This study calculate the frictional temperature of the dissimilar metal pair by theoretical analysis. Analyze the frictional temperature rise at interface dividing into the flash temperature rise and the bulk temperature rise. According the frictional temperature rise, establish the model of the temperature rise at the first cycle and the quasi-steady state cycle. And then discuss the condition of asperity contact by the measurement of experimental temperature rise. In the bulk temperature rise and the flash temperature rise, compare with the exact solution, the approximate solution of the average temperature rise that we derived have little error in specific range of Peclet number. Combine the approximate solution of the bulk temperature rise and the flash temperature rise to calculate the temperature rise of asperity contact at rubbing interface. We can evaluate the average contact length of asperity by measured values.

O desgaste de anéis de pistão e cilindro foi modelado através de um programa computacional que calcula as pressões hidrodinâmicas e de contato rugoso agindo nas superficies deslizantes de contato. Os valores previstos de desgaste são comparados com um ensaio em dinamometro de um motor diesel. / The wear of piston rings and cylinder liner was modelled through a computer code that calculates the hydrodynamic and roughness contact pressures acting in the contact surfaces. The predicted wear is compared with a 750 hours dynamometer test of a medium duty diesel engine

O desgaste de anéis de pistão e cilindro foi modelado através de um programa computacional que calcula as pressões hidrodinâmicas e de contato rugoso agindo nas superficies deslizantes de contato. Os valores previstos de desgaste são comparados com um ensaio em dinamometro de um motor diesel. / The wear of piston rings and cylinder liner was modelled through a computer code that calculates the hydrodynamic and roughness contact pressures acting in the contact surfaces. The predicted wear is compared with a 750 hours dynamometer test of a medium duty diesel engine

Rolling contact fatigue is a damage process that may arise in mechanical applications with repeated rolling contacts. Some examples are: gears; cams; bearings; rail/wheel contacts. The resulting damage is often visible with the naked eye as millimeter sized surface craters. The surface craters are here denoted spalls and the gear contact served as a case study. The work focused on the asperity point load mechanism for initiation of spalls. It was found that the stresses at asperity level may be large enough to initiate surface cracking, especially if the complete stress cycle was accounted for. The gear contact is often treated as a cylindrical contact. The thesis contains experimental and numerical results connected to rolling contact fatigue of cylindrical contacts. At the outset a stationary cylindrical contact was studied experimentally. The stationary test procedure was used instead of a rolling contact. In this way the number of contact parameters was minimized. The cylindrical contact resulted in four different contact fatigue cracks. The two cracks that appeared first initiated below the contact. The other two cracks developed at the contact surface when the number of load cycles and the contact load increased. The influence of a surface irregularity (asperity) was studied numerically with the Finite Element Method (FEM). Firstly, the stationary contact was modelled and investigated numerically. At the cylindrical contact boundary a single axisymmetric was included. The partially loaded asperity introduced a tensile surface stress, which seen from the asperity centre was radially directed. Secondly, FE simulations were performed where a single axisymmetric asperity was over-rolled by a cylindrical contact. The simulations were performed for pure rolling and rolling with slip. For both situations, tensile forward directed stresses in front of the asperity were found. The presence of slip and a surface traction greatly increased the stresses in front of the asperity. Finally, when rolling started from rest with applied slip, the distance to steady-state rolling was determined for elastic similar cylindrical rollers. / QC 20100702

Numerical modeling of fluid flow and dissolved species transport in the subsurface is a challenging task, given variability and measurement uncertainty in the physical properties of the rock, the complexities of multi-fluid interaction, and limited computational resources. Nonetheless, this thesis seeks to expand our modeling capabilities in the context of contaminant hydrogeology. We describe the numerical simulator CompFlow Bio and use it to model invasion of a nonaqueous phase liquid (NAPL) contaminant through the vadose zone and below the water table in a fractured porous rock. CompFlow Bio is a three-phase, multicomponent, deterministic numerical model for fluid flow and dissolved species transport; it includes capillary pressure and equilibrium partitioning relationships. We have augmented the model to include randomly generated, axis-aligned, discrete fracture networks (DFNs). The DFN is coupled with the porous medium (PM) to form a single continuum. The domain is discretized using a finite-volume scheme in an unstructured mesh of rectilinear control volumes (CVs). Herein we present the governing equations, unstructured mesh creation scheme, algebraic development of fracture intersection CV elimination, and coupling of PM CVs over a fracture plane to permit asperity contact bridged flow. We include: small scale two-phase water-air and NAPL-water simulations to validate the practice of intersection CV elimination; small scale simulations with water-air, NAPL-water, and NAPL-water-air systems in a grid refinement exercise and to demonstrate the effect of asperity contact bridged flow; intermediate scale 3D simulations of NAPL invading the saturated zone, based on the Smithville, Ontario, site; intermediate scale 2D and 3D simulations of NAPL invading the vadose zone and saturated zone with transient recharge, based on the Santa Susana Field Laboratory site, California. Our findings indicate that: the formulation provides a practical and satisfactory way of modeling three-phase flow in discretely fractured porous rock; numerical error caused by spatial discretization manifests itself as several biases in physical flow processes; that asperity contact is important in establishing target water saturation conditions in the vadose zone; and simulation results are sensitive to relative permeability-saturation-capillary pressure relationships. We suggest a number of enhancements to CompFlow Bio to overcome certain computational limitations.

