Les propriétés de surface, particulièrement microgéométriques, jouent un rôle essentiel dans tous les systèmes tribologiques. L’analyse de la répartition des efforts de contact dans l’interface entre surfaces rugueuses est indispensable à la prédiction du frottement, de l'usure, de l'adhérence, des résistances de contact électrique et thermique… De nombreux modèles ont été proposés ces dernières décennies pour prédire les efforts entre aspérités de surfaces rugueuses. Parmi ces modèles, les modèles statistiques sont majoritairement développés en considérant le contact ente une surface rugueuse équivalente, la surface somme - qui tient compte des microgéométries des deux surfaces en contact ainsi que de leur matériau - et un plan lisse. Cependant la validité de cette modélisation n’a pas été clairement démontrée. L’objectif de notre étude a été de développer un modèle statistique de contact entre deux surfaces rugueuses isotropes aléatoires puis de comparer les résultats obtenus pour ces deux surfaces avec ceux obtenus en considérant la surface somme définie classiquement à partir des deux surfaces rugueuses et un plan lisse. Les différences entre les résultats nous ont amenés à proposer une nouvelle modélisation de la surface somme. / Surface properties, particularly micro-geometry, play a key role in all tribological systems. The analysis of the distribution of contact forces in the interface between rough surfaces is essential for the prediction of friction, wear, adhesion, electrical and thermal contact resistance... Many models have been proposed during the last decades to predict the forces between asperities of rough surfaces. Among these models, statistical models are mainly based on the contact between an equivalent rough surface, the sum surface - which combines micro-geometry of the two surfaces in contact and their material - and a smooth plane. However, the validity of this model has not been clearly demonstrated. The aim of our study was to develop a statistical model of the contact between two random isotropic rough surfaces and then compare the results with those obtained by considering the classical sum surface. The differences between the results have led us to propose a new definition for the sum surface.

Darbe analizuojamas abrazyvinio dilimo mechanizmas. Nustatomi šiems procesams didžiausią įtaką turintys veiksniai. Analizuojama abrazyvinių dalelių formos ir jų abrazyvumo vertinimo metodika. Apžvelgiami abrazyvinio dilimo modeliai. Abrazyvinių dalelių veikiami darbinių dalių paviršiai intensyviai dyla, todėl atsižvelgiant į jų darbo sąlygas būtina tinkamai parinkti jų savybes – kietumą, stiprumą bei sudėtį (legiravimą). Šių paviršių atnaujinimui ir sustiprinimui dažnai racionalu naudoti įvairios sudėties apvirinamus sluoksnius. Šio darbo tikslas – ištirti apvirintų kietųjų sluoksnių abrazyvinio dilimo ypatybes. Taip pat, ištirti lydinių abrazyvinio dilimo įtaką dylančio paviršiaus mikrogeometriniams parametrams. Atliktais tyrimais nustatyta legiruojančių elementų įtaka apvirintų sluoksnių abrazyviniam dilimui. Nustatyta optimali apvirinto sluoksnio sudėtis abrazyvinio dilimo sumažinimui. Tai pat nustatyta, kad termiškai apdirbtų plienų ir apvirintų sluoksnių dilimo atvejais nudilimas turi ryšį su paviršiaus parametru SPQP. Tuo remiantis, matuojant paviršiaus profilį, galima prognozuoti nudilimo dydį. / There is analysis of abrasive wear mechanism in this work. The most important factors in these processes were established. There are analysed technique of abrasive particles properties and abrasive wear models. Surfaces witch are under the abrasive sway wear very fast. Considering to working conditions of these surfaces it is necessarily to choose there properties – hardness, strength and composition. For renovation and fortify of these surfaces it is often rational hard facing. The aim of this work was to estimate the influence of alloying elements content to abrasive wear. And estimate the abrasive wear influence to micro geometry of wearing surface. The influence of alloying elements to abrasive wear was estimated. To decrease abrasive wear the optimal chromium content in the arc welded alloy was investigated. Clear influence of heat treated steels and arc welded alloys abrasive wear on surface profile quality parameter SPQP is estimated. Considering with that we can measure surface profile and predict the wear rates.

