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<p>The aim of this thesis is to increase the understanding of wear in rolling/sliding contacts such as the wheel-rail contact for railroads and the roller-washer contact for roller bearings.</p><p>The Stockholm commuter train network has been the subject of papers A and B in this thesis in which the wear and surface cracks on rails has been observed for a period of three years. By comparing the wear depth with the crack length, equilibrium between these two damage mechanisms was found for a lubricated rail. By using a lubricant with friction modifiers the stresses was low enough to prevent crack propagation; at the same time, the rail was hard enough to reduce the wear rate. This is probably the most favourable state in terms of rail maintenance cost.</p><p>Roller bearings subjected to lubricant borne particles have been the subject of papers C, D and E in this thesis. Particles in the lubricating oil can have a significant impact on the wear in lubricated contacts. Even at low concentration levels can self-generated particles cause significant wear. The here presented results shows that filtration during run-in can significantly reduce both the mass loss and the number of self generated particles. A series of experiments has been carried out to study the wear of roller bearings by ingested lubricant borne hard particles. The form of the worn profile and the length of wear scratches correspond closely to the sliding within the contact. A count of the number of wear scratches on the rolling element surface indicates that the contact concentrates particles. A novel wear model based on the observation of a single point on the contacting surface when a concentration of particles passes through it has been developed and the necessary data for the model has been determined from the experiments. Comparison of the simulation results with the experimental results shows good qualitative agreement for the form change of the washer surfaces.</p>

<p>Several industrial sectors experience an increased reliance on mechatronic systems as electronics and software are being embedded into the traditional mechanical systems of these industries. Important challenges within mechatronics engineering comes from management of multi-disciplinary development project teams and the highly complex scope of problems, which in turn require extensive coordination and integration, both in terms of technical and organisational matters. </p><p>The concept of cross-functional integration in product development research has in previous research mainly addressed integration of the functions marketing, R&D, and manufacturing, and whereas the present thesis is delimited to include only the R&D organization and the functions and engineering disciplines within such an organization. </p><p>The purpose with thesis has been to investigate mechatronics engineering in order to understand and explain how co-operation, integration, and knowledge sharing between engineering disciplines can be supported. </p><p>This research has been realized by empirical studies in mechatronic development settings in engineering companies, but also by taking part in industrial and academic research projects that develop and study computer-aided mechatronics engineering. </p><p>Findings presented in this thesis show that mechatronics is a matter of integration at three organizational levels where the most substantial needs are found to be at the team-level and the individual level. Furthermore, it is identified that to be able to succeed in mechatronics engineering, managers and engineers must look beyond disciplinary needs. Subsequently, both teamwork and competence management become key issues for management of mechatronics engineering. Finally, computer-supported and model-based development of mechatronics show great potential for successful integration of engineering disciplines, even though such technological aids are still rather immature and needs further research and development. A tentative analysis model of organizational integration for mechatronics engineering is also presented and discussed in this thesis. </p><p>Based on the presented findings, it is concluded that companies incorporating electronics and software in their mechanical products must effectively manage software and electronics development of these embedded systems. Despite the focus on cross-functional integration in engineering companies, this thesis shows examples of inadequate integration of software and electronics engineering with mechanical integration in organisations dominated by the latter. </p><p>Future research studies are needed to investigate the relation between factors influencing the need for organizational integration and potential integration mechanisms. To further understand mechatronics engineering it is important to look deeper into research issues such as changed conditions for the engineering profession implied by multidisciplinary settings, social systems supporting integration of disciplines, changed work conditions due to implementation of technological aids for model-based system development, relationship between product and organizational complexity, organizational designs supporting integration of engineering disciplines, and cross-disciplinary training of highly specialized engineers.</p>

<p>The number of electric powered sub-systems in road-vehicles is increasing fast. This development is primarily driven by the new and improved functionality that can be implemented with electro-mechanical sub-systems, but it is also necessary for the transition to electric and hybrid-electric drive trains.</p><p>An electromechanical sub-system can be implemented as a physically integrated mechatronic module: controller, power electronics, electric motor, transmission and sensors, all integrated into one component. A mechatronic module, spans, as all mechatronic systems, over several closely coupled engineering disciplines: mechanics, electronics, electro-mechanics, control theory and computer science. In order to design and optimize a mechatronic system it is therefore desirable to design the system within all domains concurrently. Optimizing each domain or component separately will not result in the optimal system design. Furthermore, the very large production volumes of automotive sub-systems increase the freedom in the mechatronics design process. Instead of being limited to the selection from off-the shelf components, application specific components may be designed.</p><p>The research presented in this thesis aims at development of an integrated design and optimization methodology for mechatronic modules. The target of the methodology is the conceptual design phase, where the number of design parameters is relatively small. So far, the focus has been on design methods for the electric motor and gearhead, two of the most important components in an actuation module. The thesis presents two methods for design and optimization of motor and gearhead in mechatronic applications. One discrete method, intended for the selection of off-the-shelf components, and one method mainly intended for high volume applications where new application specific components may be designed. Both methods can handle any type of load combination, which is important in mechatronic systems, where the load seldom can be classified as pure inertial or constant speed.</p><p>Furthermore, design models relating spur gear weight, size and inertia to output torque and gear ratio are presented. It is shown that a gearhead has significantly lower inertia and weight than a motor. The results indicate that it almost always is favorable from a weight and size perspective to use a gearhead. A direct drive configuration may only be lighter for very high speed applications. The main contribution of this thesis is however the motor/gear ratio sizing methods that can be applied to any electromechanical actuation system that requires rotational motion.</p>

