcionar estabilidade estrutural. Aloja elementos como suportes para copos e componentes el\u00e9ctricos nos ve\u00edculos modernos.<\/td><\/tr>
Compartimento de arruma\u00e7\u00e3o<\/td>O apoio de bra\u00e7o funciona normalmente como tampa de uma caixa de arruma\u00e7\u00e3o oculta ou de um compartimento da consola. O compartimento \u00e9 \u00fatil para manter os objectos pessoais escondidos da vista.<\/td><\/tr>
Acolchoamento\/almofada<\/td>A parte superior do apoio de bra\u00e7o \u00e9 normalmente acolchoada ou almofadada com um material macio para melhorar o conforto.<\/td><\/tr>
Mecanismo de dobradi\u00e7a<\/td>O apoio de bra\u00e7o da consola central pode abrir e fechar de forma segura com a ajuda de um mecanismo de dobradi\u00e7as. Em alguns casos, as dobradi\u00e7as permitem ajustes verticais, bem como para a frente e para tr\u00e1s, para um conforto personalizado.<\/td><\/tr>
Eletr\u00f3nica integrada<\/td>A parte moderna do apoio de bra\u00e7o da consola central tornou-se um centro para v\u00e1rios componentes electr\u00f3nicos. As portas de carregamento, os interruptores de controlo, o ecr\u00e3 de infoentretenimento e a passagem de cabos est\u00e3o integrados no apoio de bra\u00e7o.<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

Requisitos do cliente<\/h2>\n\n\n\n

O cliente tinha requisitos rigorosos em termos de aspeto e funcionalidade. Em termos de aspeto, o cliente pretendia uma pe\u00e7a para o apoio de bra\u00e7o da consola central que n\u00e3o apresentasse defeitos que ocorrem normalmente em superf\u00edcies curvas, incluindo marcas de afundamento, linhas de soldadura e marcas de fluxo. Sendo um fabricante de autom\u00f3veis de primeira qualidade, o mais pequeno defeito de moldagem por inje\u00e7\u00e3o do apoio de bra\u00e7o da consola central pode afetar a atra\u00e7\u00e3o do habit\u00e1culo.<\/p>\n\n\n\n

Em termos de funcionalidade, esperava-se que tivesse uma boa estabilidade estrutural e que apresentasse dimens\u00f5es de encaixe para uma montagem f\u00e1cil. Outras carater\u00edsticas que preocupavam o cliente inclu\u00edam a perpendicularidade dos postes de montagem, a folga de encaixe e a toler\u00e2ncia de \u00b10,1 mm da pe\u00e7a e de \u00b10,05 mm do molde.<\/p>\n\n\n\n

Uma vez que o apoio de bra\u00e7o \u00e9 suposto suportar a press\u00e3o do bra\u00e7o, bem como sobreviver a v\u00e1rios ciclos de abertura e fecho, o fabricante tamb\u00e9m se preocupou com a durabilidade. Se o apoio de bra\u00e7o falhar demasiado cedo, pode dar uma m\u00e1 imagem do fabricante de autom\u00f3veis.<\/p>\n\n\n\n

Desafios e solu\u00e7\u00f5es<\/h2>\n\n\n\n

Cada um dos requisitos delineados pelo fabricante apresentava um desafio \u00fanico. O projeto do fabricante continha v\u00e1rias especifica\u00e7\u00f5es de materiais e dimens\u00f5es que eram mais dif\u00edceis de obter utilizando uma t\u00e9cnica de moldagem normal.<\/p>\n\n\n\n

Conseguir um aspeto impec\u00e1vel na caixa fina do apoio de bra\u00e7o da consola central<\/h3>\n\n\n\n

O primeiro de uma s\u00e9rie de desafios que se esperava que a First Mold superasse era a cria\u00e7\u00e3o de uma pe\u00e7a est\u00e1vel de paredes finas. A leveza \u00e9 extremamente importante para a efici\u00eancia do combust\u00edvel autom\u00f3vel. Uma das formas de o conseguir \u00e9 atrav\u00e9s de modifica\u00e7\u00f5es no design que promovam uma menor utiliza\u00e7\u00e3o de materiais.<\/p>\n\n\n\n

