Cone crushers are widely used in the mining, mineral processing and quarrying segments of the industry to crush ores and large rocks. In such machinery, the load to be carried is rather heavy and the motion is gyratory which creates a need for a bearing set that can withstand such severe conditions. Sandvik AB is a high-technology Swedish engineering group specialized in tools and tooling systems for metal cutting, equipment, as well as tools and services for the mining and construction industries. One of their products relevant to the mining industry is the cone crusher which utilizes a 3-piece bearing set to carry thrust load. This bearing can be classified as a Spiral Groove Bearing \footnote{The abbreviation S.G.B will be used interchangeably throughout the thesis.}, and it has been incurred that it wears out rather quickly and is believed to be running under mixed-lubrication conditions where the interfaces in the bearing-set are not fully lubricated. The aim behind this thesis is to create a multiphysics model of this bearing in order to understand deeply how it works and the reasons why it does not perform as expected as well as to predict design improvements which can improve the performance of the bearing-set, thus increasing its operating life. It has been concluded that the bearing operates under severe mixed-lubrication conditions and that the generation of a squeeze film is the only method by which lubrication takes place due to the excessive depth of the grooves which is needed to allow for an adequate amount of cold oil to flow into the grooves and cool the interface as well as to accommodate for a considerable amount of wear particles. In light of the results and insight gathered from the simulations, possible design variations of the bearing which can be advantageous in terms of mitigating asperity friction in the interfaces of the bearing are discussed and tested.

No description available.

I denna studie undersöks möjligheterna att ta fram en alternativ inslagstråd till Bolons vävda PVC-golv för att förbättra dess akustiska egenskaper. Golvet som studien utgick från var vävt i tvåskaft med PVC-garn i varp och väft. Den nya inslagstråden måste klara de processbetingelser som Bolons golvproduktion innebär utan att krympa mer än 5 %, antända eller brytas ned. För att möjliggöra förvaring, installation samt få en högre motståndskraft mot nötning bör inslagstråden fixera med PVC-varpen. Det färdiga golvet, skall klara nötning utan att trådbrott eller färgändring uppstår. Samt uppvisa en förbättrad ljudabsorption. Krympning hos garn samt garns fixering med PVC har testats genom, för studien framtagna, test. Fixeringen i det färdiga golvet testades med en dragprovsmaskin. Absorption av ljud testades genom mätning av strömningsmotstånd enligt standarden ISO 9053. Nötningstest utfördes med en stolshjulsmaskin enligt SS EN 985. Utifrån studien dras slutsatsen att ett alternativt inslagsgarn ger ökad ljudabsorption hos Bolons vävda golv. Frågetecken kvarstår dock hur väven skall stabiliseras för att erhålla användarvänlighet då de studerade materialen ej fixerar. I och med den uteblivna fixeringen samt garnens konstruktion nöts de framtagna vävarna i golvkonstruktion betydligt mer än Bolons originalgolv. / Program: Textilingenjörsutbildningen

Efficiency of internal combustion engines (ICEs) is far from optimal. Due to the continuously increasing demands on CO2 regulations, automobile industries are forced to improve such efficiency. A crankshaft roller bearing (CSRB) can lead to significant improvements in engine efficiency. However, before this can be implemented into an actual engine, several challenges have to be addressed. One such challenge is the satisfactory performance of CSRB. The current crankshaft limits the service life since it must act as a roller bearing raceway. Therefore, better material properties are required for the use of CSRB in crankshaft applications. In order to select suitable material for the CSRB, development of several characterization methods is required. These methods are based on failure modes that are expected to occur in the actual application. Surface initiated fatigue was shown to be the main failure mode that could lead to complete failure of such a component. The following three characterizations needs are identified: material characterization, lubricant characterization and surface roughness characterization. Two of these methods are partially part of this thesis. Material characterization is required to select the optimal steel candidate for the CSRB component. A method was developed to assess the damage modes on a reference 100Cr6 steel pair under conditions prevalent to CSRB application. However, fully formulated oil was excluded from this investigation and only low-additive oil was employed. Micro-pitting and wear damage modes were identified and were later assessed. Different surface roughness combinations were tested, from where micro-pitting regions were identified. In addition, the effects of surface hardness and sliding on micro-pitting and wear were investigated. It was found that hard steel contacts are more prone to micro-pitting damage compared to soft ones, but less susceptible to mild wear. In addition, higher sliding increases the degree of micro-pitting and wear. Lubricant characterization was performed to optimize the engine oil formulation for rolling contacts. A method to assess different engine oils in terms of micro-pitting and wear damages of rolling contacts was employed. The effect of viscosity, additive chemistry and different mixtures of base oils on aforementioned performance were presented and discussed. In addition, lubricant characterization will provide in-depth knowledge for engine oils’ manufacturers to improve engine oil formulations for satisfactory performances of CSRB design.

