<p>Quality of the castings is affected by several factors which the designer should take into consideration during the product development process. Although residual stress is one of those, it is often not considered in practical computations. Hence residual stresses are one of the forgotten areas in designing of machine parts. This master thesis is focused on the investigation of residual stresses in a high pressure die casted component, with the aim of extending its service life, by taking results from the study as a feedback.</p><p>The investigation of residual stresses was done on a variety of specimens, cast aluminum flywheel, provided by Husqvarna AB. This flywheel is a component in a product of the same company.In evaluating the residual stresses in the part, two tools-simulation and physical measurement were used. Moreover, comparison with these two methods is also done at an area of interest on the flywheel. The simulation was carried out by using MAGMAhpdc-a module for high pressure die casting process, from the commercial software package MAGMAsoft; while for the physical measurements, the hole drilling method was used, a method believed to be less accurate at low stresses areas.</p><p>The findings obtained from this study show that the results from both procedures are close, with small deviations observed, which reveals the reliability of the hole drilling method even when the stress levels are low. It is also found that the compressive residual stresses dominate in the component-a preferred phenomenon with regards to residual stress.</p>

Quality of the castings is affected by several factors which the designer should take into consideration during the product development process. Although residual stress is one of those, it is often not considered in practical computations. Hence residual stresses are one of the forgotten areas in designing of machine parts. This master thesis is focused on the investigation of residual stresses in a high pressure die casted component, with the aim of extending its service life, by taking results from the study as a feedback. The investigation of residual stresses was done on a variety of specimens, cast aluminum flywheel, provided by Husqvarna AB. This flywheel is a component in a product of the same company.In evaluating the residual stresses in the part, two tools-simulation and physical measurement were used. Moreover, comparison with these two methods is also done at an area of interest on the flywheel. The simulation was carried out by using MAGMAhpdc-a module for high pressure die casting process, from the commercial software package MAGMAsoft; while for the physical measurements, the hole drilling method was used, a method believed to be less accurate at low stresses areas. The findings obtained from this study show that the results from both procedures are close, with small deviations observed, which reveals the reliability of the hole drilling method even when the stress levels are low. It is also found that the compressive residual stresses dominate in the component-a preferred phenomenon with regards to residual stress.

Ce travail porte sur l'étude des effets thermiques dans un palier hydrodynamique, alimentée par une rainure circonférentielle (CGJB) sous charge statique, en tenant compte des phénomènes de rupture de film dans la zone divergente. La recherche expérimentale a été réalisée à l'Université de Poitiers ; elle a permis une détermination minutieuse des champs de pression et de température sur la portée située à l’avant d’un CGJB et dans la section médiane de sa rainure. Ces mesures sous un régime stationnaire sont originales par rapport celles existantes, quel que le type de palier, de par le grand nombre de points de mesure, 180 pour la pression et 144 pour la température, l'instrumentation de haute précision, la large plage de conditions d'exploitation (pression spécifique variant de 0,125 à 2 MPa et vitesse linéaire de l’arbre allant de 5,25 à 21 m/s). Des études du régime transitoire de démarrage au régime stationnaire établi ont été effectuées pour de faibles charges. Des expériences effectuées à l'Université "Politehnica" de Bucarest ont montré une bonne corrélation entre la perte de portance, anti-portance et la rupture du film sur un patin Rayleigh (RSP), ce qui est essentiel pour l'évaluation des phénomènes de rupture dans les paliers. Quelques modèles théoriques ont été utilisés pour évaluer les risques de serrage au démarrage qui est une instabilité thermoélastique catastrophique. Les principaux résultats sont l’obtention d’une base fiable de données expérimentales permettant le développement des modèles théoriques avancés et l’infirmation d’une répartition de pression constante dans la zone divergente et de pression et température constantes dans la rainure d'alime / The main objective of the thesis is to study the thermal effects in steadily loaded circumferential groove journal bearings (CGJBs), including cavitation phenomena occurring in the divergent zone of such bearings. Experimental research conducted at University of Poitiers – Institut Pprime – France enabled a thorough determination of film pressure and temperature fields for the front land of a CGJB plus its mid-groove section, and several performance parameters. Measurements of film pressure and temperature fields under steady-state regime surpassed existing works, regardless of journal bearing design, through: sheer number of land measurement locations, 180 for pressure and for 144 temperature; high precision state of art instrumentation; broad range of operating conditions, 0.125 … 2 MPa specific bearing pressure and 5.25 … 21 m/s shaft speeds. Transient start-up to steady-statestabilization regimes have been investigated at low loads. Experiments at University "Politehnica" of Bucharest – Romania showed a correlation between the downforce thrust and film rupture for a Rayleigh step pin (RSP), important in evaluating divergent zone cavitation phenomena. Theoretical research consisted in developing simple models for evaluating CGJBs performance in steady-state and transient start-up regimes. Several theoretical models were employed for assessing start-up seizure, catastrophic transient thermoelastic instability and damage risk. The major result is a reliable experimental data collection that: enables development of advanced theoretical models; disprove flat film pressure distributions in divergent zones, and constant pressure and temperature in the bearing supply groov