As paredes finas s\u00e3o refor\u00e7adas com nervuras para garantir a sua estabilidade. No entanto, as nervuras introduzem frequentemente pontos fracos na estrutura se o material ou o processo for inadequado. Isto pode criar problemas como a quebra do encaixe ou a deforma\u00e7\u00e3o da estrutura (levando a que o apoio de bra\u00e7o n\u00e3o abra\/feche ou fique solto). Qualquer um destes problemas encurtar\u00e1 o ciclo de vida do produto, que \u00e9 tipicamente de \u22655 anos para a maioria dos componentes autom\u00f3veis.<\/p>\n\n\n\n

Para al\u00e9m de conseguir uma apar\u00eancia livre de falhas comuns de fabrico da caixa do apoio de bra\u00e7o da consola central, o fabricante de autom\u00f3veis tamb\u00e9m queria que o apoio de bra\u00e7o da consola central tivesse uma grava\u00e7\u00e3o de textura estilizada. Para o conseguir, a grava\u00e7\u00e3o tinha de ser esculpida no molde, o que exigia uma maquina\u00e7\u00e3o CNC detalhada.<\/p>\n\n\n\n

Preocupa\u00e7\u00f5es de durabilidade com o design de encaixe<\/h3>\n\n\n\n

Para garantir a durabilidade da moldagem por inje\u00e7\u00e3o da caixa do apoio de bra\u00e7o da consola central, a First Mold teve de ultrapassar os desafios dos m\u00f3dulos de encaixe, que t\u00eam de sobreviver a milhares de ciclos de abertura e fecho. Nos projectos de encaixe, existe normalmente uma concentra\u00e7\u00e3o de tens\u00f5es \u00e0 volta da base, o que exige a adi\u00e7\u00e3o de filetes ou raios. Outros desafios que a First Mold teve de ultrapassar incluem:<\/p>\n\n\n\n

    \n
  • Falha por fadiga:<\/em><\/strong> Esta falha resulta da montagem e desmontagem repetidas dos encaixes. Uma forma de a evitar \u00e9 utilizar as curvas tens\u00e3o-n\u00famero de ciclos, tamb\u00e9m conhecidas como curvas S-N, na sele\u00e7\u00e3o de materiais.<\/li>\n\n\n\n
  • Arrepio:<\/em><\/strong> Com o tempo, o pl\u00e1stico sucumbe naturalmente \u00e0 deforma\u00e7\u00e3o sob carga sustentada, o que enfraquecer\u00e1 o encaixe. Por conseguinte, \u00e9 essencial utilizar materiais resistentes \u00e0 deforma\u00e7\u00e3o, como o polibutileno tereftalato, um pl\u00e1stico de engenharia forte e semi-cristalino, ou outros pl\u00e1sticos refor\u00e7ados para a produ\u00e7\u00e3o de encaixes. Para este projeto de fabrico da caixa do apoio de bra\u00e7o da consola central, a First Mold optou por uma mistura de acrilonitrilo butadieno-estireno (ABS), que possui elevada for\u00e7a, rigidez e resist\u00eancia ao calor, e policarbonato (PC). O material h\u00edbrido oferece um equil\u00edbrio superior de durabilidade, dureza e desempenho t\u00e9rmico.<\/li>\n<\/ul>\n\n\n\n

    Desafios de compatibilidade de montagem de pe\u00e7as do apoio de bra\u00e7o da consola central<\/h3>\n\n\n\n

    A facilidade de montagem de um projeto de encaixe depender\u00e1 da rela\u00e7\u00e3o entre as pe\u00e7as de encaixe. Elementos de design como as dimens\u00f5es do encaixe, a folga de encaixe, a perpendicularidade dos postes de montagem e a toler\u00e2ncia determinar\u00e3o o funcionamento correto das pe\u00e7as.<\/p>\n\n\n\n

