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Abrasive waterjet (AWJ) technology is used in a routine manner in manufacturing industry to cut materials that are difficult to cut by other methods. Whilst the technology for through cutting of materials is mature, the process is also being developed for controlled depth milling (CDM) of materials. The aerospace industry have a requirement to remove redundant material from components manufactured from difficult to machine Ti6Al4V and titanium aluminide alloys and thus reduce component weight. The two main processes available to facilitate this are chemical milling and AWJ-CDM. The two processes have the advantage that they impose negligible forces, thus allowing flexible structures to be processed. However, the process of chemical milling is under threat due to the high costs associated with the disposal of the spent acids. Thus, this research seeks to evaluate the A WJ-CDM process as a replacement for chemical milling for Ti6A14V and titanium aluminide alloys. The magnitude and effect of the process characteristics of chemical milling on fatigue life are well established; however, this is not the case for AJW-CDM. The aerospace industry considers the characteristics of surface roughness, grit embedment and surface morphology to be significant parameters in determining the fatigue life of components manufactured using AJW-CDM. Therefore, before AJW-CDM can be considered a viable alternative, the effect of the process variables on the workpiece characteristics have first to be established. The current research has determined the role of a number of process parameters on the material removal rate, roughness and waviness, grit embedment and surface morphology in the AJW-CDM of Ti6AI4V and titanium aluminide. Nozzle traverse speed and jet impingement angle are shown to govern the operative mechanism of material removal and thus the material removal rate. It is also shown that the surface waviness can be reduced as the traverse speed is increased and as the jet impingement angle is decreased, but it should be noted that waviness increases with number of passes of the jet over the workpiece. The surface roughness is not strongly dependent on traverse speed. Surface waviness and roughness are strongly dependent on jet impingement angle; significant reductions are possible by employing low angle milling techniques. Smaller sized grit leads to a reduction in material removal rate but also to a decrease in both waviness and roughness. It has been demonstrated that grit embedment can be minimised either by milling with a high jet traverse speed at low impingement angles or by low speed milling at jet impingement angles up to 45°in the backward direction only. However, even in the best cases, 5% of the area of a milled surface comprised of embedded grit. Surface morphology can either exhibit directional grooving or cratering, depending upon complex interactions of the various processing parameters. The understanding of the role of various process parameters on the workpiece characteristics will allow the process parameters to be optimised for given requirements. Future work needs to examine the fatigue performance of the AJW-CDM structures, and again optimisation of the processing parameters to maximise fatigue life can be performed. Masking has been employed to provide an economic manufacturing solution for the AJW-CDM process for a specific component. Thus, AJW-CDM has been established as a potential replacement process for chemical milling.

The current work begins by considering a range of common high power ultrasonic components in order to establish a standardised approach to tool design for optimum performance. The vibration behaviour of tuned components resonating longitudinally at ultrasonic frequencies around 35 kHz is modelled via finite element analysis and measured by experimental model analysis. Significant improvements in experimental validation of the models are achieved by the use of a 3D LDV, which allows modal analysis from both in-plane and out-of-plane measurement, which is critical in proposing alternative designs. The vibration characteristics of complex multiple-component systems used in ultrasonic cutting of food products are also investigated. Commonly, the design approach for ultrasonic systems neglects to account for the mutual effects of physically-coupled components in the system vibration. The design of systems also neglects the nonlinear dynamic effects which are inherent in high power systems due to the nonlinearities of piezoelectric transducers. The first issue is tackled by considering the vibration behaviour of the whole system and the influence of individual components and, particularly, offers design improvements via modification of block horns and cutting blade components, which are modelled and validated. The issue of nonlinearity is addresses by identifying the mechanisms of energy leakage into audible frequencies and characterising the common multimodal responses. For this study, design modifications focused on reducing the number of system modes occurring at frequencies below the tuned system frequency. As a consequence of these approaches, insights for the design of multiple-component systems in general are provided.