Numerical modeling of fluid flow and dissolved species transport in the subsurface is a challenging task, given variability and measurement uncertainty in the physical properties of the rock, the complexities of multi-fluid interaction, and limited computational resources. Nonetheless, this thesis seeks to expand our modeling capabilities in the context of contaminant hydrogeology. We describe the numerical simulator CompFlow Bio and use it to model invasion of a nonaqueous phase liquid (NAPL) contaminant through the vadose zone and below the water table in a fractured porous rock. CompFlow Bio is a three-phase, multicomponent, deterministic numerical model for fluid flow and dissolved species transport; it includes capillary pressure and equilibrium partitioning relationships. We have augmented the model to include randomly generated, axis-aligned, discrete fracture networks (DFNs). The DFN is coupled with the porous medium (PM) to form a single continuum. The domain is discretized using a finite-volume scheme in an unstructured mesh of rectilinear control volumes (CVs). Herein we present the governing equations, unstructured mesh creation scheme, algebraic development of fracture intersection CV elimination, and coupling of PM CVs over a fracture plane to permit asperity contact bridged flow. We include: small scale two-phase water-air and NAPL-water simulations to validate the practice of intersection CV elimination; small scale simulations with water-air, NAPL-water, and NAPL-water-air systems in a grid refinement exercise and to demonstrate the effect of asperity contact bridged flow; intermediate scale 3D simulations of NAPL invading the saturated zone, based on the Smithville, Ontario, site; intermediate scale 2D and 3D simulations of NAPL invading the vadose zone and saturated zone with transient recharge, based on the Santa Susana Field Laboratory site, California. Our findings indicate that: the formulation provides a practical and satisfactory way of modeling three-phase flow in discretely fractured porous rock; numerical error caused by spatial discretization manifests itself as several biases in physical flow processes; that asperity contact is important in establishing target water saturation conditions in the vadose zone; and simulation results are sensitive to relative permeability-saturation-capillary pressure relationships. We suggest a number of enhancements to CompFlow Bio to overcome certain computational limitations.

Surfaces are rough, unless special care is taken to make them atomically smooth. Roughness exists at all scales, and any surface-producing operation affects the roughness in certain degrees, specific to the production process. When two surfaces are brought close to each other, contact is established at many isolated locations. The number and size of these contact islands depend on the applied load, material properties of the surfaces and the nature of roughness. These contact islands affect the tribological properties of the contacting surfaces. The real contact area, which is the sum total of the area of contacting islands, is much smaller than the apparent contact area dictated by the macroscopic geometry of the contacting surfaces. Since the total load is supported by these contact islands, the local contact pressure will be very high, and dependent on the local microscopic geometry of the roughness. Thus understanding the deformation behaviour of the rough surfaces will lead to better understanding of friction and wear properties of the surfaces. In this work, the interaction of these contact islands with each other is studied when two surfaces are in contact and sliding past each other. Asperities can be thought of as basic units of roughness. The geometry and the distribution of heights of asperities can be used to define the roughness. For example, one of the earliest models of roughness is that of hemispherical asperities carrying smaller hemispherical asperities on their back, which in turn carry smaller asperities, and soon. In the present study the asperities are assumed to be of uniform size, shape and distribution. Normal and tangential loading response of these asperities with a rigid indenter is studied through elastic-plastic plane strain finite element studies. As a rigid indenter is loaded onto a surface with a regular array of identical asperities, initial contact is established at a single asperity. The plastic zone is initially confined within the asperity. When the load is increased ,the elastic-plastic boundary moves towards the free surface of the asperity, and the contact pressure decreases. The geometry and spacing are determined when the neighbouring asperities come into contact. The plastic zone in these asperities is constrained, and hence contact pressure sustained by these asperities is larger. As the indentation progresses, more asperities come into contact in a similar way. If a tangential displacement is now applied to the indenter, the von Mises stress contours shift in the direction of indenter displacement. As the tangential displacement increases, the number of asperities in contact with the indenter decreases gradually before reaching a steady sliding state. The tangential sliding force experienced by the indenter arises from two components. One is the frictional resistance between the contacting surfaces and the other is due to the plastic deformation of the substrate. If the surface is completely elastic, it has been seen that the sliding force is purely due to the specified friction coefficient. For the smooth surface, as the subsurface makes the transition from purely elastic to confined plastic zone, plasticity breaks out on the free surface, hence the sliding force increases. For surfaces with asperities, even at very small load, the asperities deform plastically and hence the sliding force is considerably higher. The frictional force is experimentally measured by sliding a spherical indenter on smooth and rough surfaces. These experimental results are qualitatively compared with two dimensional finite element results. It has been observed that for rough surface, sliding force is considerablyhigherthanthesmoothsurface,asisobservedinsimu-lations at lower loads. In contrast to the simulations, the sliding force decreases at higher loads for both the smooth and rough surfaces.

