The link suspension is the most prevailing suspension system for freight wagons in central and western Europe. The system design is simple and has existed for more than 100 years. However, still its characteristics are not fully understood. This thesis emphasizes freight wagon dynamics and comprises three parts: In the first part a review of freight wagon running gear is made. The different suspension systems are described and their advantages and disadvantages are discussed. The review covers the running gear standardized by UIC and the conventional so-called three-piece bogie. Additionally five improved three-piece bogies and twelve novel running gear designs are presented. The second part focuses on the lateral force-displacement characteristics in the link suspension. Results from stationary measurements on freight wagons and laboratory tests of the link suspension characteristics are presented. To improve understanding of the various mechanisms and phenomena in link suspension systems a simulation model is developed. Link suspension systems have strongly nonlinear characteristics including a hysteresis loop. The loop exhibits usually three characteristic sections with different tangential stiffnesses. The actual contact geometry of the links and end bearings has a significant influence on the characteristics. By wear in ordinary service - as well as by geometric tolerances on new components - the contact geometry may deviate considerably from nominal geometry. Further, it seems that elastic deformation in the contact surfaces has considerable effects on the suspension characteristics, in particular on the initial rolling stiffness for small displacements. Also, flexibilities in links and end bearings influence the characteristics. It is also observed that new components after a short period of dynamic testing can exhibit a very low amount of energy dissipation, a phenomenon that is also indicated in some stationary measurements on wagons. To summarize the second part, it appears that the link suspension characteristics are very sensitive to several factors being hard to control in the real world of freight wagon operations. The various stiffnesses and hysteresis loops have a considerable variation and may have a strong influence on the ride qualities of vehicles. As long as the characteristics can not be controlled within closer limits than found in this study, there is a strong need for sensitivity analysis to be made, both in predictive multibody simulations of vehicle dynamics, as well as in verification and acceptance tests. In the third part a study on the possibility to improve ride qualities of freight wagons with link suspensions is presented. Parametric studies with multibody dynamic simulations on freight wagons equipped with link-suspension bogies are performed. The effect of supplementary friction and hydraulic damping is investigated under various running conditions: speed, loading, tangent and curved track, wheel-rail contact geometry, track gauge and track irregularities. Substantial improvements of the lateral running behaviour of wagons with link suspension bogies can be achieved - both at ordinary speeds and at increased speeds - by using a proper combination of supplementary hydraulic dampers. Speeds up to 160 km/h could be realistic.

The general trend toward increased use of computer models and simulations during product development has led to a need for accurate and reliable product models. The function of many products relies on contact interfaces between interacting components. To simulate the behavior of such products, accurate models of both components and interfaces are required. Depending on the purpose of the simulation, interface models of different degrees of complexity are needed. In simulation of very large systems with many interfaces, it might be computationally expensive to integrate detailed models of each individual interface. Condensed models, or abstractions, that describe the interface properties with a minimum of degrees of freedom are therefore required. This thesis deals with mechanical interfaces with an emphasis on friction. In the four appended papers friction models are discussed in terms of condensed models, as well as in terms of more detailed contact models. The aim is to study how friction can be modeled in behavioral simulation of products and to discuss the convenience and relevance of using different types of friction models as building blocks of a system model in behavioral simulations. Paper A presents a review of existing condensed friction models for sliding contacts under different running conditions and discusses the models from both simulation and tribological points of view. In papers B and C a simplified contact model, called the elastic foundation model, is used to model friction in a boundary-lubricated rolling and sliding contact. The model is integrated in a dynamic rigid body model of a mechanical system, the system behavior is simulated, and the result is compared with experimental results. Paper D discusses the application of the elastic foundation model to rough surface contact problems and investigates how the error in the elastic foundation results depends on surface roughness. / QC 20101129