      \n
    • Dimens\u00f5es de encaixe:<\/em><\/strong> As duas pe\u00e7as de contacto devem ter dimens\u00f5es precisas e ser feitas de materiais flex\u00edveis. Isto permite que as duas metades se deformem temporariamente durante a montagem e recuperem a sua forma original para criar uma liga\u00e7\u00e3o estanque. A dimens\u00e3o correta garante uma resist\u00eancia adequada.<\/li>\n\n\n\n
    • Folga de ajuste:<\/em><\/strong> Este \u00e9 o espa\u00e7o entre as pe\u00e7as de contacto. O ajuste de folga inclui um espa\u00e7o significativo entre as duas pe\u00e7as, o que facilita a montagem. Por outro lado, um encaixe por interfer\u00eancia ou por press\u00e3o \u00e9 utilizado para criar uma junta mais forte e semi-permanente. Num encaixe por press\u00e3o, as pe\u00e7as s\u00e3o maiores do que os orif\u00edcios onde encaixam e requerem algum grau de for\u00e7a para serem montadas.<\/li>\n\n\n\n
    • Perpendicularidade dos postes de fixa\u00e7\u00e3o:<\/em><\/strong> Para garantir que as pe\u00e7as de encaixe encaixam corretamente, os postes de montagem devem formar um \u00e2ngulo preciso de 90 graus com a superf\u00edcie da base. Isto permite-lhes assentar de forma plana na superf\u00edcie e evitar a introdu\u00e7\u00e3o de tens\u00f5es ou desalinhamentos.<\/li>\n\n\n\n
    • Toler\u00e2ncia:<\/em><\/strong> Esta \u00e9 a varia\u00e7\u00e3o permitida nas dimens\u00f5es da pe\u00e7a. Nenhum processo de fabrico \u00e9 perfeito. Por isso, as pe\u00e7as ter\u00e3o normalmente pequenas diferen\u00e7as (na maior parte das vezes insignificantes). A toler\u00e2ncia estabelece o limite para as varia\u00e7\u00f5es aceit\u00e1veis que as pe\u00e7as podem ter. Quando as pe\u00e7as est\u00e3o dentro das toler\u00e2ncias aceites, espera-se que sejam montadas e funcionem corretamente. Para este projeto de fabrico de pe\u00e7as para o apoio de bra\u00e7o da consola central, o cliente fixou o limite para as pe\u00e7as em \u00b10,1mm e o limite para o molde em \u00b10,05mm.<\/li>\n<\/ul>\n\n\n\n

      O que os clientes beneficiaram ao trabalhar com a solu\u00e7\u00e3o da First Mold<\/h2>\n\n\n\n

      Devido ao design complexo da caixa do apoio de bra\u00e7o da consola central, a First Mold utilizou o software de simula\u00e7\u00e3o Moldflow para prever antecipadamente o enchimento\/encolhimento do produto. O Moldflow simula a forma como o pol\u00edmero fundido flui para a cavidade do molde e a preenche. Esta simula\u00e7\u00e3o ajuda a identificar armadilhas de ar, disparos curtos, enchimento irregular e linhas de soldadura.<\/p>\n\n\n\n

      O resultado permitiu \u00e0 First Mold otimizar as estruturas deslizantes\/elevadores da ferramenta de moldagem por inje\u00e7\u00e3o da caixa do apoio de bra\u00e7o da consola central. Por exemplo, para evitar o flash do molde, que leva a um aumento do desperd\u00edcio de material e a um acabamento secund\u00e1rio mais fastidioso, a First Mold assegurou que a folga entre os cursores e os elevadores \u00e9 \u22640,02 mm.<\/p>\n\n\n\n

      Com a ajuda da simula\u00e7\u00e3o virtual, a First Mold conseguiu limitar as tentativas de moldagem experimental a 2-3 vezes. As tentativas repetidas s\u00e3o demoradas e dispendiosas. Com um planeamento adequado e tirando partido das mais recentes tecnologias virtuais, a First Mold conseguiu oferecer ao cliente um melhor valor, em termos de tempo e dinheiro para colocar o produto no mercado mais rapidamente.<\/p>\n\n\n\n

      Implementa\u00e7\u00e3o de um buffer de capacidade de produ\u00e7\u00e3o 20%<\/h3>\n\n\n\n

