This report was produced at the request of ABB Robotics and the work was conducted at their facilities in Västerås, Sweden. In the development of industrial robots the structures are slimmed to increase the accuracy and speed. When conducting finite element analysis on the robots the accuracy of the component modelling and definitions of the boundary conditions becomes more important. One such component is the ball bearing which consist of several parts and has a nonlinear behavior where the balls are in contact with the rings. The task given was to develop new methods to model roller bearings in Siemens finite element modelling software NX Nastran. Then conduct a strain measurement, to compare the methods to real experimental values. The goal with the report is to find one or more methods to model roller bearings, with accurate results, that can beused in their development work. The report was conducted by first doing a study on bearings and finite element modeling, and learning to use the software NX Nastran. Then the development of the methods were done by generating ideas for bearing models and testing them on simple structures. Nine methods was produced and a tenth, the method used to model bearings today, was used as a reference. The methods was used to build bearing models in a finite element model of a six axis robot wrist. Simulations were done on the models with different load cases and the results were compared to a strain measurement of the wrists real counterpart. Only six of the models were analyzed in the result, since four of the models returned results that were deemed unusable. When compiling the result data no model was found to accurately recreate the stresses in every load case. Three methods, that allow deformation, performed similarly. One of them is suggested to be used as modelling method in the future. Worst of the methods, according to the results compiled, was found to be the method used today. It fails to describe local stresses around the bearing. For continued work it is suggested that linear contact elements is studied further. Four out of five models constructed with linear contact elements failed to return satisfactory results.

The work described in this thesis aims to conduct a systematic study of the two stage turbocharging system to improve the Diesel engine transient performance as well as NOX and CO2 emissions with a focus on the improved turbocharger matching and the control of the charging system, through the use of high fidelity engine models backed by experimental results. To perform the analytical study, commercial 1D simulation software has been used in the process of system characterisation and control strategy design. To validate the analytical results, a two stage turbocharging system was installed on a production diesel engine and tested on a transient engine test bench. The test results were then used to further calibrate the 1D engine/turbocharger model. Several other technologies were also investigated in simulation to explore their potential to further improve the system. Unlike most studies in the literature, this project focused on the system benefit of the engine and turbochargers, instead of conducting optimisation solely at the component level. The engine global parameters, such as the engine fuel consumption, emission levels and the transient response were the main parameters to be considered and were also best suited to the strengths of the 1D simulation method. The interactive use of both the analytical and experimental methods was also a strong point of this study. A novel control strategy for the system was proposed and demonstrated in the simulation. Experiments confirmed the validity of this control strategy and provided data for further model calibration. The comparison of the test results of the baseline engine to those obtained with the two stage turbocharged engine system verified the benefits of the novel turbocharging arrangement and control scheme. Transient response (T1090) was improved, with a 50% faster torque rise at 1000 rpm; the fuel consumption over the NEDC was 4% lower and NOx emissions over the NEDC were 28% lower. In the meantime, the study also revealed shortcomings of the system, such as the lack of EGR control at low speed, low load condition and a mid-speed fuel consumption deterioration of 13% on average at 3000 rpm due to excessive back pressure. With a novel 1D model corroborated using test results, exploratory simulation was done to rectify the aforementioned shortcomings and to further improve the system. Simulation results showed that by implementing VGT and ball bearing technology in the high pressure stage of the two stage system, the EGR controllability at low speed was regained and the excessive back pressure at high speed was improved. Consequently, the fuel consumption was only increased by 1.3% compared to the baseline NEDC operation and the transient response was on par with the original two stage system, with only 0.05s slower in torque rise at 1000 rpm, and still 48% faster than the baseline VGT system. Furthermore, the NOx emission can be expected to be greatly improved in the upcoming more intensive drive cycles compared to the NEDC cycle, with simulation showing NEDC NOX emissions dropped by 1%, comparing to a substantial reduction of 11% in WLTC.

