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<p>The purpose of this thesis was to study the influence of manufacturing variations on gear performance. The manufacturing variations inherent in different manufacturing methods were studied to include the effect of real surfaces. Real surfaces have surface irregularities at least on some scale, which can significantly influence how loads are transmitted at the gear contact. To some extent, the lubricant design can help to prevent contact that could lead to tooth failures by forming a protective surface boundary layer. An experimental study was used to consider the compositions of these layers with a surface analysis method.</p><p>In Paper <strong>A</strong> a robust design approach was used to find out to what extent the current standard for calculation of surface durability treats manufacturing variations and the choice of lubricant. The results show that the simplest calculation method used is not enough to predict the effect of these on surface durability. Additionally, the standard quality levels are poorly incorporated in the standard calculating procedures for surface durability, and the quality of the gear tooth is restricted to include only a few parameters.</p><p>In Paper <strong>B</strong> a pin-on-disc machine was used to evaluate the tribofilm formation by the additives and the corresponding wear occurring in the boundary lubrication regime in environmentally adapted lubricants. Studies of the additive and base fluid interaction were carried out using glow discharge-optical emission spectroscopy. It was found that the chemically reacted surface boundary layers played an important role in terms of wear. More specifically, the oxide layer thickness had significant influence on wear. The findings also demonstrate the complexity of lubrication design formulations coupled to these layers. For example, it was found that the pre-existing surface boundary layer (before any lubricant had been added) played an important role in allowing the lubricant to react properly with the surfaces.</p><p>The aim of Paper <strong>C</strong> was to contribute to the knowledge of how different surface topographies, tied to manufacturing methods, influence the early life contact conditions in gears. Topographical measurements of differently manufactured tooth flanks were used as data input to a contact analysis program. The variation in surface topography inherent in the manufacturing method was found to have a strong influence on the contact area ratio.</p>

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The purpose of this thesis was to study the influence of manufacturing variations on gear performance. The manufacturing variations inherent in different manufacturing methods were studied to include the effect of real surfaces. Real surfaces have surface irregularities at least on some scale, which can significantly influence how loads are transmitted at the gear contact. To some extent, the lubricant design can help to prevent contact that could lead to tooth failures by forming a protective surface boundary layer. An experimental study was used to consider the compositions of these layers with a surface analysis method. In Paper A a robust design approach was used to find out to what extent the current standard for calculation of surface durability treats manufacturing variations and the choice of lubricant. The results show that the simplest calculation method used is not enough to predict the effect of these on surface durability. Additionally, the standard quality levels are poorly incorporated in the standard calculating procedures for surface durability, and the quality of the gear tooth is restricted to include only a few parameters. In Paper B a pin-on-disc machine was used to evaluate the tribofilm formation by the additives and the corresponding wear occurring in the boundary lubrication regime in environmentally adapted lubricants. Studies of the additive and base fluid interaction were carried out using glow discharge-optical emission spectroscopy. It was found that the chemically reacted surface boundary layers played an important role in terms of wear. More specifically, the oxide layer thickness had significant influence on wear. The findings also demonstrate the complexity of lubrication design formulations coupled to these layers. For example, it was found that the pre-existing surface boundary layer (before any lubricant had been added) played an important role in allowing the lubricant to react properly with the surfaces. The aim of Paper C was to contribute to the knowledge of how different surface topographies, tied to manufacturing methods, influence the early life contact conditions in gears. Topographical measurements of differently manufactured tooth flanks were used as data input to a contact analysis program. The variation in surface topography inherent in the manufacturing method was found to have a strong influence on the contact area ratio.