      Para ajudar o cliente a satisfazer a capacidade de moldagem por inje\u00e7\u00e3o do apoio de bra\u00e7o da consola central, a First Mold utilizou v\u00e1rias m\u00e1quinas de moldagem por inje\u00e7\u00e3o do mesmo modelo. Foi reservada uma capacidade de produ\u00e7\u00e3o m\u00ednima de 20% como reserva.<\/p>\n\n\n\n

      Por outras palavras, se todos os moldes para o fabrico de pe\u00e7as para o apoio de bra\u00e7o da consola central estiverem a trabalhar a uma capacidade de 80%, ir\u00e3o satisfazer a procura atual do cliente. Se todos os moldes estiverem a trabalhar a uma capacidade de 100%, o n\u00famero de pe\u00e7as que ser\u00e3o criadas ser\u00e1 20% superior \u00e0 procura. Este excesso de 20% cria uma reserva para falhas que podem resultar de manuten\u00e7\u00e3o, picos s\u00fabitos de procura e interrup\u00e7\u00f5es inesperadas.<\/p>\n\n\n\n

      A capacidade de produ\u00e7\u00e3o adicional de 20% tamb\u00e9m pode ser \u00fatil para testar novos materiais sem afetar negativamente as linhas de produ\u00e7\u00e3o.<\/p>\n\n\n\n

      Documenta\u00e7\u00e3o do processo de aprova\u00e7\u00e3o de pe\u00e7as de produ\u00e7\u00e3o<\/h3>\n\n\n\n

      A First Mold opera ao abrigo do sistema de certifica\u00e7\u00e3o IATF 16949 e fornece documenta\u00e7\u00e3o PPAP. Esta documenta\u00e7\u00e3o demonstra que as ferramentas de moldagem por inje\u00e7\u00e3o do apoio de bra\u00e7o da consola central que fornecemos cumprem consistentemente os requisitos t\u00e9cnicos e de qualidade das pe\u00e7as do apoio de bra\u00e7o da consola central do cliente.<\/p>\n\n\n\n

      \"Conce\u00e7\u00e3o<\/figure>\n\n\n\n

      FAQ<\/h2>\n\n\n\n
      O primeiro molde pode incluir grava\u00e7\u00e3o na ferramenta de fabrico de pe\u00e7as do apoio de bra\u00e7o da consola central?<\/strong>

      A First Mold pode incluir texturas na cavidade do molde, utilizando t\u00e9cnicas de maquina\u00e7\u00e3o CNC de alta precis\u00e3o, sem comprometer a sua exatid\u00e3o dimensional. O molde \u00e9 submetido a meticulosos testes de garantia de qualidade e tratamento para assegurar que cumpre os requisitos de funcionalidade do cliente.<\/p> <\/div>

      Como \u00e9 que a First Mold evita defeitos comuns em pe\u00e7as finas do compartimento do apoio de bra\u00e7o da consola central?<\/strong>

      A First Mold baseia-se em software de simula\u00e7\u00e3o avan\u00e7ado, na otimiza\u00e7\u00e3o dos par\u00e2metros do processo de moldagem e na implementa\u00e7\u00e3o de medidas robustas de controlo de qualidade para garantir que os moldes fornecem pe\u00e7as consistentes e de alta qualidade. <\/p> <\/div> <\/div>","protected":false},"excerpt":{"rendered":"

      Este estudo de caso apresenta as necessidades, os desafios e as solu\u00e7\u00f5es comuns dos clientes na produ\u00e7\u00e3o de bases para apoios de bra\u00e7os para autom\u00f3veis.<\/p>","protected":false},"author":2,"featured_media":22088,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"case-study-category":[66],"case-study-tag":[75],"class_list":["post-22087","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","case-study-category-injection-molding-cases","case-study-tag-consumer-electronic"],"acf":{"photo_gallery":{"case_study_gallery":[[{"id":22090,"title":"The appearance surface of the armrest must have a certain degree of smoothness","caption":"The appearance surface of the armrest must have a certain degree of 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