<p>The aim is to share experience gained when simulating (and doing measurements on) the turbocharged SI-engine as well as describing the limits of current state of the technology. In addition an overview of current boosting systems is provided.</p><p>The target readers of this text are engineers employed in the engine industry as well as academia who will get in contact, or is experienced, with 1D engine performance simulation and/or boosting systems. Therefore the text requires general knowledge about engines.</p><p>The papers included in the thesis are, in reverse chronological order:</p><p>[8] SAE 2005-XX-XXX Calculation accuracy of pulsating flow through the turbine of SI-engine turbochargers - Part 2 Measurements, simulation correlations and conclusions Westin & Ångström</p><p>To be submitted to the 2005 SAE Powertrain and Fluid Systems Conference in San Antonio</p><p>[7] SAE 2005-01-2113 Optimization of Turbocharged Engines’ Transient Response with Application on a Formula SAE / Student engine Westin & Ångström</p><p>Approved for publication at the 2005 SAE Spring Fuels and Lubricants Meeting in Rio de Janeiro</p><p>[6] SAE 2005-01-0222 Calculation accuracy of pulsating flow through the turbine of SI-engine turbochargers - Part 1 Calculations for choice of turbines with different flow characteristics Westin & Ångström</p><p>Published at the 2005 SAE World Congress in Detroit April 11-14, 2005</p><p>[5] SAE 2004-01-0996 Heat Losses from the Turbine of a Turbocharged SI-Engine – Measurements and Simulation Westin, Rosenqvist & Ångström</p><p>Presented at the 2004 SAE World Congress in Detroit March 8-11, 2004</p><p>[4] SAE 2003-01-3124 Simulation of a turbocharged SI-engine with two software and comparison with measured data Westin & Ångström</p><p>Presented at the 2003 SAE Powertrain and Fluid Systems Conference in Pittsburgh</p><p>[3] SIA C06 Correlation between engine simulations and measured data - experiences gained with 1D-simulations of turbocharged SI-engines Westin, Elmqvist & Ångström</p><p>Presented at the SIA International Congress SIMULATION, as essential tool for risk management in industrial product development in Poissy, Paris September 17-18 2003</p><p>[2] IMechE C602/029/2002 A method of investigating the on-engine turbine efficiency combining experiments and modelling Westin & Ångström</p><p>Presented at the 7th International Conference on Turbochargers and Turbocharging in London 14-15 May, 2002</p><p>[1] SAE 2000-01-2840 The Influence of Residual Gases on Knock in Turbocharged SI-Engines Westin, Grandin & Ångström</p><p>Presented at the SAE International Fall Fuels and Lubricants Meeting in Baltimore October 16-19, 2000</p><p>The first step in the investigation about the simulation accuracy was to model the engine as accurately as possible and to correlate it against as accurate measurements as possible. That work is covered in the chapters 3 and 5 and in paper no. 3 in the list above. The scientific contribution here is to isolate the main inaccuracy to the simulation of turbine efficiency.</p><p>In order to have anything to compare the simulated turbine efficiency against, a method was developed that enables calculation of the CA-resolved on-engine turbine efficiency from measured data, with a little support from a few simulated properties. That work was published in papers 2 and 8 and is the main scope of chapter 6 in the thesis. The scientific contributions here are several:</p><p>· The application on a running SI-engine is a first</p><p>· It was proven that CA-resolution is absolutely necessary in order to have a physically and mathematically valid expression for the turbine efficiency. A new definition of the time-varying efficiency is developed.</p><p>· It tests an approach to cover possible mass accumulation in the turbine housing</p><p>· It reveals that the common method for incorporating bearing losses, a constant mechanical efficiency, is too crude.</p><p>The next step was to investigate if different commercial codes differ in the results, even though they use equal theoretical foundation. That work is presented in chapter 4, which corresponds to paper 4. This work has given useful input to the industry in the process of choosing simulation tools.</p><p>The next theory to test was if heat losses were a major reason for the simulation accuracy. The scientific contribution in this part of the work was a model for the heat transport within the turbocharger that was developed, calibrated and incorporated in the simulations. It was concluded that heat losses only contributed to a minor part of the inaccuracy, but that is was a major reason for a common simulation error of the turbine outlet temperature, which is very important when trying to simulate catalyst light off. This work was published in paper 5 and is covered in chapter 7.</p><p>Chapter 8, and papers 6 and 8, covers the last investigation of this work. It is a broad study where the impact of design changes of both manifold at turbines on both simulation accuracy as well as engine performance. The scientific contribution here is that the common theory that the simulation inaccuracy is proportional to the pulsation amplitude of the flow is non-valid. It was shown that the reaction was of minor importance for the efficiency of the turbine in the pulsating engine environment. Furthermore it presents a method to calculate internal flow properties in the turbine, by use of a steady-flow design software in a quasi-steady procedure. Of more direct use for the industry is important information of how to design the manifolds as well as it sheds more light on how the turbine works under unsteady flow, for instance that the throat area is the single most important property of the turbine and that the system has a far larger sensitivity to this parameter than to any other design parameters of the turbine. Furthermore it was proven that the variation among individual turbines is of minor importance, and that the simulation error was of similar magnitude for different turbine manufacturers.</p><p>Paper 7, and chapter 9, cover a simulation exercise where the transient performance of turbocharged engines is optimised with help from factorials. It sorts out the relative importance of several design parameters of turbocharged engines and gives the industry important information of where to put the majority of the work in order to maximize the efficiency in the optimisation process.</p><p>Overall, the work presented in this thesis has established a method for calibration of models to measured data in a sequence that makes the process efficient and accurate. It has been shown that use of controllers in this process can save time and effort tenfold or more.</p><p>When designing turbocharged engines the residual gas is a very important factor. It affects both knock sensitivity and the volumetric efficiency. The flow in the cylinder is in its nature of more dimensions than one and is therefore not physically modelled in 1D codes. It is modelled through models of perfect mixing or perfect displacement, or at a certain mix between them. Before the actual project started, the amount of residual gases in an engine was measured and it’s influence on knock was established and quantified. This was the scope of paper 1. This information has been useful when interpreting the model results throughout the entire work.</p>

