In today’s industry, the sustainable use of raw materials and the development of new green technology in mass production, with the aim of saving resources, energy and production costs, is a significant challenge. Deep drawing as a widely used industrial sheet metal forming process for the production of automotive parts belongs to one of the most energy-efficient production techniques. However, one disadvantage of deep drawing regarding the realisation of green technology is the use of lubricants in this process. Therefore, a novel approach for modifying the conventional deep drawing process to achieve a lubricant-free deep drawing process is introduced within this thesis. In order to decrease the amount of frictional force for a given friction coefficient, the integral of the contact pressure over the contact area has to be reduced. To achieve that, the flange area of the tool is macro-structured, which has only line contacts. To avoid the wrinkling, the geometrical moment of inertia of the sheet should be increased by the alternating bending mechanism of the material in the flange area through immersing the blankholder slightly into the drawing die.

Electrochemical quartz crystal microbalance has been employed to investigate electro-responsiveness of an ionic liquid as an additive in lubricant oils on a gold surface. Polarisation of the surface reveals changes in frequency where an increase in magnitude amplified the observed response, corresponding to a controllable alternation of the ionic liquid configuration on the surface as a function of applied potential. The frequency changes are due to different packing of the anion and cation, respectively, on the surface as their mass densities and geometries are different. Relaxation of the system was reversible to the application of a potential and it was also found to be diffusion dependent, where the ratio between the ion diffusivities could be extracted from the results. Measurement of the system relaxation reveals a potential decay of that of a discharging capacitor, with an internal resistance inducing an initial potential drop due to the resistivity of the oil medium. The discharge behaviour was also proven to show high internal reproducibility validity within experiments. This newly discovered insight in responsive differences of ion packing is of importance, not only for ionic liquid additives in tribology, but for understanding and exploiting ionic liquids in an array of electrochemical applications.

No description available.

Smörjmedel är en nödvändighet för maskiner för att minska slitage och energiförbrukning. Dock är över 95% av de använda smörjmedlen i dag fossilbaserade. Smörjmedel baserade på vegetabiliska oljor finns tillgängliga men har ofta en lägre oxidativ stabilitet och sämre lågtemperaturegenskaper än deras fossilbaserade motsvarigheter. Ett annat hinder att övervinna är att ersätta vanligt använda förtjockningsmedel i halvfast smörjmedel med biobaserat alternativ vilket också visat sig vara en utmanande uppgift. Representanter för marina biomassa som mikro- och makroalger har potential att användas i framtiden som förnybar råvara källor på grund av deras kemiska sammansättningar såväl som gynnsamma odlingsförhållanden. Mikroalger har ett högt lipidinnehåll och vissa arter har ett högt innehåll av kolväten som liknar råolja. Makroalger har ett högt innehåll av polysackarider med en förtjockningsförmåga i vatten. Även om mikroalger innehåller lovande kolväten och lipider som kan användas i smörjmedelsapplikationer är det idag inte ekonomiskt möjligt att använda mikroalger för att producera produkter med lågt värde. Även makroalger är för kostsamma att kultivera för billiga produkter, För att kunna använda polysackarider som tillsatser i olja måste de vara mer hydrofoba. I denna studie oxiderades alginat först i en ringöppningsreaktion, för att senare reduceras i en Schiff-basformation och reduktion till en mer amfifil polysackarid. Resultaten visade en hög nedbrytning av polysackariden både i oxidationsreaktionen och i reduktionsreaktionen, från en startmolekylvikt av 580 000 g/mol till ~ 10 000 g/mol. Etanol kunde användas i oxidationsreaktionen för att öka den möjliga alginatkoncentrationen. Både FTIR- och 1H-NMR-resultaten indikerade en lyckad oxidation och reduktion. Framtida arbete involverar inblandning av det hydrofobt modifierade alginatet i en basolja och utvärdering av effekten av den erhållna biobaserade basoljekomponenten på oljeegenskaperna, till exempelökning av viskositeten, oxidationsstabilitet och förtjockningsbeteenden. / Lubricants are a necessity for machineries in order to reduce friction and wear. However, over 95% of the lubricants used today are fossil-based. Vegetable oil-based lubricants are available but often possess lower oxidative stability and poorer low temperature properties than their fossil-based counterparts. Vegetable oils are therefore not a perfect solution to reduce crude oil usage. Another obstacle to overcome would be a replacement of commonly used thickeners in semisolid lubricants with bio-based alternative, which has proven to be a challenging task. Marine biomass representatives such as micro-and macroalgae have the potential to be used in the future as renewable feedstock sources due to their chemical compositions as well as beneficial cultivation conditions such as usage of non-arable land and saltwater. Microalgae have a high lipid content, and in some species a high content of hydrocarbons similar to crude oil. Macroalgae have a high content of polysaccharides, some with gelling abilities. Even though microalgae contain promising hydrocarbons and lipids that can be used in lubricant applications, it is currently not economically feasible to use microalgae to produce low valueproducts. Macroalgae are also too expensive to cultivate to be used in low price products. In order to use polysaccharides as additives in oil, they need to be more amphiphilic. In this study, alginate, derived from brown seaweed, was first oxidized in a ring opening reaction to later be reduced in a Schiff base formation and reduction to introduce more hydrophobic side groups. The results revealed a severe degradation of the polysaccharide both in the oxidation and in the reduction reaction, from a starting molecular weight of 580 000 g/mol to ~ 10 000 g/mol. Ethanol was proved to be a suitable solvent in the oxidation reaction which increased the possible alginate concentration. Both FTIR and 1H-NMR results indicated a successful oxidation and reduction. Future work involves incorporation of the hydrophobically modified alginate in a base oil and evaluation of the presence of the obtained bio-based base oil component on the oil properties, for example viscosity increase, oxidation stability and thickening behaviors.