Journal bearings are being used in various locations of an internal combustion engine. They contribute to a large portion of total engine friction and lowering it means a significant contribution to CO2 reduction. Operating under heavy loads, journal bearings are often subject to mixed regime of lubrication where a part of bearing load is carried by asperities. This necessitates accurate modelling of asperities contact in order to get more realistic predication of friction losses in journal bearings contact. The evaluation method at Scania couples 3D confocal measurement of bearings’ surface roughness to a Multi-body Dynamic Analysis of journal bearings lubrication utilizing AVL EXCITE. During running-in, asperity peaks are reduced due to wear caused by metal-to-metal contact resulting in change of bearing surface profile and different contact zones in axial and circumferential direction. The aim of this thesis is to include these different contact zones and run-in wear profile of the bearing to the existing evaluation method at Scania to simulate run-in effects more precisely. Surface measurements were made on a run-in big end bearing surface at edges, center and region after oil hole. From these measurements, using the existing Local Scale Model at Scania, asperity pressure curve and flow factors were obtained, which were used to perform AVL EXCITE big end bearing simulations with multiple surface contact patches. The results show that the inclusion of multiple surface patches and run-in wear profile lead to a significant change in distribution and also magnitude of bearing performance parameters e.g. pressure, friction losses, clearance height. / Glidlager är en av de mest använda komponenterna i motorer. De bidrar till en stor del av motorns totala friktion och en minskning av denna bidrar i hög grad till minskade utsläpp av CO2. Glidlager som arbetar under hög last utsätts ofta för blandfilmssmörjning där en del av lasten bärs av mekanisk kontakt mellan ytornas asperiteter. Detta kräver en noggrann modellering av asperitetskontakter för att få en realistisk prediktion av friktionsförluster i glidlager.Utvärderingsmetoden på Scania kopplar ihop 3D-mätning av lagrets ytfinhet i ett konfokalmikroskåp med en dynamisk tribologiberäkning i MBS-programvaran (Multi Body Simulation) AVL Excite.Under inkörning nöts asperiteterna ner på grund av metallkontakten mellan ytorna vilket påverkar lagerytans profil och ger olika kontaktzoner i axiell och periferiell riktning.Syftet med examensarbetet är att inkludera de olika kontaktzonerna och lagrets profil efter inkörning i Scanias befintliga utvärderingsmetod i syfte att noggrannare kunna simulera inkörning av lagren.Ytfinhetsmätningar utfördes med ett konfoklamikroskop på ett inkört vevlager vid kanterna, i mitten och i närheten av oljehålet.Med hjälp av dessa mätningar och en av Scanias befintliga kontaktmodeller beräknades asperitetstryck och flödesfaktorer vilka användes för att utföra vevlagerberäkningar i AVL Excite med olika kontaktegenskaper i olika regioner.Resultaten visar att införandet av regioner på lagerytan med olika lokala kontaktegenskaper och lagerprofil efter inkörning ger en signifikant förändring av såväl storleken som fördelningen av olika lagerresultat såsom till exempel lagertryck, friktionsförluster och oljefilmstjocklek.

This master’s thesis introduces a slide bearing analysis using the MBS software tool of FEV Virtual Engine, including real surface topography based on 3D roughness measurements. The first half of the thesis gives a brief overview about gasoline combustion engines, slide bearing usage in engines, slide bearing construction and about essential approaches for the characterization of elasto-hydrodynamic behavior. In the second half, the process of model building, rough surface measurement and preparation of analyses are described. At the end of this thesis, the results of the analyses are shown and discussed.