<p>Given a special focus on Design for Environment (DfE) methods and tools, the objectives of this thesis are to, <i>“Identify basic design-related requirements that a method or tool should fulfill in order to become actively used by engineering designers”</i>, and to <i>“Investigate how those basic requirements could be used to make DfE methods and tools more actively used in industry among engineering designers”</i>.</p><p>The research has shown that designers in general have three main purposes for utilizing methods and tools, of which the last two could be seen as subsets of the first one. The purposes are to: (1) <i>facilitate various kinds of communication within the product development process;</i> (2)<i> integrate knowledge and experience into the methods and tools as a know-how backup;</i> and (3) contribute with structure in the product development process. The low degree of follow-up implies a risk that methods and tools are used that affect the work within the company in a negative way. In order to be able to better follow-up methods and tools regarding both their utilization and usefulness, there is a need for a better definition of requirements for methods and tools.</p><p>Most of all designers’ related requirements are related to their’ aims to fulfill the product performance and keep down the development time. This can be concluded as four major requirements, that a DfE method or tool, as well as a common method or tool, must exhibit: (1)<i> be easy to adopt and implement, </i>(2)<i> facilitate designers to fulfill specified requirements on the presumptive produc</i>t, and at the same time (3) <i>reduce the risk that important elements in the product development phase are forgotten</i>. Both these two latter requirements relate to a method or tool’s degree of appropriateness. The second and the third requirements are related to the fourth requirement, which is found to be the most important: that the use of the method or tool (4)<i> must reduce the total calendar time (from start to end) to solve the task.</i> The conclusion is that DfE methods and tools must be designed to comply to a higher degree with the main users - in this case the designers’ requirements for methods and tools</p>

<p>Powder compaction is a production method commonly used in the manufacturing industry today. In order to minimize costly experiments and to optimize serial production of details several methods to analyze the powder compaction process are developed and used. One method is to use micromechanical analysis where the local description of contact between two individual particles is of great importance. In this dissertation a visco-plastic contact law has been used and further developed in order to understand the powder compaction process at packing, low relative density compaction up to high relative density compaction.</p><p>In order to relax some assumptions from previous theoretical studies simulation with the discrete element method (DEM) was performed. Up to 10.000 spherical particles were used in packing and early compaction simulation. It was found that rearrangement of particles is one of the major densification mechanisms in the early phases of compaction. At die compaction this effect of rearrangement was shown to be more pronounced than predicted from theoretical analyses. It was also found that the size ratio of particles is of importance when the number fraction of small particles in the compound is high.</p><p>The finite element method has been used for numerical analyses to investigate the local contact problem between two particles when self-similarity no longer prevail. Based on the numerical results a suggestion for an approximate compliance relation was made. With this approximate formula the local compliance behaviour between two dissimilar particles was analysed. These findings are directly applicable to simulations with the discrete element method. Finally, an investigation using the finite element method to evaluate the range of the accuracy for theoretical and approximate compliance formula has been done with compounds of different regular lattices. It was found that the range of accuracy is much dependent on the number of contacts within the lattices, specially new forming contacts during the compaction.</p>

