Surface texturing of rubbing surfaces represents the way how to increase tribological performances by improving the lubrication film formation and diminishing friction and wear. Its application in machine components requires detailed understanding of the mechanism taking place between rubbing surfaces in microscopic scale. This diploma thesis is focused on the processes taking place in tribology systems to consider the possibility of surface texturing applications in highly loaded machine parts operated under transient operational conditions.

Le palier hydrodynamique est une solution de guidage en rotation particulièrement appréciée pour ses caractéristiques d’amortissement à hautes vitesses de rotation. Cependant les performances des machines tournantes lubrifiées par un film fluide sont impactées par des effets non linéaires difficiles à analyser. La prédiction du comportement du système par la simulation nécessite une modélisation avancée de l’écoulement de lubrifiant dans le palier hydrodynamique. Enfin, l’état de surface semble avoir un impact important sur l’écoulement du fluide lubrifiant, lui-même agissant sur les caractéristiques statiques et dynamiques des parties tournantes. Cette étude vise à améliorer les modèles numériques liés à l’impact de l’état de surface des paliers hydrodynamiques sur la dynamique de ligne d’arbre. La méthode d’homogénéisation multi-échelles a été utilisée à cet effet dans un algorithme multi-physiques pour décrire l’interaction entre la structure flexible en rotation et les films fluides des supports de lubrification. Différents modèles ont été utilisés pour prendre en compte la présence de zone de rupture de film lubrifiant. Des méthodologies non-linéaires fréquentielles ont été mises en place afin de permettre l’étude paramétrique des solutions périodiques d’un tel système et de leur stabilité. Afin de confronter ce modèle complexe à la réalité, un banc d’essai miniature a également été conçu. Différents échantillons présentant des états de surface modifiés par ablation à l’aide de LASER femto-seconde ont été testés. L’étude expérimentale a permis de vérifier certaines tendances prévues par la simulation. Des améliorations des performances des paliers hydrodynamiques par rapport aux vibrations auto-entretenues du système ont été démontrées pour certaines textures. En revanche toutes les améliorations ne sont pas prédites par les algorithmes d’homogénéisation multi-échelles. La présence de recirculation dans les aspérités du motif a été mise en évidence à partir de la résolution locale des équations de Navier-Stokes. Ce résultat participe à la remise en question des hypothèses classiques utilisées en texturation, et peut justifier les améliorations obtenues expérimentalement avec les paliers texturés. / The hydrodynamic bearing provides good damping properties in rotating machineries. However, the performances of rotor-bearings systems are highly impacted by nonlinear effects that are difficult to analyze. The rotordynamics prediction requires advanced models for the flow in the bearings. The surface of the bearings seems to have a strong impact on the lubricant flow, acting on the static and dynamic properties of the rotating parts. This study aims to enhance the simulation of the bearings’ surface state effect on the motion of the rotating shaft. The flexible shaft interacts with textured hydrodynamic bearings. Multi-scales homogenization is used in a multi-physics algorithm in order to describe the fluid-structure interaction. Different models are used to account for the cavitation phenomenon in the bearings. Nonlinear harmonic methods allow efficient parametric studies of periodic solutions as well as their stability. Moreover, a test rig has been designed to compare predictions to real measurements. Several textured shaft samples modified with femto-seconds LASER surface texturing are tested. In most cases the experimental study showed similar results than the simulation. Enhancements of the vibration behaviors of the rotor-bearing system have been revealed for certain texturing patterns. The self-excited vibration, also known as "oil whirl" phenomenon, is stabilized on a wide rotating frequency range. However, the simulation tool does not predict well the enhancements that are observed. Vortices in surface texturing patterns have been revealed numerically with Navier-Stokes equation resolution. These results are opposed to the classical lubrication hypothesis. It is also a possible explanation of the enhancements that are experimentally measured with textured bearings.