Aortic stenosis is a serious cardiovascular disease that requires urgent attention and surgical intervention. If not treated, aortic stenosis can result in heart attack or cardiac arrest. Transcatheter Aortic Valve Replacement is a surgical technique that is used to treat aortic stenosis. Like all heart surgery, the procedure is difficult to perform and may lead to life-threatening complications. It is therefore important for a surgeon to be able to plan and rehearse the surgery before the operation to minimise risk to the patient. A detailed study was carried out to develop a 3D-printed, improved surgical tool for patient-specific planning and rehearsal of a Transcatheter Aortic Valve Replacement procedure. With this new tool, a cardiologist will be able better to understand a specific patient’s heart geometry and practice the procedure in advance. Computer tomography images were processed using image segmentation software to identify the anatomy of a specific patient’s heart and the surrounding blood vessels. Using materials design concepts, a polymer composite was developed that is able to mimic the mechanical properties of aortic tissue. State-of-art multi-material 3D printing technology was then used to produce a replica aorta with a geometry that matched that of the patient. An artificial aortic valve, identical to the type used in the Transcatheter Aortic valve replacement procedure, was then fitted to the replica aorta and was shown, using a standard test, to be a good fit with no obvious leaks. / Aortastenos är en hjärtsjukdom som får mycket uppmärksamhet och kräver kirurgi på grund av dess katastrofala komplikationer. Den allvarligaste komplikationen av aortastenos är hjärtinfarkt och resulterande hjärtstopp. Transcatheter Aortic Valve Replacement är en kardiovaskulär intervention som erbjuds för patienter med aortastenos. Denna typ av hjärtkirurgi är komplex och kan orsaka livshotande situationer för patienten om något går snett under operationen. Det är därför viktigt för kirurgen att kunna planera ingreppet innan han eller hon utför själva operationen för att minimera fara för patienten. Denna detaljerade studie ämnar utveckla och förbättra det kirurgiska verktyget för preoperativ planering av Transcatheter Aortic Valve Replacement genom 3D- tryckning. Forskningsarbetet kommer att ge kardiologer ett nytt sätt att förstå patientens hjärta i detalj och ett ökat förtroende för att träna på ingreppet på förhand. Datortomografibilder behandlades med hjälp av en bildsegmentationsprogramvara för att kunna skapa en anatomiskt korrekt kopia av patientens hjärta och tillhörande kärl. Genom att applicera material-vetenskapslära kan ett nytt kompositmaterial utvecklas med exakt samma mekaniska egenskaper som naturlig aortavävnad. Den mest moderna 3D-trycktekniken användes sedan för att producera en patientspecifik aorta. En artificiell aortaklaff placerades i den nyproducerade aortamodellen och tester visade en perfekt matchning utan läckage.

Nozzles are used in a wide range of applications. Nevertheless, the geometric of non-circular orifices have not been widely studied. This project has examined fluid jets exiting through a non-circular orifice, in the gravitational direction. Furthermore, its transformation to a circular cross-section due to a surface tension forces. How the length to a circular cross-section changes with the nozzles geometry and bath depth of the tundish was the main focus of this studied. A water model and high-speed camera was used to capture the profile of the fluid jet. Four different nozzles were attached one by one to five different tundishes with different bath depths. The result showed that with deeper bath depths the circular cross-section occurred further down from the nozzles orifice. The length to the circular cross-section also depended on the orifice area, a larger area gave a longer distance than a smaller area. It was shown that the length to circular cross-section followed a quadratic function, when the measured values were analyzed based on the Weber number. The profile of the fluid jet was dependent on the material of the nozzle, the geometries of the orifice, the bath depth and the surface tension.

This thesis project was executed at ABB AB. The purpose of the thesis was to formulate aselection of ionic liquids with different thickeners as greases and experimentally understand thetribological characteristics and electrical properties. The performance of four ionic liquids, 1-Ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (IL6), 1-Butyl-3-methylimidazoliumbis(trifluoromethylsulfonyl)imide (IL2), 1-Hexyl-3-methylimidazoliumbis(trifluoromethylsulfonyl)imide (IL3), and 1-Hexyl-1-methylpyrrolidiniumbis(trifluoromethylsulfonyl)imide (IL4) and two thickeners, polytetrafluoroethylene (PTFE)powder and lithium stearate were evaluated for tribological and electrical properties. Two ionicliquids, 1-Ethyl-3-methylimidazolium dicyanamide, 1-Butyl-3-methylimidazolium dicyanamidefailed to form stable greases due to poor miscibility with the thickeners. Frictional tests for all thecomposed grease were performed and afterwards analyzed with a light optical microscope forassessment of the wear tracks. Electrical conductivity was measured with a contact resistancetest setup. Moreover, the dropping point for the greases was measured to ensure theformulations were qualified as lubricant greases. Ionic liquid greases containing PTFE as athickener show better thermal stability than those containing lithium stearate. In regards to antiwearand friction reduction, the results indicate better tribological properties for the IL3 and IL4with the 25 wt% of PTFE and lithium stearate. The electrical conductivities were similar for allthe ionic liquid grease formulations which were higher than the general purpose grease as thereference. The work has paved the way for further investigation of ionic liquid based greaseswhich show potential in mitigation of bearing current in electric machines.