<p>This study focuses on the wear of piston rings in a hydraulic radial piston motor. The piston ring has to satisfy increasing demands for reliability and longer service life. It has two contacting surfaces, the face and the flank, and operates under a boundary lubrication state.</p><p>This first part of the project aimed to detect and characterise piston ring wear. Measurement by weighing gives an overall value for wear defined as loss of mass. Two-dimensional form and surface roughness measurements show the distribution of wear on the piston ring face in contact with the cylinder bore and the piston ring flank in contact with the piston groove. Three-dimensional analyses, both quantitative and qualitative, allow the wear mechanisms to be identified.</p><p>The wear of piston rings from an actual hydraulic motor was characterised. As well, rig testing was performed in two different test rig set-ups, one simulating the sliding movement of the piston ring and the other the tilting movement at the end of the strokes. Wear during the running-in period was investigated, and the findings indicate that the period when this takes place is of short duration. In the long term, mild wear makes the surfaces smoother than they were when new, resulting in a very low wear coefficient. Significant levels of wear were measured on both contacting surfaces of the piston ring. In cases in which the flank exhibits more wear than the face, the wear on the flank can be reduced by proper design of the piston groove.</p><p>The second part of the project aimed to evaluate use of a textured surface for the cylinder bore counter surface and a coated surface for the piston ring. Three modelling experiments were performed to characterise the friction and wear properties under lean boundary lubrication conditions. Under such conditions, textured surfaces have the advantage of retaining more lubricant and supplying it over a longer time. Stable friction was also a distinctive feature of the textured surface. Use of a coating could also possibly reduce the amount of wear. Though a smooth surface, like a polished one, is hard to beat for a working texture, a coated surface is far ahead of a smooth uncoated one. Different manufactured and commonly used cylinder bore surfaces, including textured ones, were evaluated in the sliding movement test rig. That allowed favourable wear properties, such as lowest wear coefficient, to be determined with the use of a roller burnished surface.</p><p>A final part of the research involved simulating wear on the piston ring face throughout the entire service life of a hydraulic motor. This allowed us to determine the roles of surface roughness and coating in prolonging service life and achieving acceptable and secure piston ring operation. The model is simple and realistic, but still needs to be refined so as to correspond even better to reality.</p>

<p>Because of increasing environmental demands, especially on dealing with products end of life phase, product manufacturers and designers must consider the future disposal of their products. For conventional materials like steel and aluminium well-functioning recycling methods exists. This is not the case for structures of polymer composites, which are used more extensively, especially for structures like vehicles and vessels. Several techniques do exist but they are not yet commercially available. The current disposal methods of polymer composites are landfill and incineration.</p><p>Polymer composites are materials, which consist of several materials like fibre, matrix, and additives. In the form of sandwich constructions also foam core material is added. This circumstance complicates the waste treatment of composite materials. In this thesis a model for assessing possible future waste treatment techniques for polymer composites including sandwich structures is presented. The model is meant to be used as an aid for preparing future disposal for end of life products for planning waste treatment and for facilitating communication in contacts with waste receivers.</p><p>Recommendations for waste treatment have been formed for a number of polymer composites. These recommendations are based on the analysis of costs and environmental effects and they compare different scenarios for mechanical material recycling and energy recovery by waste incineration. The result of this study points out material recycling as the preferable method for the main part of the studied materials. But this recommendation is strongly dependent on type of virgin material replaced by the recycled material. Energy recovery can also be considered if the polymer composite waste replaces coal, which is non renewable. Though incineration will always result in a cost for the waste producer.</p><p>In the recommendations mentioned above no information concerning implementation of the different waste disposal techniques is included. Therefore, in this study a model for assessing possible waste disposal techniques for polymer composites is presented. The model is based on internal factors, which are related to the waste and to the processes. To implement the model relevant waste properties must be identified in order to fulfil the conditions set by the required processes involved.</p><p>A case study was carried out using the proposed model for assessing different waste disposal techniques for the hull of the Visby Class Corvette in the Royal Swedish Navy. Six different techniques were studied for the hull structure. Since almost all the important waste properties were known and the waste was assessed to be treatable all the included techniques except one are shown to be usable in the future.</p><p>Many investigations have pointed out material recycling as the best alternative considering environmental effects. This is also valid for polymer composite materials. Since recycling polymer composites is a complicated process, especially recycling thermoset composite it is important to aquire comprehensive information about the constituents of these materials.</p>