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En väl fungerande järnväg är en viktig del av Sveriges och stora delar av världens infrastruktur. Hundratusentals människor transporterar sig dagligen till och från arbete efter den svenska järnvägen samtidigt som det efter samma spår sker en storskalig godstransport genom tungt lastade godståg.   Att kunna planera underhållet av ett järnvägssystem är en viktig del för att erhålla en hög funktionssäkerhet hos systemet. Plötsliga fel och haverier av järnvägshjul är i dagsläget en stor anledning till driftstörningar och driftstopp. Med en utökad kunskap kring spridningen av nötningen i järnvägshjulet kan man prediktera slitage och prognostisera hjulets livslängd och då även planera framtida underhåll. På så sätt kan funktionssäkerheten öka, detta genom att minska risken för driftstörningar.   Arbetets resultat kommer att redovisas genom en statistisk analys av hjulparametrar i en teknisk rapport innehållande nödvändig teori samt överskådliga figurer i form av tabeller, diagram och plottar. Figurerna är baserade på analys av insamlade mätdata från LKAB:s lokverkstad i Kiruna, Sverige.   Studien visar att nötning och skador uppträder runt om hela hjulets omkrets där flänsbredden är den parameter där det sker störst förändring. / A well-functioning railway is an important part of Sweden's amongst many other countries infrastructure. On daily basis hundreds of thousands of people use the railway as their primary mode of transportation. Meanwhile on the same track there’s a large-scale transportation of goods by heavy loaded cargo trains.   Planning the maintenance of the railway and its components is important in order to achieve a high-level functionality of the system. Sudden failure of railway wheels is one of the biggest causes of downtime of the railway system. Increased knowledge about the spread of wear around the wheel could result in a higher level of functionality of the system, this by being able to predict the wear and prognosis the need of maintenance.   This project will be presented as a statistical analysis in the form of a technical report which contains the necessary theory as well as figures in the form of diagrams and plots. The figures are based on analysis of collected measurement data from LKAB’s locomotive workshop in Kiruna, Sweden.   This study shows that abrasion and other types of wheel damage occur all around the circumference of the wheel and the flange width is the parameter where most abrasion occurs.

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This thesis is based on two different projects, one more focused on applied research and one on more basic research. The first project examines the po- tential of nitriding as an alternative to case hardening in tribologically loaded components while the second project involves micro scale studies of the relations between roughness, transfer and friction between metals. The first project consists of an evaluation of the tribological properties of nitrided steels. The aim is to increase the understanding of the wear and fric- tion behavior of different nitrided steels in relation to the choice of steel grade, microstructure, thickness and composition of the compound layer, among other parameters. This study is a part of a bigger project called Surf- Nit, which primary objective is to optimize the nitriding process in order to increase the use of nitrided steels for applications like high stress compo- nents. Today case hardening is the standard heat treatment for these applica- tions but nitriding is both more environmentally friendly and less time con- suming. In the present study, the steel grade with the highest content of ni- tride-forming elements and highest hardness showed the best wear re- sistance, regardless of the composition of the compound layer. Further, steels of a given grade but with different phase compositions of the compound layer showed differences in their wear behaviour. It was also shown that nitrided steels with ε-phase in the compound layer acted more brittle than those containing Υ’. The goal of the more basic project is to increase the understanding of the mechanism behind sliding friction. The main focus has been the relation between friction and material transfer. A better understanding can be of help when developing new tribological materials, for example wear resistant components that can operate without lubrication. It could also enable specif- ic recommendations for surface finishes to avoid material transfer and be of help when trying to make more realistic tribological models. Scratch tests have been performed on samples with different surface roughness and dif- ferent surface composition. It was shown that nano scale topography had a bigger impact on both material transfer and friction compared to micro scale topography. Experiments both in air and in situ in a SEM have been per- formed to determine the effect of presence of air on the friction and material transfer. The experiments in air resulted in more material transfer and higher friction than those performed in vacuum. Both lubricated and unlubricated contacts have been studied in order to see how surfaces otherwise separated by boundary lubrication will be affected if the lubrication fails.