Machines operating in dusty environments, such as mining and civil works, are prone to premature failure, leading to production losses. To address this problem, this research project examines the interaction between solid contaminants and the bearing micro-geometry, in lubricated surface contacts. In particular, it seeks to identify anti-wear additives that are effective in reducing wear under abrasive conditions, making machine elements more dirt tolerant. In general, the influence of antiwear additive is so small that it is difficult to isolate it. Manufactures often make claims about their antiwear products, which are difficult to verify. Hence, there is a need to characterising the antiwear additives available with a well-defined parameter, making it easier for consumers to compare the efficacy of various additives, and be able to select the most suitable additive for a given environment. Effect of micro-geometry parameters such as radial clearance, out-of-roughness and surface roughness was examined and a Film Shape Factor (FSF) – also termed gamma ratio – has been proposed for ensuring adequate separation of journal bearings operating in hydrodynamic lubrication regime, where the out-of-roundness values are higher than the surface roughness values. In this research, an experimental study has been conducted on journal bearings, to examine the influence of five antiwear additives on the bearing wear and micro-geometry. The test additives were provided by the industry partner without revealing their chemical identity or composition; however, these included some of the most commonly used antiwear additives. The tests were performed under three conditions: pure base oil, base oil containing contaminants, and base oil containing contaminants treated with five different additives. The experiments were aimed at choosing one wear measuring technique that evaluates the performance of an individual additive reliably, and based on this technique the additives were characterised. To achieve these objectives, a multi-wear parameter approach (MWPA) was developed, which employed three main wear measurement methodologies, i.e. weight loss, micro-geometry and particle counts –to examine the effect of the antiwear additives. Minimum oil film thickness was also measured to study the lubrication status in the bearing contacts. The MWPA helped in comparing different wear measuring methods, and in selecting the most reliable one. This approach also helped in developing short duration wear tests, thereby saving time, while still getting reliable results without repeating these. Wear experiments were performed on seven sets of bronze bearings and steel sleeve shafts. The test contaminant was 16 micron Aluminium oxide Al2O3 powder mixed in oil with 4% concentration by weight. These solid contaminants were treated with five different antiwear additives to study their influence on the bearings. Bearings were operated such that the minimum oil film thickness in the bearing was equal to the size of the contaminants. These tests were run for a constant sliding distance of 7536m. The results showed that most of the wear measuring techniques do not suit heavily contaminated test conditions. However, the out-of-roundness technique proved to be the most reliable and practical. Based on this technique a methodology was developed which gave a wear characteristic number (N). A unique value of N can be derived for each additive, thereby ranking the additives for their efficacy. The finding of this research provides a better understanding of the methodologies used for measuring wear in journal bearings subjected to dusty environments, and examines the efficacy of each one of these. The wear characteristic number (N) can be used by manufacturers with support from international standards organisations, so that the users can confidently choose the most appropriate antiwear additive for their application. Machines operating in a dusty environment, such as mining industry and civil works are prone to premature failure with subsequent production losses. In response to this problem, this research project examines the interaction between solid contaminant particles and the lubricant film micro-geometry in lubricated surface contacts. In particular, it seeks to identify lubricant anti-wear additives, which are effective in reducing wear under abrasive conditions and thus making machine elements more dirt tolerant.

Due to their large torque-speed ratio and transmission efficiency, planetary gears are widely used in the automotive industry. However, high amplitude vibrations remain their critical weakness, which limits their usage especially when new strict noise legislations come into action. A new approach to handle the instability problems of planetary gears encountered in real industrial context is presented in this work. First, the dynamic response of a planetary gear failing to pass the noise regulations is theoretically investigated through an analytical model. The equations of motion were solved using the Spectral Iterative Method. The observed experimental results correlated well with those from the developed model. In order to limit the resonance phenomena, impacts of different macro and micro-geometry modifications were analytically investigated: quadratic teeth profile, different planets positioning, different number of teeth and number of planets. Optimum modifications were retrieved and are expected to be tested experimentally on a test bench and on the truck. Finally, the analytical model’s limits and sensitivity to different parameters were investigated in order to certify its reliability, and suggestions for improvements were presented.