Neste trabalho foram realizadas otimizações no processo de fabricação de micro cavidades na superfície do aço DIN 16MnCr5, com o objetivo de reduzir o coeficiente de atrito dinâmico entre duas superfícies. Para a confecção das micro cavidades (dimples) foi utilizado um laser com pulsos ultracurtos, de largura temporal de algumas dezenas de femtossegundos. Além de estudos de variação de fluência do laser, também foi analisado o resultado da utilização de diferentes perfis de energia do feixe. Para a caracterização das micro cavidades, foram utilizadas técnicas como a microscopia eletrônica de varredura, para análise morfológica, interferometria de luz branca e microscopia confocal para análise topográfica, dimensional e perfilométrica. Foram realizados ensaios de desgaste, em tribômetro para análise da variação do coeficiente de atrito após a texturização. Após os ensaios, percebeu-se que a texturização com pulsos ultracurtos apresenta grande vantagem na confecção de micro cavidades devido a precisão e ausência de interação térmica entre o laser e o material. Em relação ao atrito, as amostras texturizadas apresentaram redução da força e do coeficiente de atrito, porém, foram observados sinais de aumento da pressão de contato entre as superfícies. / In this work, optimizations were realized in the dimples manufacturing process on DIN 16MnCr5 steel surface, the target were to reduce the coefficient of dynamic friction between two surfaces. A laser with ultrashort pulses, temporal width of a few tens of femtoseconds, was used to manufacture dimples. In addition to studies of variation of laser beam fluency, the results of the use of different beam energy profiles were also analyzed. For analysis of dimples, techniques such as scanning electron microscopy (SEM), for morphological analysis, white light interferometry and confocal surface microscopy were used for topographic, dimensional and perfilometry. Wear tests were performed to analyze the variation of the friction coefficient in texturing surface. After the tests, it was observed that the texturing with ultrashort pulses presents a great advantage in manufacturing of dimples, due to the precision and absence of thermal interaction between the laser beam and the material. In relation to the friction coefficient, the textured samples presented a reduction of the friction force and consequently of the friction coefficient, but an increase in the contact pressure between the studied surfaces was observed.

L'objectif principal de cette thèse est de conduire, à travers une étude théorique et expérimentale, vers une meilleure compréhension des différents effets induits par la texturation de surface dans un contact lubrifié. Le but ultime est de proposer un motif de texture qui permette de réduire le frottement et le niveau de fuite d'une garniture mécanique. L'étude bibliographique a permis d'identifier les différents travaux théoriques et expérimentaux réalisés sur la lubrification en présence de textures, les phénomènes physiques interagissant avec les textures et les différentes méthodes utilisées pour leur mise en forme. Une étude théorique utilisant un modèle conservatif basé sur l'équation de Reynolds est ensuite présentée. Dans la première partie de cette étude, les faces de frottement sont supposées parfaitement parallèles et les effets thermoélastiques sont négligés. Dans la seconde partie, les échanges de chaleur avec les anneaux et les déformations thermoélastiques sont pris en compte. Une étude paramétrique a permis de mieux comprendre l'influence des paramètres géométriques des textures, des défauts de formes et des déformations thermoélastiques des faces sur le fonctionnement de la garniture. En outre, cette étude a permis de définir une texture capable d'améliorer significativement les performances d'une garniture mécanique. Des essais expérimentaux ont ensuite été réalisés avec une garniture mécanique texturée et une garniture mécanique non texturée. Des mesures de couple de frottement et des relevés de température effectués par thermographie infrarouge ont montré que l'utilisation des textures permet de réduire de manière significative la température et le couple de frottement par rapport à une garniture à surfaces lisses. Enfin, une comparaison théorie/expérimentation a permis de valider le modèle développé qui prédit de façon correcte le comportement de la garniture texturée. / The main objective of this thesis is to lead, through a theoretical and experimental study, to a better understanding of the various effects induced by surface texturing in lubricated contacts. The ultimate goal is to provide a texture pattern that reduces friction and leakage of a mechanical seal. The literature review identified different theoretical and experimental works performed on lubrication in the presence of textures, physical phenomena interacting with textures and the different methods used for their manufacturing. A theoretical study using a conservative model based on Reynolds equation is then presented. In the first part of this study, the friction surfaces are assumed perfectly parallel and thermoelastic effects are neglected. ln the second part, heat transfer to the rings and thermoelastic deformations are taken into account. A parametric study then allows bettering our understanding of the influence of geometrical parameters of textures, defects and thermoelastic deformations of the faces on the performance of a mechanical seal. In addition, this study has identified a texture capable of significantly improving the performance of a mechanical seal. Experimental tests were then carried out with bath textured and untextured mechanical seals. Friction torque measurements and temperature measurements achieved by means of infrared thermography have shown that the use of textures allows to significantly reduce heat and friction torque compared with a seal with smooth surfaces. Finally, a comparison theory/experiment validated the developed model that predicts correctly the behavior of the textured mechanical seal.