The wear of a machine, whether it is due to fatigue or abrasive wear, will add contaminants, in the form of particulates, to the system in question. Since a total breakdown of the machine can be rather costly, one wants to be able to foresee breakdowns and increase the machine life. Follow-up checks of machines are often performed to enable one to detect an increase in wear, and thereby replace the machine or remove it for service. This licentiate thesis mainly deals with the problems associated with contamination control and sample withdrawal. A survey of where and how to take a representative sample is performed using Stokes' law and the migration of spheres in a channel. Some different techniques to measure the contamination are also presented, together with their advantages and disadvantages. Sampling routines for proper sample withdrawal are included. The thesis also includes some field aspects concerning the influence of particles and the wear of grease-lubricated rolling element bearings. / Godkänd; 2001; 20070316 (ysko)

In the field of tribology, there are numerous theoretical models that may be described mathematically in the form of integro-differential systems of equations. Some of these systems of equations are sufficiently well posed to allow for numerical solutions to be carried out resulting in accurate predictions. This work has focused on the contact between rough surfaces with or without a separating lubricant film. The objective was to investigate how surface topography influences contact conditions. For this purpose two different numerical methods were developed and used. For the lubricated contact between rough surfaces the Reynolds equation were used as a basis. This equation is derived under the assumptions of thin fluid film and creeping flow. In highly loaded, lubricated, non- conformal contacts of surfaces after running-in, the load concentration no longer results in plastic deformations, however large elastic deformations will be apparent. It is the interaction between the hydrodynamic action of the lubricant and the elastic deformations of the surfaces that, in certain applications, enable the lubricant film to fully separate the surfaces. This is commonly referred to as full film elastohydrodynamic (EHD) lubrication. Typical machine elements that operates in the full film EHD lubrication (FL) regime include rolling element bearings, cams and gears. Unfortunately, a cost effective way of machining engineering surfaces seldom results in a surface topography that influence contact conditions in the same way as a surface after running-in. Such topographies may prevent the lubricant from fully separating the surfaces because of deteriorated hydrodynamic action. In this case the applied load is carried in part by the lubricant and in part by surface asperities and/or surface active lubricant additives. This could also be the case in lubricant starved contacts, which is a common situation in not only grease lubricated contacts but also in many liquid lubricated contacts, such as high speed operating rolling element bearings. The load sharing between the highly compressed lubricant and the surface and/or surface active lubricant additives is the reason why this lubrication regime is most commonly referred to as mixed EHD lubrication (ML). Machine elements that while running operate in the FL regime may experience a transition into the ML regime at stops or due to altered operating conditions. It is not possible to simulate direct contact between the surfaces using a numerical method based on Reynolds equation. A parameter study, of elementary surface features passing each other inside the EHD lubricated conjunction, was performed. The results obtained, even though no direct contact could be simulated, does indicate that a transition from the FL to the ML regime would occur for certain combinations of the varied parameters. At start-ups, the contact in a rolling element bearing could be both starved and drained from lubricant. In this case the hydrodynamic action becomes negligible in terms of load carrying capacity. The load is carried exclusively by surface asperities and/or surface active lubricant additives. This regime is referred to as boundary lubrication (BL). Operation conditions could also make both FL and ML impossible to achieve, for example, in the case in a low rpm operating rolling element bearing. The BL regime is in this work modeled as the unlubricated frictionless contact between rough surfaces, i.e., a dry contact approach. A variational principle was used in which the real area of contact and contact pressure distribution are those which minimize the total complementary energy. A linear elastic-perfectly plastic deformation model in which energy dissipation due to plastic deformation is accounted for was used. The dry contact method was applied to the contact between four different profiles and a plane. The variation in the real area of contact, the plasticity index and some surface roughness parameters due to applied load were investigated. The surface roughness parameters of the profiles differed significantly. / Godkänd; 2004; 20070128 (ysko)