Orientadores: Katia Lucchesi Cavalca Dedini, Fábio Nonato de Paula / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-27T08:34:01Z (GMT). No. of bitstreams: 1 Bizarre_Leticia_M.pdf: 4812387 bytes, checksum: 829ed9f477cd979dbcfe654cfeff692c (MD5) Previous issue date: 2015 / Resumo: Com a necessidade da diminuição do tempo de projeto, a utilização de modelos computacionais para simulação de componentes constitui fase fundamental no projeto preliminar de máquinas e equipamentos e permite avaliar parâmetros de projeto para minimizar testes físicos em protótipos. Dentro deste contexto, o trabalho aqui apresentado segue dando continuidade à modelagem de mancais de elementos rolantes, neste caso esferas, anteriormente desenvolvido para contato puramente radial. O estudo da dinâmica de mancais de elementos rolantes e a compreensão de sua modelagem computacional permitem conhecer sua influência sobre o sistema completo. Será inserido o modelo de lubrificação Elastohidrodinâmica (EHD) no modelo dinâmico do mancal, permitindo obter parâmetros equivalentes de rigidez e amortecimento, para posterior caracterização do mancal, utilizando uma análise no domínio do tempo. Uma vez estimada a distribuição de forças, são calculados parâmetros de carga e lubrificação, bem como a geometria no contato, os quais são utilizados no modelo EHD. Este último contém a soluçãodas equações que descrevem o comportamento da região lubrificada, empregando o método numérico de multi-níveis. Desta forma, calcula-se a pressão no contato e a espessura de filme. Utiliza-se uma aproximação para as forças não lineares na região em que a relação entre força e deformação no contato tem comportamento aproximadamente linear. Nesta região, os parâmetros físicos de rigideze de amortecimento total do conjunto esferas, pista interna e pista externa são estimados, e também para cada uma das esferas, tendo em consideração a presença do contato angularnas esferas e a aplicação de forças nas direções axial e radial / Abstract: Considering the necessity of decrease design time, the use of computer models for simulation of components is an essential phase in the preliminary design of machinery and equipment and allows to evaluate design parameters to minimize physical tests on prototypes. Inside this context, the work presented here follows continuing the modeling of rolling element bearings, in this case balls, previously developed for pure radial contact.The dynamics study of the rolling element bearings and the understanding of their computer modeling allow us to know its influence on the complete system.The model for Elastohydrodynamic lubrication (EHD) is inserted in the dynamic model of the bearing, and this allows to obtain equivalent parameters of stiffness and damping, for further characterization of the bearing using a time domain analysis.After the estimated distribution of forces, lubrication and load parameters are calculated, as well as the geometry of the contact, which are used in EHD model.The latter contains the solution of equations that describe the behavior of lubricated region, using the numerical method of multilevel.Thus, the contact pressure and film thickness are calculated.It is used an approximation to the nonlinear forces in the region where the relation between force and deformation of the contact has approximately linear behavior.In this region, the physical parameters of stiffness and damping of the complete set spheres, inner raceway and outer raceway are estimated, and also, for each sphere is taking into account the presence of the angular contact of the spheres, and the application of forces in both axial and radial directions / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestra em Engenharia Mecânica

In this study, residual stresses introduced via application of shot peening on the raceways of bearing rings and their effect on the fatigue life was investigated experimentally. For improvement of residual compressive stress state, shot peening operation with different parameters was utilized. Residual stress measurements were conducted via X-ray diffraction technique. Optimization of residual stress state during the production of ball bearings is the main target of this study. Process parameters for shot peening and super-finishing were studied for determination of the parameters that induce the most favorable residual stress state. The fatigue life of ball bearings were determined by life cycle tests and tabulated to show the results of the study. The results of the thesis are believed to help for optimization of residual stress distribution and improvement of service life of ball bearings.

The aim of this thesis is to analyze the kinematic and dynamic characteristics of a high-speed bearing system. The examined kinematic characteristics will include the maximal speed, fatigue life and stiffness of a bearing system. The stability and transmission force of a bearing system as well as the vibration of its shaft were the studied dynamic characteristics. These analyses were based on the kinemitics of bearing systems, rotor dynamics and elastohydrodynamic lubrication theory. According to these analyses, the interaction and consequence among these characteristics and the parameters of a bearing system will be explained. After these analyses, preliminary and simple design trends about a high-speed bearing system are going to be proposed.

The aim of this thesis is to develop a Computer-aided Design software for high speed angular contact ball bearing system. First, to analyze the interaction of among the characteristics and parameters of a high-speed spindle system with angular contact ball bearing. These analyses were based on the kinematics of bearing systems and rotor dynamics. According to these analyses, several design charts for bearing system will be established by computer simulations. Secondly, an optimum design for high speed spindle system will also be proposed. After these analyses, an Computer-Aided Design software for high speed bearing system will be established. From the study, preliminary design trends about high speed spindle system will be proposed.