Cette étude est dédiée à l’influence du fraisage de finition avec outil à extrémité hémisphérique sur l’intégrité de surface et la durée de vie en fatigue de pièces en acier bainitique à haute limite d'élasticité. L'intégrité de surface – microgéométrie, contraintes résiduelles et écrouissage – est caractérisée expérimentalement pour différentes valeurs des paramètres d'usinage, dont l'angle d'inclinaison de l'outil. L'hétérogénéité du champ de contraintes résiduelles perpendiculairement aux sillons générés par l’outil est mise en évidence à différentes profondeurs. Des essais de fatigue en flexion sur éprouvettes brutes d'usinage ou polies, avec ou sans traitement thermique de relaxation des contraintes résiduelles, mettent en évidence l'influence de l’intégrité de surface sur la tenue en fatigue. Des essais de fatigue en traction avec mesures d'auto-échauffement mettent en évidence une compétition entre mécanismes de micro-plasticité et de micro-fissuration. Une approche hybride est proposée pour prévoir l'état mécanique de la pièce usinée après fraisage. L'effet sur la surface usinée d'un chargement thermo-mécanique équivalent à l'opération de coupe et déduit d'essais d'usinage instrumentés est alors simulé numériquement sans modéliser l’enlèvement de matière. Une approche probabiliste est proposée pour prévoir l'influence de l'intégrité de surface sur la tenue en fatigue. Cette approche, restreinte au cas où le mécanisme de microfissuration est prédominant est validée grâce à la prise en compte de la microgéométrie. Le modèle est alors de type mécanique de la rupture et basée sur une mesure de la population de tailles d’entaille au fond des creux générés par l'outil. / This study is dedicated to the influence of ball-end tool finishing milling on surface integrity and fatigue life of components made of high-strength bainitic steels. Surface integrity, defined in terms of microgeometry, residual stresses and hardening, was experimentally characterized for different values of the machining parameters, including the tool inclination. Fluctuations of the residual stresses field – measured by X-ray diffraction – perpendicular to the grooves generated by the tool were exhibited at different depths beneath the surface. Fatigue bending tests performed on machined or polished flat specimens, submitted or not to a heat treatment to relax the residual stresses, exhibited the influence of the surface integrity on fatigue life. Fatigue tension tests and self-heating measurements exhibited a competition between micro-plasticity and micro-cracking mechanisms. A hybrid approach is proposed to predict the mechanical state induced by the milling process. This approach consists in simulating – without modelling the removal of the material- the effect of a thermo-mechanical loading equivalent to the cutting process. This thermo-mechanical loading should be derived from temperature and cutting forces measurements preformed during cutting tests. A probabilistic approach is proposed to predict the influence of surface integrity on fatigue life. This approach was validated for cases when micro-cracking mechanism is predominant. The approach is then based on fracture mechanics and takes account of the micro-geometry via the micro-cracks size population measured in the valleys of the grooves generated by the tool.

Les modèles de réflexion complexes, avec leurs nombreux paramètres dont certains restent non intuitifs, sont difficiles à contrôler pour obtenir une apparence désirée. De plus, même si un artiste peut plus aisément comprendre la forme de la micro-géométrie d'une surface, sa modélisation en 3D et sa simulation en 4D demeurent extrêmement fastidieuses et coûteuses en mémoire. Nous proposons une solution intermédiaire, où l'artiste représente en 2D une coupe dans un matériau, en dessinant une micro-géométrie de surface en multi-couches. Une simulation efficace par lancer de rayons en seulement 2D capture les distributions de lumière affectées par les micro-géométries. La déviation hors-plan est calculée automatiquement de façon probabiliste en fonction de la normale au point d'intersection et de la direction du rayon incident. Il en résulte des BRDFs isotropes complètes et complexes, simulées à des vitesses interactives, et permettant ainsi une édition interactive de l'apparence de réflectances riches et variées. / Complex reflection models, with their many parameters, some of which are not intuitive at all, are difficult to control when trying to achieve a desired appearance. Moreover, even if an artist can more easily understand the shape of the surface micro-geometry, its 3D modeling and 4D simulation remain extremely tedious and expensive in memory. We propose an intermediate solution, where the artist represents a 2D cross section of a material, by drawing a multi-layered surface micro-geometry. An efficient 2D ray tracing simulation captures the light distribution specific to those micro-geometries. Off plane deflection is automatically calculated in a probabilistic way, based on the surface normal at the intersection point and the incident ray direction. This results in complete and complex isotropic BRDFs, simulated at interactive rates, and allowing interactive editing of rich and varied materials.

Les modèles de réflexion complexes, avec leurs nombreux paramètres dont certains restent non intuitifs, sont difficiles à contrôler pour obtenir une apparence désirée. De plus, même si un artiste peut plus aisément comprendre la forme de la micro-géométrie d'une surface, sa modélisation en 3D et sa simulation en 4D demeurent extrêmement fastidieuses et coûteuses en mémoire. Nous proposons une solution intermédiaire, où l'artiste représente en 2D une coupe dans un matériau, en dessinant une micro-géométrie de surface en multi-couches. Une simulation efficace par lancer de rayons en seulement 2D capture les distributions de lumière affectées par les micro-géométries. La déviation hors-plan est calculée automatiquement de façon probabiliste en fonction de la normale au point d'intersection et de la direction du rayon incident. Il en résulte des BRDFs isotropes complètes et complexes, simulées à des vitesses interactives, et permettant ainsi une édition interactive de l'apparence de réflectances riches et variées. / Complex reflection models, with their many parameters, some of which are not intuitive at all, are difficult to control when trying to achieve a desired appearance. Moreover, even if an artist can more easily understand the shape of the surface micro-geometry, its 3D modeling and 4D simulation remain extremely tedious and expensive in memory. We propose an intermediate solution, where the artist represents a 2D cross section of a material, by drawing a multi-layered surface micro-geometry. An efficient 2D ray tracing simulation captures the light distribution specific to those micro-geometries. Off plane deflection is automatically calculated in a probabilistic way, based on the surface normal at the intersection point and the incident ray direction. This results in complete and complex isotropic BRDFs, simulated at interactive rates, and allowing interactive editing of rich and varied materials.