The present study deals with the effects of sparsely distributed three-dimensional elements on two-dimensional (2-D) and three-dimensional (3-D) turbulent boundary layers (TBL) such as those that occur on submarines, ship hulls, etc. This study was achieved in three parts: Part 1 dealt with the cylinders when placed individually in the turbulent boundary layers, thereby considering the effect of a single perturbation on the TBL; Part 2 considered the effects when the same individual elements were placed in a sparse and regular distribution, thus studying the response of the flow to a sequence of perturbations; and in Part 3, the distributions were subjected to 3-D turbulent boundary layers, thus examining the effects of streamwise and spanwise pressure gradients on the same perturbed flows as considered in Part 2. The 3-D turbulent boundary layers were generated by an idealized wing-body junction flow. Detailed 3-velocity-component Laser-Doppler Velocimetry (LDV) and other measurements were carried out to understand and describe the rough-wall flow structure. The measurements include mean velocities, turbulence quantities (Reynolds stresses and triple products), skin friction, surface pressure and oil flow visualizations in 2-D and 3-D rough-wall flows for Reynolds numbers, based on momentum thickness, greater than 7000. Very uniform circular cylindrical roughness elements of 0.38mm, 0.76mm and 1.52mm height (k) were used in square and diagonal patterns, yielding six different roughness geometries of rough-wall surface. For the 2-D rough-wall flows, the roughness Reynolds numbers, based on the element height (k) and the friction velocity, range from 26 to 131. Results for the 2-D rough-wall flows reveal that the velocity-defect law is similar for both smooth and rough surfaces, and the semi-logarithmic velocity-distribution curve is shifted by an amount depending on the height of the roughness element, showing that this amount is a function of roughness Reynolds number and the wall geometry. For the 3-D flows, the data show that the surface pressure gradient is not strongly influenced by the roughness elements. In general, for both 2-D and 3-D rough-wall TBL, the differences between the two roughness patterns (straight and diagonal), as regards the mean velocities and the Reynolds stresses, are limited to about 3 roughness element heights from the wall. The study on single elements revealed that the separated shear layers emanating from the top of the elements form a pair of counter rotating vortices that dominate the downstream flow structure. These vortices, termed as the roughness top vortex structure (RTVS), in conjunction with mean flow, forced over and around the elements, are responsible for the production of large Reynolds stresses in the neighborhood of the element height aft of the elements. When these elements are placed in a distribution, the effects of RTVS are not apparent. The roughness elements create a large region of back flow behind them which is continuously replenished by faster moving fluid flowing through the gaps in the rough-wall. The fluid in the back flow region moves upward as low speed ejections where it collides with the inrushing high speed flow, thus, leading to a strong mixing of shear layers. This is responsible for the generation of large levels of turbulent kinetic energy (TKE) in the vicinity of the element height which is transported, primarily, by turbulent diffusion. As regards the 3-D rough-wall TBL, the effect of flow three-dimensionality is seen in the large skewing of the distributions of mean velocities, Reynolds stresses and TKE, aft of the elements. In general, the regions of large TKE production-rates seem to propagate in the direction of the local velocity vector at the element height. The data-sets also enable the extraction of the turbulent flow structure to better describe the flow physics of these rough-wall turbulent boundary layers. / Ph. D.

A presente tese se refere ao estudo do efeito de uma rugosidade tri-dimensional sobre a evolução de ondas Tollmien-Schlichting (T-S) em uma camada limite do tipo Blasius. Os experimentos foram realizados em condições controladas sobre um aerofólio cujo perfil permitiu a obtenção de uma extensa região de escoamento sem gradiente de pressão. As ondas T-S foram excitadas artificialmente utilizando-se uma fonte pneumática localizada a montante da rugosidade. A interação entre a onda T-S gerada e a rugosidade ocorreu a alguns comprimentos de onda a jusante da fonte. Foi utilizado nos experimentos uma rugosidade com altura oscilatória. A freqüência de oscilação da rugosidade foi aproximadamente 1500 vezes menor do que a freqüência das ondas T-S excitadas. Sendo assim, assumiu-se a rugosidade como sendo estacionária em relação as ondas geradas. A medição do comportamento das ondas de instabilidade bem como o campo de velocidade média do escoamento foram feitas utilizando-se a técnica de anemometria a fio quente. Os resultados obtidos mostram uma amplificação de perturbações em uma pequena faixa de números de onda transversal. Comparações entre os resultados experimentais e os obtidos a partir da teoria de instabilidade secundária da camada limite são apresentadas no trabalho. Essas comparações sugerem que nos experimentos ocorreu a amplificação das perturbações devido a instabilidade secundária do tipo K, ou fundamental. / The current thesis is devoted to a study of the effect of a shallow 3-D roughness element on the evolution of a 2-D Tollmien-Schlichting wave in a Blasius boundary layer. The experiments were carried out under controlled disturbance conditions on an airfoil section which could provide a long run with zero pressure gradient flow. A pneumatically driven slit source was used to introduce the T-S wave upstream of the lower branch of the neutral stability curve. A few wavelengths downstream, the T-S wave interacted with a cylindrical roughness element. The height of the roughness was slowly oscillating in time, which allowed a continuous measurement of the T-S wave response downstream of the roughness. The oscillation frequency was approximately 1500 times lower than the frequency of the Tollmien-Schlichting wave and therefore, behaved as a steady roughness with respect to the T-S wave. Hot wire anemometry was used to measure wall normal profiles of longitudinal velocity and spanwise scans close to the maximum of the eigenfunction of the T-S wave. The oscillation of the roughness and the synchronization of all equipments permitted the use of ensemble average techniques. The experimental results were compared with the boundary layer secondary instability theory. The analysis of the compared results suggests that the disturbances were amplified by a resonance mechanism known as K-type or fundamental.