Orientador: Katia Lucchesi Cavalca Dedini / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-23T01:22:57Z (GMT). No. of bitstreams: 1 Nonato_Fabio_D.pdf: 15501749 bytes, checksum: e33de59a100f07bcab576880e3654db0 (MD5) Previous issue date: 2013 / Resumo: A representação dinâmica dos contatos mecânicos em modelos computacionais de mancais de elementos rolantes baseia-se comumente no clássico modelo de Hertz para o contato seco, mesmo sendo a presença de um meio lubrificante imperativa para evitar o desgaste prematuro destes componentes. Desta maneira, os efeitos dinâmicos da presença de um filme fluídico nas interfaces de contato são desconsiderados, quando tais mancais são lubrificados por óleo. Com o intuito de introduzir tais efeitos em um modelo de mancal de elementos rolantes de esferas, este trabalho propõe um método baseado na aproximação dinâmica das características de cada contato lubrificado por vínculos de rigidez não linear e amortecimento viscoso. Estes vínculos dinâmicos são caracterizados a partir da resposta dinâmica da simulação completa do contato elastohidrodinâmico (EHD) elíptico, através da implementação de um integrador temporal que utiliza o método de diferenças finitas em múltiplos níveis para solução da parcela hidrodinâmica do problema. Posteriormente, aplica-se a aproximação do contato EHD por vínculos não lineares a um modelo do mancal radial de esferas, de dois graus de liberdade, com o intuito de analisar vibrações transversais no mancal, em modelos computacionais de máquinas rotativas. A comparação entre os resultados obtidos pelo modelo proposto e os valores obtidos pelo equacionamento completo por diferenças finitas mostrou ser adequada à representação do comportamento estacionário e dinâmico do contato. Observa-se a presença do enrijecimento do mancal devido à presença do filme EHD, quando analisando a resposta do mancal linearizado, efeito observável anteriormente apenas em investigações experimentais. Por fim, a integração temporal de um modelo de elementos finitos de um rotor apoiado por mancais lubrificados representou adequadamente o comportamento em frequência de uma montagem experimental de rotor. Conclui-se, portanto, que o modelo não linear proposto para o mancal de elementos rolantes radiais de esfera, sob influência da lubrificação EHD, é promissor para descrever o comportamento destes componentes quando em aplicação / Abstract: The dynamic representation of mechanical contacts in computational models of rolling element bearings is commonly based on the classic Hertz's model for the dry contact, even though the presence of a lubricant medium being essential to avoid premature wear of such components. Thus, the dynamic effects of the fluid film on the contacting interfaces are overlooked when such bearings are under oil lubrication. With the intent of introducing such effects in a radial deep groove ball bearing model, this work proposes a method based on the dynamic approximation of each lubricated contact by dynamic links of non-linear stiffness and viscous damping. Such dynamic links are characterized from the response of a complete dynamic simulation of the elastohydrodynamic (EHD) elliptic contact, through an implementation of a numerical integrator, which uses the multi-level finite difference method for the solution of the hydrodynamic portion of the problem. Afterwards, the approximation of each contact by dynamic links is applied to a complete rolling element bearing model, with two degrees of freedom, with the intent of analyzing transverse vibrations on the bearings applied to rotating machinery computational models. The comparison between the results attained through the proposed model and the values simulated using the complete finite difference model showed an adequate representation of the stationary and dynamic behaviors of the contact. When evaluating the linearized bearing model, the presence of fluid stiffening is observed, which was previously only observed through experimental investigations. Lastly, the time integration of a finite element model of a rotor supported by lubricated bearings portrayed the frequency content of an experimental set-up of the rotor adequately. It is concluded that the proposed nonlinear model for the deep grove ball bearing, under the influence of the EHD lubrication, is promising to describe the behavior of such components when on application / Doutorado / Mecanica dos Sólidos e Projeto Mecanico / Doutor em Engenharia Mecânica

Les conditions de fonctionnement rencontrées dans la problématique de nouvelles générations d'alternateurs automobiles avec des chargements variables et un environnement mécanique complexe déformable ont un effet non négligeable sur le comportement mécanique du roulement et par conséquent sur sa durée de vie. Il est proposé dans ce travail une approche permettant de prendre en compte ces paramètres dans l'estimation de la durée de vie des roulements. La répartition des efforts obtenue des considérations statiques sont utilisés dans un modèle dynamique simplifié permettant de déterminer de l'état de contrainte au cours du temps dû au passage de billes sur la piste de roulement. L'approche multi-échelle de Dang Van couplée à une loi de cumul d'endommagement a permis de déterminer le nombre de cycles avant l'apparition des premiers signes de fatigue. La dernière phase du travail concerne l'aspect expérimental qui a montré que le phénomène de fatigue n'est pas la seule cause de dégradation des roulements montés dans les alternateurs automobiles. / The operating conditions encountered in the new generations of automotive alternators with variable loads and a deformable complex mechanical environment have a significant effect on the mechanical behavior of the bearing and hence its fatigue lifetime. An approach that takes into account these parameters in the ball bearing fatigue lifetime has been proposed in this work. The load distribution obtained from static considerations are used in a simplified dynamic model in order to determine the time-dependent stress state due to ball rolling on the raceway. The Dang Van multiscale approach coupled with a damage law was applied to determine the number of cycles before the apparition of the first signs of fatigue. The last phase of work involves the experimental aspect that shows that the fatigue phenomenon is not the only cause of degradation of bearings mounted in automotive alternators.