Neste trabalho foram realizadas otimizações no processo de fabricação de micro cavidades na superfície do aço DIN 16MnCr5, com o objetivo de reduzir o coeficiente de atrito dinâmico entre duas superfícies. Para a confecção das micro cavidades (dimples) foi utilizado um laser com pulsos ultracurtos, de largura temporal de algumas dezenas de femtossegundos. Além de estudos de variação de fluência do laser, também foi analisado o resultado da utilização de diferentes perfis de energia do feixe. Para a caracterização das micro cavidades, foram utilizadas técnicas como a microscopia eletrônica de varredura, para análise morfológica, interferometria de luz branca e microscopia confocal para análise topográfica, dimensional e perfilométrica. Foram realizados ensaios de desgaste, em tribômetro para análise da variação do coeficiente de atrito após a texturização. Após os ensaios, percebeu-se que a texturização com pulsos ultracurtos apresenta grande vantagem na confecção de micro cavidades devido a precisão e ausência de interação térmica entre o laser e o material. Em relação ao atrito, as amostras texturizadas apresentaram redução da força e do coeficiente de atrito, porém, foram observados sinais de aumento da pressão de contato entre as superfícies. / In this work, optimizations were realized in the dimples manufacturing process on DIN 16MnCr5 steel surface, the target were to reduce the coefficient of dynamic friction between two surfaces. A laser with ultrashort pulses, temporal width of a few tens of femtoseconds, was used to manufacture dimples. In addition to studies of variation of laser beam fluency, the results of the use of different beam energy profiles were also analyzed. For analysis of dimples, techniques such as scanning electron microscopy (SEM), for morphological analysis, white light interferometry and confocal surface microscopy were used for topographic, dimensional and perfilometry. Wear tests were performed to analyze the variation of the friction coefficient in texturing surface. After the tests, it was observed that the texturing with ultrashort pulses presents a great advantage in manufacturing of dimples, due to the precision and absence of thermal interaction between the laser beam and the material. In relation to the friction coefficient, the textured samples presented a reduction of the friction force and consequently of the friction coefficient, but an increase in the contact pressure between the studied surfaces was observed.