No description available.

No description available.

Bearbetningsprocesser är en viktig del av tillverkningsindustrin. Dessa företag måste kontinuerligt förbättra sina processer och göra dem mer effektiva, minska de ekologiska fotavtrycken och driftskostnaderna. Syftet med denna rapport är att förbättra en rund brotschningsprocess för ett bilföretag. Brotschverktyget är tillverkat av solid HSS och belagt med TiN, som dras genom ett hål i arbetsstycket. På grund av att flera skärkanter fungerar samtidigt är skärkraften hög. Med skärverktygets lågavlastningsvinkel spelar smörjmedlet en kritisk roll i brotschningsprocessen. Arbetet studerar olika skärvätskor i ett laboratorium, genom att simulera påverkan av skärvätskor i en brotschningsprocess med tappningsoperationer under liknande förhållanden. Momentvärdena och beteendet av processen har studerats för de olika smörjmedlen. Studien visade att smörjmedlet har en stor påverkan på vridmoment och spånbildningen. Relationen mellan smörjviskositet och smörjningsförmåga studerades. Dessutom undersöktes sambandet mellan spånbildning och vridmomentbeteende, vilket visar vikten av spånens utrymningskapacitet. Processen har utförts genom att använda olika typer smörjmedel för att undersöka deras påverkan på skärkrafterna och hur de utvecklades under hela processen. Resultaten och den efterföljande analysen har visat att viskositeten har stort inflytande i processen. Viskositeten är omvänt proportionell mot vätskans kapacitet för att komma åt vissa kritiska områden, vilket ökar friktionskrafterna och genereringen av långa spån. Både spånstorleken och smörjmedlets förmåga att utrymma har starka influenser på processen. / Machining processes are an important part of the manufacturing industry. Companies within the manufacturing industry are required to continuously improve their processes and make them more efficient, to reduce the ecological impact and operational costs. The aim of this thesis is to be able to improve a circular broaching process for an automotive company. The broaching tool is made from solid High-Speed Steel and TiN coated, which is pulled through a hole in the workpiece. Due to multiple cutting edges acting simultaneously, the cutting force is high. With a low relief angle of the cutting tool and low cutting speed, the lubricant plays a critical role in the broaching process. The thesis studies different cutting fluids in a laboratory, by simulating the impact of cutting fluids in a broaching process with tapping operations under similar conditions. The torques values and the behaviour of it during the process have been recorded for different lubricants. The lubricants were found to have a strong influence in the torque required and the chip formation. The relation between lubricant viscosity and lubrication performance was studied. In addition, the relation between chip formation and torque behaviour was explored, showing the importance of chip evacuation capacity. The process has been carried out by using different lubricants to examine the required cutting forces and how they evolved throughout the process. The results and the consecutive analysis have shown an influence of the viscosity in the process. The viscosity is inversely proportional to the capacity of the fluid to access certain critical areas, increasing the friction forces and the generation of long chips. Both the chip size and the ability of the lubricant to evacuate have strong influences on the process.

