Pappersbruket BillerudKorsnäs AB är idag en av Sveriges ledande tillverkare och leverantör av förpackningspapper, kartong samt wellråvaror. Företaget har en framtida målsättning att i tillverkningsprocessen bli självförsörjande på energi och detta genom en intern förbränning av biobränsle i form av bark och flis i sodapannor. Sodapannan utgör på så sätt fabrikens energidistributionssystem. Vid den kontinuerliga förbränningen av svartlut följer stoft och slagg med rökgaserna och fastnar på sodapannans värmeytor som består av rörpanel. Detta är problematiskt då slagg på värmeytorna försämrar värmeupptagningen och gör den ineffektiv. Rengöringen av sodapannans värmeytor sker med hjälp av 74 stycken robusta utdragbara sotblåsare, varav cirka 50 är av modell IK-SD. På senare tid har företaget haft återkommande problem med att snäckhjulet i sotblåsarnas växellådor havererar. Genom observationer, överslagsberäkningar och datorbaserade analyser möjliggjordes en hållfasthetsutredning av snäckhjulet. Den tangentiella kraften som påfrestar snäckhjulets kuggar överstiger den beräknade högsta tillåtna tangentiella kraften. Säkerheten mot ytumattning beräknas med överslagsberäkningar till 0,92 och med databaserade analyser till 0,72. Detta innebär att en obefintlig säkerhet råder mot ytutmattning. Snäckhjulets kuggytor drabbas av ytutmattning på grund av påfrestande kuggkrafter samt hårda driftförhållanden, vilket efter en tid leder till kuggbrott. Haveri av snäckväxeln orsakas av bristande smörjning, höga temperaturer och höga kuggkrafter. Höga drifttemperaturer av snäckväxeln orsakar en reducerad smörjförmåga av smörjfettet, vilket leder till extrem förslitning och efter en tid brott av snäckhjulets kuggar.

I pappersmaskiner används kräppblad för att kräppa av pappret från en stor roterande cylinder, en så kallad yankee-cylinder. Dessa blad utstår stora nötningar och beläggs därför med antingen en kromoxidbeläggning eller en hårdmetallsbeläggning för att öka bladets nötningsbeständighet. Bladen beläggs med termisk sprutning, kromoxiden via plasmasprutning och hårdmetallen via "High-Velocity-Oxy-Fuel"-sprutning (HVOF). I detta arbete har slitagetester utförts på belagda kräppblad genom att använda en "slider-on-flat-surface" (SOFS) tribometer för att ta reda på vilken av dessa beläggningar som är bäst lämpad för att användas på kräppblad. Vid användning av SOFS belastas kräppbladen med en normalkraft och glider mot en platta till önskad total glidsträcka är uppnådd. För att kunna genomföra slitagetesterna i SOFSen behövdes en fixtur konstrueras och tillverkas och kräppblad behövde kapas till önskad geometri. Det skapades tre koncept för fixturen och med en beslutsmatris gjordes valet vilken av dem som skulle tillverkas. Den tillverkade fixturen håller kräppbladen stabila i både sidled och i glidriktningen och håller kräppbladen i en vinkel likt i verkligheten. Slitagetesterna utfördes vid tre olika glidsträckor med konstant normallast. Efter slitagetesterna analyserades bladen i stereomikroskop och svepelektronmikroskop för att identifiera nötningsmekanismer. De dominerande nötningsmekanismerna var abrasiv och adhesiv nötning. På grund av porositet i beläggningarna ökades antalet sprickor och mer och mer fragment lossnade vid ökande glidsträcka under slitagetesterna. Det visade sig efter mätningar av bortnött bredd på bladet att det hårdmetallbelagda kräppbladet hade bäst nötningsbeständighet. Detta på grund av dess hårda tungstenkarbider som minskade den abrasiva nötningen och spricktillväxten i beläggningen och dess högre duktilitet jämfört med kromoxiden. / Creping blades are used in paper machines for creping tissue paper from a rotating cylinder called a yankee cylinder. These blades experience severe wear and are therefore coated by either chromium oxide or a hard metal coating to make the blades more wear resistant. The coatings are sprayed on to the blade by thermal spraying processes, the chromium oxide coating with plasma spraying and the hard metal coating with "High-Velocity-Oxy-Fuel" (HVOF) spraying. In this thesis wear testing of the coated creping blade using a "slider-on-flat-surface" (SOFS) tribometer has been done to find out which of these coatings that is best suited for coating on the creping blade. When using the SOFS, the creping blade is subjected to a chosen normal force and is scraped against a counterface for a set total distance. In order to execute the wear tests in SOFS, construction and manufacturing of a holder for the creping blades was needed and the creping blades had to be cut to correct geometry. Three concepts were created for the holder and the decicion about which one to manufacture was made with a decision matrix. The new holder holds the creping blades stable in side movements and in the sliding direction. It also keeps the blade at a set angle to the counterface as in the real application. The wear tests consisted of three sliding distances with constant normal load. The blades were analyzed in a stereo microscope and in a scanning electron microscope to identify the wear mechanisms when the wear tests were completed. The major wear mechanisms were abrasive and adhesive wear. Because of porosity in the coatings, the number of cracks increased and fragments from the blades came loose when increasing the sliding distance during the wear tests. It showed that by measuring the eroded width on the blades that the hard metal coated blade had the best wear resistance because of the hard tungsten carbides that lowered the abrasive wear and the crack growth in the coating and because of its higher ductility in comparison to chromium oxide.