Les circuits intégrés (CI) de puissance sont utilisés dans les systèmes embarqués automobiles en raison de leur capacité à réunir sur la même puce des dispositifs basse tension et haute tension (HV). Dans de tels systèmes, le bruit de couplage électrique induit par la commutation des étages de puissance est un problème majeur. Pendant la commutation, les tensions et les courants parasites produisent un décalage local de la tension de substrat allant jusqu'à une centaine de millivolt, perturbant ainsi le circuit basse tension. Ces signaux parasites entraînent des dysfonctionnements. Les solutions existantes reposent sur le layout et sont difficiles à optimiser par simulation électrique. L'absence d'une stratégie de modélisation interdit de fait une stratégie de conception s'appuyant sur la prédiction de ces perturbations. Nous présentons ici une méthode d'extraction et de simulation post-layout pour la modélisation des parasites de substrats. Nous avons développé un logiciel (CAO) pour l'extraction du substrat fondé sur la reconnaissance de forme. L'extraction utilise un algorithme de maillage pour la génération du modèle du substrat. Les courants de substrat peuvent être pris en compte lors de la simulation post-layout, autorisant l'analyse des dysfonctionnements éventuels induits par les couplages à travers le substrat. Ce travail a été validé par plusieurs cas d'études industriels, une configuration en miroir de courant, et un test automobile standard en technologie amsHV. Cette méthodologie est aussi appliquée à une technologie HV BCD de STMicroelectronics. Ainsi, en utilisant notre approche, il devient possible de simuler des bruits de substrat avant fabrication. / Smart Power Integrated Circuits (ICs) are intensively used in automotive embedded systems due to their unique capabilities to merge low power and high voltage (HV) devices on the same chip. In such systems, induced electrical coupling noise due to switching of the power stages is a big issue. During switching, parasitic voltages and currents, lead to a local shift of the substrate potential that can reach hundreds of millivolts, and can severely disturb low voltage circuits. Such parasitic signals are known to represent the major cause of failure and costly circuit redesign in power ICs. Most solutions are layout dependent and are thus difficult to optimize using available electrical simulator. The lack for a model strategy prohibits an efficient design strategy and fails at giving clear predictions of perturbations in HV ICs. Here, we present a post-layout extraction and simulation methodology for substrate parasitic modeling. We have developed a Computer-Aided-Design (CAD) tool for substrate extraction from layout patterns. The extraction employs a meshing algorithm for substrate model generation. The behavior of the substrate currents can be taken into account in post-layout simulation, and enables an exhaustive failure analysis due to substrate coupling. Several industrial test cases are considered to validate this work, the interferences of substrate currents in a current mirror configuration, and a standard automotive test in amsHV technology. This methodology is also applied to a HV BCD technology of STMicroelectronics. Eventually, by using the proposed CAD tool, it becomes possible to simulate the behaviors of substrate noises before fabrication.

L’utilisation des plaquettes bois dans le secteur de l’énergie est en pleine croissance depuis les objectifs fixés par le grenelle de l’environnement. Cette utilisation croissante nécessite de plus en plus de matière première ainsi que des matériels de transformation. Ces machines de type déchiqueteuse / broyeur forestier consomme beaucoup d’énergie et dont la principale source est le pétrole. C’est pourquoi cette recherche propose dans un premier temps de définir un moyen d’évaluer la performance énergétique de ces machines puis dans un deuxième temps d’évaluer l’influence des paramètres de coupe sur la performance énergétique. Ce critère est défini comme le rapport entre la tonne de plaquettes sèches et l’énergie consommée par la déchiqueteuse. Il permettra d’évaluer une déchiqueteuse du marché. L’évaluation de la performance énergétique est réalisée en deux endroits distincts de la déchiqueteuse, proche de la coupe et de manière globale. Les différents résultats de l’influence des paramètres de coupe sont présentés afin de caractériser les plus importants dans le but d’une optimisation de la machine étudiée. Cette optimisation a permis de doubler la performance énergétique de la machine. La thèse a également mis en évidence les limites de l’utilisation de certains organes de sécurité réduisant la performance énergétique de 40%. Les différents travaux de recherche doivent permettre d’aider les concepteurs dans le dimensionnement de la source d’énergie nécessaire pour déchiqueter le bois / Consumption of fuelwood, mainly in the form of wood chips, is growing to achieve the goal fixed by the “Grenelle de l’Environment” Laws. Increasing wood chip production needs more and more raw materials and use of wood chippers or shredders is well established. These machines are very energy-consuming particularly in gasoline. First, this thesis presents original methods for measuring chipper performance and focuses on influence of cutting parameters on energy efficiency. Wood chipper energy performance is defined by the ratio between tonnes of dry wood chips and power consumed by the machine to produce them. Using energy efficiency determination method, all wood chippers will be compared and will help customer to choose the machine that consumes the least energy to produce wood chips. Wood chipper performance is measured at two different locations: one closer to the cutting area and the other at the wood chipper drive. The results show that wood chipper performance factor is properly defined and cutting parameters impacts wood chip performance. Cutting optimization halves the chipper fuel consumption to produce the same wood chips quantity. The results also show the limits of safeguard that reduce by 40% chipper performance. This thesis must help designers for developing more efficient machines to reduce their impact on the environment