Droplet evaporation and condensation are two important topics of interest, since these two phase-change phenomena not only occur in the cycle of global water, e.g., the formation of rain, fog, dew, and snow in nature, but also play a critical role in a variety of applications including phase-change heat transfer enhancement, surface chemistry and energy system optimization. Especially, in the past two decades, the rapid development of the nature-inspired non-wetting surfaces has promoted the applications of droplet-based phase change phenomena in various scenarios. However, most previous studies focused on the sessile droplets on one flat surface in the open space, and the effects of surface topography, i.e., surface curvature or configurations, on droplet evaporation and dropwise condensation are still elusive. This dissertation aims to explore droplet-based evaporation and condensation in more complex spaces and to elucidate how the surface topography affects the evaporating or coalescing droplet dynamics during these phase-change processes. The coalescence-induced jumping of nanodroplet on curved superhydrophobic surface is modeled via molecular dynamic simulations. As the surface curvature increases from 0 to 2, the corresponding energy conversion efficiency of jumping droplet during the coalescence process could be significantly improved about 20 times. To explain this curvature-enhanced jumping effect, the contact line dissipation, i.e., an important source of energy dissipation in nanoscale, is considered in our scaling energy analysis. And this energy-effective jumping of coalesced droplet could be mainly attributed to the reduction of contact line dissipation due to the decrease of contact line length and contact time on curved surface. As the droplets are confined between two parallel or non-parallel low-energy surfaces, i.e., hydrophobic or superhydrophobic surfaces, with a narrow gap, the total evaporation time of the squeezed droplets would be dramatically prolonged about two times. An ellipsoidal segment diffusion-driven model is established to successfully predict the evolution of contact radius and volume of the squeezed droplets during the evaporation process and to clarify it is the vapor enrichment inside the confined space giving rise to the mitigated evaporation. If two hydrophobic surfaces are configured as non-parallel, the confined droplet inside the V-shaped grooves would be self-transported towards the cusp/corner during the evaporation. Based on our energy and force analyses, the asymmetrically confined droplet would move towards an equilibrium location le, where the Laplace pressure induced force is balanced with normal adhesion force, to minimize its Gibbs surface energy. As le decreases during the evaporation, this equilibrium location would directionally shift towards the cusp, which could be regarded as the origin of this evaporation-triggered unidirectional motion. For the first time, the solvent transport and colloidal extraction could be accurately controlled in a combined manner. / Doctor of Philosophy / Droplet evaporation and condensation are two important topics of interest, since these two phase-change phenomena not only occur in the global cycle of water including the formation of rain, fog, dew, and snow in nature, but also play a critical role in a variety of applications including heat transfer enhancement, surface chemistry, and the energy system optimization. Generally, the droplets in these scenarios are deposited on one flat surface opened to the atmosphere. and the effects of surface topography on droplet evaporation and dropwise condensation are still elusive. This dissertation aims to explore droplet-based evaporation and condensation in more complex spaces and to clarify how the surface curvature or configurations affects evaporating or condensing droplet dynamics accompanying these phase change processes. As the coalesced droplet jumps off the curved superhydrophobic surfaces during dropwise condensation, the corresponding energy conversion efficiency would be significantly improved about 20 times due to the increases of curvature. It is demonstrated that the decrease of contact line length and contact time would give rise to the reduction of contact line dissipation, which should be the main factor driving this energy-effective jumping of the coalesced droplets. As the droplets are confined between two parallel or non-parallel low-energy surfaces, i.e., hydrophobic or superhydrophobic surfaces, with a narrow gap, the total evaporation time of the squeezed droplets would be dramatically prolonged about two times in the small space. An ellipsoidal segment diffusion-driven model is established to successfully predict the evolution of contact radius and volume of the squeezed droplets during the evaporation and to clarify it is the vapor enrichment in the confined space giving rise to the mitigated evaporation. If two hydrophobic surfaces are configured as non-parallel, the confined droplet inside the V-shaped grooves would be self-transported towards the cusp/corner of the structure during evaporation. Based on our energy and force analyses, the asymmetrically confined droplet would move towards an equilibrium location le, where the Laplace pressure induced force is balanced with normal adhesion force, to minimize its Gibbs surface energy. As le decreases in the scale of during the evaporation, this equilibrium location would directionally shift towards the cusp, which could be regarded as the origin of this evaporation-triggered unidirectional motion.

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