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.

This project has been executed at the forestry machine track manufacturer Olofsfors AB and has been aimed at development of a rig for simulation of the wear that occurs in the linkage of Olofsfors AB forestry machine tracks. The problem is that link hooks in the tracks wears out first, often several times faster than other components. Olofsfors AB want to be able to test this wear in a controlled environment. The purpose of the wear rig is to distinguish what type of wear that is in effect as well as be able to optimize materials for Olofsfors AB: s products.   The project began with an pilot study of different types of relevant wear and different types of complete methods of wear measurement and simulation to better understand the problem. After this a market screening of existing machines and rigs that could be of interest was done. The project continued with creation of concepts of wear rigs and methods of wear. After a selection process the project proceeded with one concept to a 3D prototype.   From the market screening it could be found that the market is very thin with few suppliers. Their products are relatively expensive and need specially made test samples. The recommendation to Olofsfors AB will therefore be to construct a rig themselves. The market screening could be used by Olofsfors AB as a basis if they decide to expand their test activity in the future.    The project reached the overall goals and delivered a prototype that passes the set demands. This means that the project is basically ready to move on to construction of a physical wear rig. There are still some problems to overcome but these will be easiest to solve during the construction phase. / Projektet har utförts hos skogmaskinbandstillverkaren Olofsfors AB och har gått ut på att ta fram en rigg för att simulera den nötning som uppstår i länksystemet på Olofsfors AB:s skogsmaskinband. Problemet är att länkkrokar i banden nöts ut först, ofta flera gånger snabbare än andra komponenter. Nu vill Olofsfors AB kunna testa denna nötning i kontrollerade miljöer. Syftet med nötningsriggen är att kunna avgöra vilken typ av nötning som verkar samt kunna göra materialoptimering för Olofsfors AB:s produkter.   Projektet inleddes med en förstudie av olika typer av relevant nötning samt olika typer av färdiga metoder för att mäta och simulera nötning för att förstå problemet bättre. Efter detta gjordes en marknadsundersökning av befintliga maskiner och riggar som kan vara av intresse. Projektet fortsatte med konceptgenerering av nötningsriggar och nötningsmetoder. Efter utsållning gick projektet vidare med ett koncept till en 3D-prototyp.   Från marknadsundersökningen konstaterades det att marknaden är väldigt smal med få leverantörer. Deras produkter är relativt dyra och kräver speciella provbitar. Rekommendationen till Olofsfors AB blir därför att konstruera en egen rigg. Marknadsundersökningen kan användas som underlag av Olofsfors AB om de vill expandera sin testverksamhet i framtiden.   Projektet nådde de övergripande målen och levererade en prototyp som klarar av uppsatta krav. Detta innebär att projektet är i stort sett redo att gå vidare till konstruktion av en fysisk nötningsrigg. Vissa problem kvarstår, men dessa löses enklast under konstruktionsfasen.

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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.

No description available.

No description available.

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)