L'adhésion des revêtements est l'objectif premier de tout système afin de pouvoir apporter les propriétés de surface voulues par projection thermique. De façon conventionnelle, des traitements de sablage sont régulièrement employés afin de promouvoir des phénomènes d'ancrage mécanique entre les deux matériaux mis en contact.Néanmoins, selon la nature même des matériaux, un certain nombre de limitations peuvent être observées aussi bien d'un point de vue usage que tenue. Une fragilisation des surfaces peut en effet être remarquée dès lors qu'ils'agit du traitement de matériaux ductiles. Pour palier certaines de ces contraintes, des traitements palliatifs sont alors recherchés parmi lesquels les traitements laser apparaissent particulièrement bénéfiques dont la texturation laser. Les revêtements barrière thermique sont l'application visée de cette étude avec comme objectif une optimisation de leur durabilité à chaud (oxydation, fluage). Une sous-couche d'accroche est habituellement déposée mais les modes d'endommagement recensés semblent se concentrer autour de cette dernière. L'objectif de c etravail a donc visé à remplacer la sous-couche par une topographie de surface spécifique du substrat générée partexturation laser et permettant un ancrage mécanique suffisant aux chargement mécaniques et thermiques subis par les aubes de turbines hautes températures.Lors de l'interaction laser-matière, une élévation en température de l'extrême surface jusqu'à la température defusion et de vaporisation du matériau peut être observée et permettre la formation de motifs. Les dimensions de tels motifs sont donc liées à l¿énergie par impulsion et au nombre d¿impulsions. Pour valider de tels effets, les mécanismes de perçage ont donc été étudiés grâce à une modélisation thermo hydraulique et une validation postmortem des échantillons. Les dimensions des motifs alors contrôlées, le remplissage des surfaces texturées par des particules fondues projetées par le procédé APS a été étudié afin de minimiser le nombre de défauts proche de l'interface. Deux modes de rupture ont pu être identifiés en fonction de la morphologie de surface pour descontraintes de traction et de cisaillement. Les fissures se propagent à l'interface jusqu'à avoir des changements dedirection. L'énergie de propagation de la fissure augmente donc jusqu'à atteindre une valeur limite correspondant àla ténacité du revêtement. Dans ce cas, la tenue n'est pas fonction de la surface totale en contact mais de larépartition spatiale et l'ouverture des motifs, la seule limite de la tenue du revêtement restant la cohésion du dépôt.D'un point de vue applicatif, le but de cette étude a été de caractériser les modes d'endommagements de systèmes barrière thermique sans sous-couche pour des conditions rencontrées en service. Les mécanismes d'endommagement dus à l'oxydation et à l'allongement viscoplastique à 1100C ont donc été isolés par des essais àdes flux thermiques isothermes et cyclés, de fluage et de fatigue thermomécanique. Le traitement laser modifiant localement la microstructure des surfaces, une modification des couches d'oxydes a tout d'abord pu être identifiée.En effet, contrairement aux traitements conventionnels où la croissance d'oxyde n'est pas constante (point limitant de la durée de vie du système), l'apparition de spinelles et d'une couche dense d'alumine protectrice en surface des matériaux texturés a pu être observée. L'ancrage mécanique ainsi créé a démontré alors une durée de vie nettement améliorée face à des conditions extrêmes. / Coating adhesion is requiered to rpomote specific surface properties by thermal spraying. Conventional prior-surface treatments have been developed to create anchoring zones but the adhesion strenght and their applications are limited. Laser surface texturing increases and adapts the adhesion surface. Therefore, two interface failure modes have been related to texture morphologies for tensile and shear stresses. The energy released rate at the interface increases up to coating toughness when the crack path is sharp. Mixed-mode failures have been observed with adhesive and cohesive cracks around and above pattern respectively. So, the adhesion stengyh is function of the contact aera precisely linked to pattern distribution and morphology. Thermal barrier coating system without bond coat life-span has been evaluated for thermomechanical stresses (YSZ coating on single crystal based Nickel). The bond coat has been remplaced by an adapted substrate surface topography. According ti the laser parameters (energy per pulse, pulse numbers) pattern morphology can be created. Therefore, textured surface filling by melted particles has been studies to minimize interface defaults and created mixed-mode failures for during plasma spray coatings. The drilling mechanisms have been evaluated by numerical modeling and experimental analysis. The pattern dimensions and heat affected zones has been identified. The laser treatment changes the microstructure locally.Oxydation tests have been performed to study the surface pre-tratments effects on oxide nature and mass gain rate. The damaging mechanisms ave been studied under isotherm and cyclic high temperature tests and also under creeping and thermo-mechanical fatigue tests. Grit-blasting change the natural oxides, limits life-span and bucking failure mode have been obeserved. Natural oxides have been analyzed for the textured substraes also but anchoring mechanism enables large life-span under high temperature tests. Mechanical applied stresses (constant and cyclic) validate the beneficial effects of patterned surfaces. The interface is stronger than the coating toughness and the patterns do not create early cracks under thermo-mechanical solicitations.