other / no / The effect of sulphuric acid on the chemical and physical behaviour of the piston ring lubricant in a marine engine cylinder was investigated. To reveal the basic influence of H2SO4 on the lubricant film, the saturated hydrocarbon Squalane (C30H62) was chosen as a simple model oil. The interfacial tension between aqueous H2SO4 (0-98% w/w) and C30H62 was measured between -3 and 165 degrees C to understand droplet formation in the lubricant. Interfacial tension decreases with increasing acid concentration and is temperature dependent. / The wettability of engine parts with corrosive sulphuric acid was characterised by the contact angle. The contact angle of H2SO4 (0-98% w/w) on a grey cast iron cylinder liner material (Wartsila, RT84) and a piston ring chrome-ceramic coating (Federal Mogul Goetze, CKS, empty set960 mm) immersed in C30H62 was measured over a temperature range from 20 to 165 degrees C. In general, larger contact angles were measured under higher temperature conditions and on chrome surfaces. / In addition to the physical measurements, chemical reaction between H2SO4 and C30H62 was observed which influenced the interfacial tension, visual appearance, phase separation and formation of solid matter. The reaction time was found to be faster than the neutralisation times of commercially formulated lubricants. The reaction products were analysed using FTIR spectroscopy and EDX to find oxidation and sulphonation.

No / A comparison has been made between compaction, sintering, microstructural and mechanical properties of the 6061 aluminium alloy prepared via premixed elemental (EL) and prealloyed (PA) powders (as received and degassed) with and without additions of sintering aids and various solid and/or liquid lubricants. Both EL and PA powders were cold pressed at different pressures, ranging from 250 to 770 MPa, and sintered under vacuum in the range 580-640°C for 30-120 min. and then under pure nitrogen atmosphere for comparison. Vacuum degassing of the PA powder provided better compressibility and thus higher green densities than those for the as received PA or the premixed EL powder compacts pressed at compaction pressures ¿340 MPa. Near full sintered densities of ~98%TD were obtained for both EL and PA 6061 Al alloys. Degassed PA Al with 0·6 wt-% paraffin wax (PW) or with only 0·12 wt-%Pb addition as sintering aid and no lubricant, and premixed EL with only 0·12 wt-%Pb addition and no lubricant gave the best optimum properties. It became apparent that additions of some solid lubricants such as lithium stearate (LS) and acrawax to both the premixed EL and PA powders provided reasonable green densities, but had deleterious effect on sintered densities and microstructures, particularly under vacuum sintering. Heating data curves during the sintering cycle, revealed formation of both transient and persistent liquid phases for the EL and mainly supersolidus liquid phase sintering (SLPS) mechanism for the PA. Tensile properties of the degassed, vacuum or nitrogen sintered PA Al alloy in T6 condition were higher than those of the equivalent alloy prepared by EL mixing with the former giving a tensile strength of 330 MPa and 6-8% elongation to failure, which are similar to those of the commercial (wrought) 6061 Al alloys.

No description available.