This thesis provides a way of mapping the temperature development of the tap-changer oil for some different standardized loading cases. The project was in collaboration with Hitachi Energy for one of their production cites situated in Ludvika, Sweden. The software used for the simulation environment was COMSOL 6.1 which is a finite element solver. Heat transfer from the tap-changer oil to the ambience is an important property to understand in order to be able to model the future tap-changers that can withstand harsch working environments. CAD files for the housing of a tap-changer model, as well as a mathematical model for the oil and heat transfer number, was made. Combined with COMSOLS inbuilt physics tools various temperature plots of the oil and housing could be made, following the creation of the user app that was shared with the company. The resulting temperature plots made it is possible to distinguish which models that operates below the temperature limits, and the ones passing the limit can then be adressed accordingly. Since it is a quite simple model, not including the fluidic dynamics of the oil and with a simple geometry, some errors is to be expected. An interesting finding in this project was the change of placement for the maximum temperature for one specific operation cycle. This could be of use for a future thermal management study that could be implemented into other operation cycles.

WC cemented carbides are composites consisting of WC and a binder phase. WC/Co is widely used as cutting tools due to its excellent combination of hardness and toughness. This thesis work was performed at the R&D department of Sandvik Coromant and aimed to find the alternative binder phase to substitute cobalt. Several compositions of Fe-Ni and Fe-Ni-Co binder have been investigated in this study. The WC/Co reference samples were also prepared. The initial compositions were decided by the CALPHAD method. The samples were then produced by the means of powder metallurgy. The producing conditions, especially the sintering conditions, were manipulated to achieve full dense and uniform samples. The samples were analyzed by XRD, LOM, SEM, and EDS. Mechanical properties test has also been performed.The results showed that adjustment on carbon content is necessary to attain desirable structure. Increasing Fe content in the binder tends to make the materials harder. For Fe-Ni and Fe-Ni-Co, the martensitic transformation is essential to the mechanical performance. The induced “transformation toughening” in 72Fe28Ni and 82Fe18Ni binders significantly promoted the toughness. Furthermore, the grain growth inhibition by Fe was confirmed. The relations between sintering temperature, grain size and mechanical properties have been discussed. Compared with the WC/Co references, several compositions showed close and even superior mechanical performance which might provide solutions for the future alternative binder phase.

Two types of shear flows are investigated in this thesis; numerical simulations are performed for the analysis and control of the perturbation arising in a boundary layer over a flat plate, whereas PIV measurements are analysed for the investigation of a confined turbulent jet. Modal structures of the flows are identified: the aim is to understand the flow phenomena and to identify reduced-order models for the feedback control design. The attenuation of three-dimensional wavepackets of streaks and Tollmien-Schlichting (TS) waves in the boundary layer is obtained using feedback control based on arrays of spatially localized sensors and actuators distributed near the rigid wall. In order to tackle the difficulties arising due to the dimension of the discretized Navier-Stokes operator, a reduced-order model is identified, preserving the dynamics between the inputs and the outputs; to this end, approximate balanced truncation is used. Thus, control theory tools can be easily handled using the low-order model. We demonstrate that the energy growth of both TS wavepackets and streak-packets is substantially and efficiently mitigated, using relatively few sensors and actuators. The robustness of the controller is investigated by varying the number of actuators and ensors, the Reynolds number and the pressure gradient. The configuration can be possibly reproduced in experiments, due to the localization of sensing and actuation devices. A complete analysis of a confined turbulent jet is carried out using timeresolved PIV measurements. Proper orthogonal decomposition (POD) modes and Koopman modes are computed and analysed for understanding the main features of the flow. The frequencies related to the dominating mechanisms are identified; the most energetic structures show temporal periodicity. / QC 20110214