Conselho Nacional de Desenvolvimento Científico e Tecnológico / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / Fundação de Amparo a Pesquisa do Estado de Minas Gerais / A texturização superficial é uma importante ferramenta a ser utilizada na diminuição do atrito em contatos lubrificados, sendo sua eficácia atestada tanto em simulações como experimentalmente. Uma grande barreira para a utilização em escala industrial da texturização superficial e a dificuldade de se encontrar métodos de inserção destes padrões superficiais que combinem rapidez de implementação e baixo custo, tornando assim a técnica mais competitiva. O objetivo deste trabalho é investigar a viabilidade de se inserir texturas superficiais na superfície interna de cilindros automotivos de ferro fundido cinzento, utilizando método de texturização superficial sem mascaramento (MECT), o qual combina baixo custo e elevada velocidade de texturização. Uma vez estabelecidos os parâmetros de texturização do método MECT para o ferro fundido cinzento, foram conduzidos ensaios anel-bloco a fim de comparar os ganhos na redução do atrito e do desgaste de amostras texturizadas quando comparadas a amostras polidas mecanicamente e eletroquimicamente. O MECT se mostrou um método viável, rápido e de baixo custo para texturização de camisas de cilindros automotivos. Nos ensaios anel-bloco as amostras texturizadas superficialmente apresentaram menores coeficiente de atrito e volume desgastado em relação as amostras polidas mecanicamente e eletroquimicamente. / Surface texturing is an important tool to be used for reduction of the friction force in lubricated contacts, being its effectiveness evidenced in simulations and experimentally. A major barrier to use surface texturing in an industrial scale is the difficulty of finding application methods of these surface patterns that combine both high speed and low cost, thus making the surface texturing a more competitive technique. The objective of this work is to investigate the potentiality of inserting surface textures on the inner surface of an automotive cylinder liner made of grey cast iron, using Maskless Electrochemical Texturing Method (MECT), which is a both low cost and high-speed texturing process. Once established the texturing parameters for the method MECT for the grey cast iron, were made Block-on-Ring tests to compare the improvement in reducing friction force and wear of the textured samples in comparison with samples mechanically and electrochemically polished. The method MECT proved to be a viable method for texturing of automotive cylinder liners, being both fast and low cost. In the Block-on-Ring tests, the texturized samples showed lower friction coefficient and wear volume compared to the mechanically and electrochemically polished samples. / Dissertação (Mestrado)

Fundação de Amparo a Pesquisa do Estado de Minas Gerais / Surface texturing can be used to improve the tribological performance of mechanical contacts, in particular in the case of lubricated systems. The purpose of this work is to improve an alternative method for surface texturing based on electrochemical machining. Electrochemical dissolution combines high speed, good reproducibility and high cost-benefit ratio, which are important factors when an industrial application of surface texturing is pursued. Since the area to be textured is not required to be masked, the technique is optimized, without the need of a pre or post treatment of each surface. Another nonconventional machining technique, Electrical Discharge Machining (EDM), was used to drill microholes in the cover of the tool that will be used in the microtexturing operations. The pattern of microholes in the tool is copied onto the workpiece through the action of electrochemical dissolution. The improvement of the electrochemical texturing technique was achieved with the design of an electronic circuit with a data acquisition system and of an electrochemical cell and with the specification of the electrolyte pumping system, which improved the surface finish of the textured workpiece, as well as with the development of tools that made possible the confection of different microtexture patterns. In the electrochemical cell, the tool material was AISI 230 ferritic stainless steel and the workpiece material