Este trabalho tem a intenção de contribuir com informações sobre a integridade superficial resultante do processo de torneamento em material endurecido de componentes mecânicos fabricados em aço cementado ABNT 8620 (DIN 21 NiCrMo 2). A análise das tensões residuais do corpo de prova foi experimentalmente conduzida pelo Método do Furo Cego Incremental, no qual um pequeno furo é introduzido na superfície do componente e a deformação aliviada é registrada por meio de extensômetros especiais, e também, pelo método da difração de raios-X. A superfície foi analisada através de parâmetros obtidos do mapeamento tridimensional da topografia superficial com instrumento de interferometria laser. Os parâmetros de rugosidade, selecionados para medição, visaram uma caracterização funcional das superfícies obtidas, tais como capacidade de carga, capacidade de retenção de fluidos lubrificantes e resistência ao desgaste. Também foram executados ensaios metalográficos para avaliar a existência de camadas de material alteradas abaixo da superfície. Os resultados indicaram que o torneamento em material endurecido foi capaz de produzir uma superfície resultante com boa área de contato, boa capacidade de carregamento e razoável capacidade de retenção de fluidos uma vez que nem todos os parâmetros se encontraram na faixa funcional ideal. O torneamento em material endurecido induziu tensão de compressão nas camadas das amostras cementadas, cuja condição original era tensão residual de tração. Não foram detectadas alterações expressivas na camada cementada, principalmente na região limítrofe da área transversal com a superfície devido ao aquecimento e rápido resfriamento imposto pelo processo de usinagem. / The aim of the present work is to provide relevant information regarding the obtained surface integrity during hard turning process of mechanical components manufactured from case hardened steel ABNT 8620 (DIN 21 NiCrMo 2). The sample residual stress analysis has been experimentally conducted by the incremental Blind Hole method, in which a small hole is machined on the surface of the component and the relieved deformation is recorded through special strain gages, and by the X-ray diffraction technique. The surface was examined by parameters obtained from the surface topography three-dimensional mapping with a laser interferometer instrument. The selected roughness parameters analysis intends to have a functional characterization such as bearing capacity, fluid and lubricants retention ability and contact wear resistance. In the search for altered material layers beneath the surface, metallographic studies were carried out. The functional bearing area curve analysis parameters indicated that the resulting surface has a good area contact, good bearing capacity and reasonable ability to fluid retention as the reduced valley depth parameter did not produced negative values for all conditions tested. The hard turnig process was able to add compression residual stress condition at the surface, and no significant changes were found at the case hardened layer due to rapid heating and cooling imposed by the hard turning process.

Este trabalho tem a intenção de contribuir com informações sobre a integridade superficial resultante do processo de torneamento em material endurecido de componentes mecânicos fabricados em aço cementado ABNT 8620 (DIN 21 NiCrMo 2). A análise das tensões residuais do corpo de prova foi experimentalmente conduzida pelo Método do Furo Cego Incremental, no qual um pequeno furo é introduzido na superfície do componente e a deformação aliviada é registrada por meio de extensômetros especiais, e também, pelo método da difração de raios-X. A superfície foi analisada através de parâmetros obtidos do mapeamento tridimensional da topografia superficial com instrumento de interferometria laser. Os parâmetros de rugosidade, selecionados para medição, visaram uma caracterização funcional das superfícies obtidas, tais como capacidade de carga, capacidade de retenção de fluidos lubrificantes e resistência ao desgaste. Também foram executados ensaios metalográficos para avaliar a existência de camadas de material alteradas abaixo da superfície. Os resultados indicaram que o torneamento em material endurecido foi capaz de produzir uma superfície resultante com boa área de contato, boa capacidade de carregamento e razoável capacidade de retenção de fluidos uma vez que nem todos os parâmetros se encontraram na faixa funcional ideal. O torneamento em material endurecido induziu tensão de compressão nas camadas das amostras cementadas, cuja condição original era tensão residual de tração. Não foram detectadas alterações expressivas na camada cementada, principalmente na região limítrofe da área transversal com a superfície devido ao aquecimento e rápido resfriamento imposto pelo processo de usinagem. / The aim of the present work is to provide relevant information regarding the obtained surface integrity during hard turning process of mechanical components manufactured from case hardened steel ABNT 8620 (DIN 21 NiCrMo 2). The sample residual stress analysis has been experimentally conducted by the incremental Blind Hole method, in which a small hole is machined on the surface of the component and the relieved deformation is recorded through special strain gages, and by the X-ray diffraction technique. The surface was examined by parameters obtained from the surface topography three-dimensional mapping with a laser interferometer instrument. The selected roughness parameters analysis intends to have a functional characterization such as bearing capacity, fluid and lubricants retention ability and contact wear resistance. In the search for altered material layers beneath the surface, metallographic studies were carried out. The functional bearing area curve analysis parameters indicated that the resulting surface has a good area contact, good bearing capacity and reasonable ability to fluid retention as the reduced valley depth parameter did not produced negative values for all conditions tested. The hard turnig process was able to add compression residual stress condition at the surface, and no significant changes were found at the case hardened layer due to rapid heating and cooling imposed by the hard turning process.