<p>Lubrication and friction of modern rolling element bearings were investigated to develop a physics-based bearing friction model. A test rig was designed and developed to measure the frictional torque of radially loaded rolling element bearings with oil bath lubrication. Deep groove ball bearings and radial needle roller bearings were studied at various loads, speeds and lubrication conditions. Experimental results indicate that bearing friction models currently used in industry can be inaccurate, especially when predicting bearing fluid drag losses. A separate test rig was designed and developed to investigate the lubrication and friction of rolling element bearing cage pockets, as new cage pocket designs could improve bearing efficiency. Cage pocket oil starvation was observed for certain operating conditions, and the starvation was found to correlate strongly with cage pocket friction. In order to better understand friction and lubrication characteristics of bearings, computational fluid dynamics (CFD) models were developed to compare with the experimental results. Fluid motion inside the rolling element bearings was investigated using CFD to determine fluid drag torque of bearing components. Fluid drag torque obtained from CFD and experimental measurements are in good agreement. Results from the CFD models also included pressure distributions over bearing surfaces and fluid velocity near rolling elements, but were limited to global length scales. At the micro-scale, rolling element bearing lubrication and friction is dictated by elastohydrodynamic lubrication (EHL). The radial needle roller bearings and deep groove ball bearings used in this investigation are characterized by line and elliptical contacts, respectively. EHL modeling was therefore developed for line contacts with a strongly coupled fluid solid interaction (FSI) solver. Solid bodies were modeled with finite element (FE) software to incorporate inhomogeneities such as inclusions and surface features which affect EHL pressure, film thickness and friction. Results were used to investigate lubricant film thickness at lubricated line contacts under various operating conditions. This work was further extended to model EHL circular contacts with an FSI approach, combining CFD and FE software. The newly developed FSI EHL model provided critical insights regarding fluid behavior in and around EHL point contacts and fluid properties within the lubricant film. Given the modeling results at the micro and macro scale within the rolling element bearings, a better understanding of bearing friction and lubrication is developed, and supported by experimental data.</p>

The author developed a computational framework for the study of the correlation between airway morphology and aerosol deposition based on a population of human subjects. The major improvement on the previous framework, which consists of a geometric airway model, a computational fluid dynamics (CFD) model, and a particle tracking algorithm, lies in automatic geometry construction and mesh generation of airways, which is essential for a population-based study. The new geometric model overcomes the shortcomings of both centerline (CL)-based cylindrical models, which are based on the skeleton and average branch diameters of airways called one-dimensional (1-D) trees, and computed tomography (CT)-based models. CL-based models are efficient in terms of pre- and post-processing, but fail to represent trifurcations and local morphology. In contrast, in spite of the accuracy of CT-based models, it is time-consuming to build these models manually, and non-trivial to match 1-D trees and three-dimensional (3-D) geometry. The new model, also known as a hybrid CL-CT-based model, is able to construct a physiologically-consistent laryngeal geometry, represent trifurcations, fit cylindrical branches to CT data, and create the optimal CFD mesh in an automatic fashion. The hybrid airway geometries constructed for 8 healthy and 16 severe asthmatic (SA) subjects agreed well with their CT-based counterparts. Furthermore, the prediction of aerosol deposition in a healthy subject by the hybrid model agreed well with that by the CT-based model. To demonstrate the potential application of the hybrid model to investigating the correlation between skeleton structure and aerosol deposition, the author applied the large eddy simulation (LES)-based CFD model that accounts for the turbulent laryngeal jet to three hybrid models of SA subjects. The correlation between diseased branch and aerosol deposition was significant in one of the three SA subjects. However, whether skeleton structure contributes to airway abnormality requires further investigation.

Atherosclerosis is an arterial disease that occurs due to the build-up of lipids, cholesterol and other substances in the arterial wall, collectively called plaque, leading to narrowing of the vessel lumen and, in time, disruption to the blood supply. The study of flow through atherosclerotic vessels is especially important since plaques not only cause a reduction in the vessel lumen but can rupture from the arterial wall, causing a blood clot in the vessel that may ultimately lead to heart attack or a stroke. Elevated level of oxidated low density lipoprotein (LDL) is a known risk factor associated with the genesis of atherosclerosis in arterial walls. Previous studies reported in literature have explored the transport of LDL through the arterial wall using analytical and mathematical models. In this work, we have presented a computational framework for the study of LDL transport in the lumen and the porous arterial wall. We have employed a four-layer arterial wall model and used governing equations to model the transport of LDL. We have used physiological parameters for the wall layers from literature and have validated the model based on the calculated filtration velocities and LDL concentration profiles in the arterial wall. We have further used this established model to study the effect of change in permeability and pressure on the LDL concentration. We have also studied the effect of pulsatile flow on the transport of LDL through the porous walls to examine the validity of the initial assumption of steady state and have seen that pulsation increases the time averaged net flux of LDL species by about 20%. We have next modeled a drug-eluting stent (DES), which is one of the popular remedies to cure atherosclerosis. The validation of DES model is followed by a combined study to analyze the effect of stent placement on LDL transport. Although there is no chemical reaction between the drug and LDL, we have noticed recirculation zones near the stent strut which result in accumulation of LDL molecules in the arterial wall. Future studies are aimed at incorporating variable porosity and permeability and a stenosed region in the geometry. The deformation of arterial wall due to pulsatile blood flow may lead to alteration of wall properties, which can give a realistic view of macromolecular transport.

Heat transfer and solidification models were developed for use in a numerical model of a continuous caster to provide a means of predicting how the developing shell would react under variable operating conditions. Measurement data of the operating conditions leading up to a breakout occurrence were provided by an industrial collaborator and were used to define the model boundary conditions. Steady-state and transient simulations were conducted, using boundary conditions defined from time-averaged measurement data. The predicted shell profiles demonstrated good agreement with thickness measurements of a breakout shell segment – recovered from the quarter-width location. Further examination of the results with measurement data suggests pseudo-steady assumption may be inadequate for modeling shell and flow field transition period following sudden changes in casting speed. An adaptive mesh refinement procedure was established to increase refinement in areas of predicted shell growth and to remove excess refinement from regions containing only liquid. A control algorithm was developed and employed to automate the refinement procedure in a proof-of-concept simulation. The use of adaptive mesh refinement was found to decrease the total simulation time by approximately 11% from the control simulation – using a static mesh.

This work includes the development of computational fluid dynamic (CFD) and finite element analysis (FEA) models to investigate fluid flow , solidification, and stress in the shell within the mold during continuous casting. The flow and solidification simulation is validated using breakout shell measurements provided by an industrial collaborator. The shell can be obtained by the solidification model and used in a FEA stress model. The stress model was validated by former research related to stress within a solidifying body presented by Koric and Thomas. The work also includes the application of these two models with a transient solidification model and a carbon percentage investigation on both solidification and deformation.