Examensarbetet har genomförts inom området produktutveckling på institutionen för ingenjörsvetenskap. Delar av arbetet utfördes på produktionstekniskt centrum (PTC).Examensarbetet innefattar undersökning av den kombinerande användningen av topologioptimering och svetsbaserad additiv tillverkning (WAAM) mot en pendelarm från ett bandsystem. Utifrån arbetets syfte skulle följande frågeställningar besvaras: Hur fungerar topologioptimering och WAAM? Hur genomförs topologioptimering med Autodesk Inventor? Går det kombinera topologioptimering och WAAM på ett effektivt sätt? Måste optimerade objekt justeras manuellt för att kunna produceras i den givna WAAM processen? Vidare sattes ett teoretiskt ramverk på WAAM processen, topologioptimering och FEM-analys för att kunna besvara de frågeställningar som angivits. Detta gjordes med målet att få en djupare förståelse för de olika koncepten och hur de används i praktiken. Tillsammans med uppdragsgivaren studerades den produktionsrigg som användes i arbetet samt sattes hållfasthetskrav, verkande krafter och mått på pendelarmen. När dessa punkter var fastställda påbörjades optimeringsprocessen på pendelarmen vilket gjordes med Autodesk Inventor.Optimeringsprocessen bestod av FEM-analys, topologioptimering samt slutgiltig bearbetning mot WAAM processen. Även en kort genomgång av tillverkningsprocessens beredningsparametrar presenteras. Från arbetets syfte formulerades även tre punkter som beskriver att arbetet skulle resultera i En topologioptimerad och tillverkningsmöjlig pendelarm. Analysering mellan den icke optimerade och den optimerade pendelarmen. En analysering av hur topologioptimeringen och WAAM kombineras med hänsyn till angivna begränsningar och krav. I resultatet analyseras den digitala och fysiska modellen utifrånde angivna punkterna, även optimeringsmetodiken analyseras också utifrån implementeringsförmågan och användarvänligheten. Metoden som används i arbetet visar sig vara mycket användbar vid denna form av optimeringsproblem som innefattar enstaka komponenter av lägre geometrisk komplexitet. Slutligen diskuterades olika aspekter från arbetet och hur eventuell förbättring eller utveckling kan implementeras. En reflekterande slutsats ges också utifrån de frågeställningar som presenterades i arbetets början och hur väl de har besvarats / This Bachelor thesis has been carried out in the field of product development in the Department of Engineering. Parts of the thesis was carried out at the Production Technology Centre (PTC). The thesis includes investigation of the combined use of topology optimization and Wire Arc Additive Manufacturing (WAAM) applied on a linking arm for a track system. Based on the purpose of the work, the following questions will be answered: How do topology optimization and WAAM work? How is topology optimization carried out with AutodeskInventor? Is it possible to combine topology optimization and WAAM effectively? Do optimized objects need to be adjusted manually to be produced in the given WAAM process? Furthermore, a theoretical framework was set for the WAAM process, topology optimization and FEM analysis to be able to answer the questions that have been stated previously. This was done with the aim of gaining a deeper understanding of the different concepts and how they are used in practice. Together with the client, the production rig used in the work was studied and strength requirements, acting forces and dimensions of the linking arm were established. Once these points were established, the optimization process on the linking arm begun, which was done in Autodesk Inventor. The optimization process consisted of FEM analysis, topology optimization and final processing towards the WAAM process. A brief review of the manufacturing process's preparation parameters is also presented. From the purpose of the work, three points were also formulated that describe that the work should result in a topology-optimized and manufacturing-possible linking arm. Analysis between the non optimized and the optimized linking arm. An analysis of how the topology optimization and WAAM are combined with regards to specified limitations and requirements. In the results section, the digital and physical model is analysed based on the specified points, the optimization methodology is also analysed based on the implementation ability and user-friendliness. The method used in the work proves to be very useful in this form of optimization problems which include individual components of lower geometric complexity. Finally, various aspects of the work were discussed and how any improvement or developments can be implemented. A reflective conclusion is given based on the questions presented at the beginning of the work and how well they have been answered.

This thesis explores the formation of segregation and inclusions during solidification of steel and cast iron. A better understanding of the formation mechanism should result in decreasing fraction of defects during solidification of ingot and strand material. Density driven macrosegregation was studied both experimentally and theoretically to see the effect of channel segregation on the total segregation. Formation of these pencil-like segregations is due to natural convection in the solidifying metal caused by liquid enrichment of elements with lower density compared to the bulk. It is suggested to change the composition to compensate for this density difference. Inclusion precipitation can be finite by limitations in segregation. Saturated liquid is found in the last solidified areas, often between dendrites. Here the enrichment of the liquid is possible due to microsegregation. Meanwhile crystals form and solidify the elements with low solubility in the solid is pushed out in the remaining liquid. Soon the liquid is saturated to the level where spontaneous formation of inclusions occurs. Microstructure studies by aid of SEM and micro-probe measurements are analysed to find at what point during solidification process the inclusions start to form. In steel making this formation has a detrimental effect on the mechanical properties in contrary to the production of nodular cast iron where the inclusions have a beneficial effect on the graphite formation. Inoculation of cast iron aims at reaching higher number density of graphite nodules, nodule morphology modification and control of nodule distribution during solidification. Late precipitation of nucleation sites has shown to have a positive impact on preventing chill. To find the most potent inoculation agent different additives were tested. Special effort has been made to analyse the effect of oxides and sulphides as nucleation sites. / QC 20101102