Orientador: Amauri Hassui / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-26T11:59:41Z (GMT). No. of bitstreams: 1 Silva_LeviNascimentoda_M.pdf: 11286121 bytes, checksum: d7352e1bfd0d6ee9393542544bcda5b2 (MD5) Previous issue date: 2014 / Resumo: Em virtude do aumento da concorrência, as montadoras de veículos têm exercido pressões sobre os fornecedores participantes da longa cadeia produtiva no sentido de reduzir custos e aumentar a agilidade no desenvolvimento de novos produtos, sem negligenciar a qualidade e a confiabilidade das peças. Na fabricação de autopeças, por exemplo, quando se pensa em tolerâncias pequenas e em acabamento de peças endurecidas, há discussões sobre o uso da retificação convencional ou do torneamento duro. Estudos mostram que a retificação traz maiores custos, tempos de preparação maiores e impactos ambientais negativos e apresentam, como alternativa mais eficiente, o torneamento e faceamento contínuo ou interrompido de peças endurecidas com perfis retos, como os rolamentos com discos axiais. Ao invés de rolamentos axiais, neste trabalho, foi proposto o processo de torneamento duro para fabricar as pistas de rolagem em rolamentos de esferas de contato angular utilizados em sistemas de embreagem. Neste caso, diferentemente dos rolamentos axiais com perfil reto, o tornamento foi do tipo contínuo com perfil côncavo em que, à medida que a ferramenta avança, o contato da aresta de corte com a peça e, consequentemente, a seção do cavaco gerado variam. Duas velocidades de corte foram utilizadas, sendo mantidos constantes o avanço e a profundidade de corte. Características como parâmetros de rugosidade, circularidade, raio e forma da pista, coeficientes de simetria, achatamento e razão de material, dentre outros, foram controlados e comparados com amostras com pistas retificadas. A vida em fadiga de rolamentos é determinada por uma boa lubrificação e pelo bom acabamento das pistas. Quando um dos dois falha, ocorre desprendimento de material das pistas, seguido pelo começo de fraturas abaixo da superfície de contato. Por isso, após a fabricação, o controle e a montagem das amostras, foram realizados também ensaios comparativos de durabilidade. Os resultados encontrados permitiram concluir que as pistas fabricadas por torneamento duro, com as ferramentas e parâmetros utilizados apresentaram vida útil menor que aquelas produzidas por retificação / Abstract: The automotive markets have become more competitive and the car makers push the suppliers in the productive chain to focuse on cost reduction and fast development of new products, without neglecting quality and reliability. Regarding autoparts manufacture process, with small tolerances and finishing of hard parts, there are discussions about the use of conventional grinding or hard turning. Studies show that grinding increases costs, preparation times and negative environmental impacts and point out, as more effective process, the continuous or interrupted hard turning or hard facing in hard components with straight profile, such as thrust bearings with discs. Instead of thrust bearings, the aim of this work is to propose the hard turning of raceways in contact ball bearings used in clutch systems. In this case, the turning was continuous with concave profile: while the tool moves, the cut edge contact with the component and consequently the generated chip section change. Two cut speeds were used and feed rate and cut depth have been remained constant. Characteristics like rougheness parameters, roundness, raceway radius and its profile, skewness, kurtosis and bearing ratio were measured and compared with those in specimens with ground raceways. The fatigue life in ball bearings is determined by good lubrication and raceways with good finishing. When one of them fails, it occurs material deterioration (spalling) followed by cracks under the contact surface. For that reason, after manufacturing, measurements and assembly of the specimens, comparative durability tests were performed. The results could assess that the raceways manufactured by hard turning with toolings and defined parameters showed reduced fatigue life in comparison to specimens made by grinding / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

This master thesis deals with the influence of assembly clearance on strain and stress in the radial ball bearing. The theme of this thesis was commissioned by ZKL - Research and development, a. s. For six different assembly clearances and selected ball bearing was made force-loaded static analysis of global computational models. Subsequently was made a static analysis of local computational models loaded by strain according to the results of global models. The output of analysis of local models was sizes of stress, which led to the analysis of bearing with two other models of material. For the solution of the problem was used pre/post processor Patran and solver MSC.Marc.