Published Article / Spin casting is widely used as a batch manufacturing process for decorative products. In the process, moulds are filled by taking advantage of the centrifugal effect, which is used to increase the pressure within the moulds, resulting in more detailed products. In this study, we analyse the different parameters that could affect the casting of mechanical parts through spin casting. Through this study, the user will be guided in the selection of parameters that will result in a certain degree of accuracy. The parameters were determined by performing numerous experiments using zinc alloy and tin-based pewter as casting materials. Results were obtained by casting approximately 15 000 parts in various positions, and at various clamping pressures, rotational speeds and temperatures in both the mould and the material. The experiments were undertaken by varying one parameter at a time, and with each set parameter repeated once, resulting in 100 test pieces per parameter for evaluation. From the results obtained, a series of critical factors and parameters, which are driven by part characteristics or features, has been studied. Contrary to following a modelling approach, the research was conducted following an action-research approach, with planned activities, but where actual results have defined the follow-up procedures. These guidelines will help industrial users ensure the accuracy of parts produced by spin casting. Also, since this project attempted to create a database of results that can be applied in future, it furthermore implies that the data created for the first time can be used in a numerical modelling approach in further / follow-up research. No such data was available from any previous research.

Yes / In CAD, when considering the question of new designs of complex mechanical parts, such as engine pistons, a parametric representation of the design is usually defined. However, in general there is a lack of efficient tools to create and manipulate such parametrically defined shapes. In this paper, we show how the geometry of complex mechanical parts can be parameterised efficiently enabling a designer to create and manipulate such geometries within an interactive environment. For surface generation we use the PDE method which allows surfaces to be defined in terms of a relatively small number of design parameters. The PDE method effectively creates surfaces by using the information contained at the boundaries (edges) of the surface patch. An interactively defined parameterisation can then be introduced on the boundaries (which are defined by means of space curves) of the surface. Thus, we show how complex geometries of mechanical parts, such as engine pistons, can be efficiently parameterised for geometry manipulation allowing a designer to create alternative designs.

La durée de vie des pièces mécaniques en contact est fortement affectée par la présence d'hétérogénéités dans le matériau, comme des renforts (fibres, particules), des précipités, des porosités, ou encore des fissures. Des hétérogénéités dures et de formes complexes peuvent créer des surcontraintes locales, initiatrices de fissures par fatigue à proximité de la surface de contact. Une analyse quantitative des surcontraintes créées par les hétérogénéités est nécessaire à la compréhension des mécanismes d'endommagement. Cette étude s'applique à des roulements de ligne d'arbre qui font partie des éléments critiques de moteurs en aéronautique. Elle vise à déterminer précisément la distribution du champ de pression sur l'aire effective de contact et à prédire le profil et l'évolution des champs de contraintes/déformations à chaque passage de la charge sur un volume élémentaire représentatif prenant en compte le gradient de dureté, la présence de carbures et l'existence des contraintes initiales d'origine thermochimique. Une partie de l’étude est consacrée au développement d’un solveur du problème de contact roulant élasto-plastique avec présence d’hétérogénéité par les méthodes semi analytiques assurant un excellent gain en temps et ressources de calculs. Ensuite, un algorithme homogénéisation a été conçu pour analyser le comportement effectif d’un massif élasto-plastique hétérogène sous indentation. Enfin une partie expérimentale est dédiée à la caractérisation microstructurale des aciers étudiés dans le but de déterminer leurs propriétés. Les analyses des résultats de cette étude concourent à soutenir que bien que les inclusions de particules non métalliques soient responsables de la haute résistance de ces matériaux, certaines d’entre elles (celles de longueur dépassant les dizaines de micromètre ou celles qui forment des chaines dans une direction particulière) deviennent, au cours des cycles de fatigue, les principales sources d’endommagement depuis l’échelle locale jusqu’à la rupture globale de la structure. / The lifetime of contacting mechanical parts is strongly affected by the presence of heterogeneities in their materials, such as reinforcements (fibers, particles), precipitates, porosities, or cracks. Hard heterogeneities having complex forms can create local overstress that initiating fatigue cracks near the contact surface. The presence of heterogeneities influences the physical and mechanical properties of the material at microscopic and macroscopic scales. A quantitative analysis of the over-stresses generated by heterogeneities is necessary to the comprehension of the damage mechanisms. The present study is applied to rolling bearings which are the critical elements of the aero-engine's mainshaft. The performance required for these bearings, led SKF Aerospace to introduce a new technology of hybrid bearing with ceramic rolling elements on high-strength steels having experienced a double surface treatment (carburizing followed by nitriding). The study aims to precisely determine the pressure field distribution on the effective contact area and to predict the profile and the evolution of the stress/strain fields at each loading cycle on a representative elementary volume that takes into account the gradient of hardness, the presence of carbides and the existence of an initial compressive stress from thermochemical origin. A major part of this study is devoted to develop a heterogeneous elastic-plastic rolling contact solver, by semi-analytical methods ensuring an excellent saving of calculation time and resources. Thereafter, a homogenization algorithm was built to analyze the effective behavior of a heterogeneous elastic-plastic half-space subjected to an indentation loading. Finally, an experimental part is dedicated to the microstructure characterization of the studied steels with intent to determine their properties. A description of the carbides behavior inside the matrix during micro-tensile tests was carried out under SEM in-situ observation. In the scheme of all analyses conducted in the present work, it can be argued that, although the heterogeneities (such as carbides or nitrides) are responsible for the high resistance of the studied materials, some of them (those whose length exceeds tens of micrometer or those which form stringers in a particular direction) become, over fatigue cycles, the main sources of damage, from their local scale up to the macroscopic failure of the structure.

Induction machine; outer rotor; water pump; thermal network; thermal analysis; optimization; electromagnetic model; finite element method; thermal insulation class