was carbon steel AISI 1010o. Sodium Chloride was chosen as the electrolyte tool makes the electrical contact between the electrodes. During the electrochemical texturing tests, the effect of important parameters such as the gap between electrodes, the applied voltage and the total texturing time were evaluated, and the best values found were a gap of 100 mm, a voltage between 30V and 40V and a texturing time between 20s and 60s. Different texturing patterns were obtained with good results, including dots, trace-dots and chevrons. A tribological test showed a reduction in friction and wear of a textured surface lubricated with MoS2, when compared with a smooth surface. / A texturização superficial pode ser utilizada para melhorar o desempenho tribológico de contatos mecânicos, em particular em regimes lubrificados. O presente trabalho tem o objetivo de aprimorar uma metodologia alternativa para a texturização de superfícies baseada em princípios de usinagem eletroquímica. A dissolução eletroquímica alia rapidez, reprodutibilidade e elevado custo-benefício, que são extremamente importantes quando se visa a aplicação da microtexturização em escala industrial. O não mascaramento da área a ser texturizada otimiza a técnica, dispensando um tratamento prévio e posterior de cada superfície. Uma técnica também não convencional de usinagem, a eletroerosão, foi utilizada para a microfuração da tampa da ferramenta a ser usada na microtexturização. O padrão de microfuração da ferramenta é copiado à peça pela ação da dissolução eletroquímica. O aprimoramento da técnica de texturização eletroquímica foi acompanhado pelo projeto de um circuito eletrônico com sistema de aquisição de dados, de uma célula eletroquímica e pelo dimensionamento de um sistema para bombeamento e fluxo de eletrólito, que permitiram uma melhora no acabamento superficial das peças microtexturizadas, além do desenvolvimento de ferramentas que viabilizaram a confecção de diferentes padrões de microtexturização. Na célula de texturização eletroquímica, o material da ferramenta foi o aço inoxidável ferrítico AISI 430 e o da peça foi o aço carbono 1010. O eletrólito escolhido para promover o contato elétrico entre os eletrodos foi o NaCl. Durante a texturização eletroquímica foram avaliados parâmetros importantes como o distanciamento entre eletrodos, a tensão aplicada e o tempo total de texturização, sendo que os melhores resultados foram obtidos para um distanciamento de 100 mm, uma tensão de 30 a 40 V e um tempo de texturização entre 20 e 60 s. Foram texturizados ainda padrões com formatos de ponto, traço-ponto e V , obtendo-se bons resultados. Um teste tribológico mostrou uma redução do atrito e uma diminuição do desgaste de uma superfície texturizada lubrificada com MoS2, quando comparada com uma superfície lisa. / Mestre em Engenharia Mecânica

Tato disertační práce se zaměřuje na studium závislosti mezi reakčním momentem ložiska mazaného plastickým mazivem s lithným mýdlem a vlastnostmi maziva, jako například tloušťka vytvářeného mazacího filmu, jeho reologie, struktura zpevňovadla, trakční vlastnosti či vliv topografie povrchu. Typ maziva poskytujícího nižší odpor závisí na podmínkách provozu ložiska, zejména rychlosti. Chování mazacího filmu za nízkých rychlostí má vliv na reakční moment ložiska v nízkých rychlostech. Mez toku a trakční chování koreluje s momentem ložiska za vysokých rychlostí. Schopnost zpevňovadla vstupovat do kontaktu má vliv na tloušťku filmu, vzhled kavitační oblasti na výstupu kontaktu a chování hladovění. Důvod vstupu zpevňovadla do kontaktu je jeho chemická struktura. Vysoká polárnost hydroxylových sloučenin zpevňovadla podporuje jeho vtažení kontaktními povrchy. Mazivo s nejvyšší polaritou prokázalo na površích obsahujících denty nejčastější vstup do prostoru dentů. Na základě předchozích pozorování je navržen popis principu mechanismu mazání.

The diploma thesis deals with the analysis of the effects surface texturing on starved contact. Experimental verification was realized on apparatus simulating contact between a steel ball and glass disc using colorimetric interferometry and high-speed camera. The work deals with lubrication regimes, problems with starved contacts and surface texturing which can reduce effects of starvation on non-conformal surface contacts.