In this thesis, a stacked double-layer flat plate oscillating heat pipe charged with degassed DI water was designed, fabricated and characterized under different operating conditions (orientation, system or cooling water temperature and heat load). The oscillating heat pipe was designed to dissipate 500 W within a footprint of 170 x 100 mm2. The oscillating heat pipe had a total of 46 channels (23 channels per layer) with a nominal diameter of 2 mm. Tests were performed to characterize the performance of the oscillating heat pipe for (i) axial heat transfer and (ii) as a heat spreader. The stacked oscillating heat pipe showed a distinctive feature in that it overcame the absence of the gravity effect when operated in a horizontal orientation. The thermal performance was found to be greatly dependent on the operational parameters. The oscillating heat pipe was able to dissipate a heat load greater than 500 W without any indication of dry-out. An increase in the cooling water temperature enhanced the performance and was accompanied with an increase in the on/off oscillation ratio. The lowest thermal resistance of 0.06 K/W was achieved at 500 W with a 50℃ cooling water temperature, with a corresponding evaporator heat transfer coefficient of 0.78 W/cm2K. The oscillating heat pipe improved the heat spreading capability when locally heated at the middle and end locations. The thermal performance was enhanced by 27 percent and 21 percent, respectively, when compared to a plain heat spreader. / Thesis / Master of Applied Science (MASc)

Automotive transmission rattle is the noise generated due to impacts between manual transmissions meshing gear teeth in the presence of backlash. It is considered to be a Noise, Vibration and Harshness (NVH) phenomenon and is originated due to combustion irregularities (engine order vibrations), especially in diesel vehicles. This thesis focuses in the case of creep rattle for the MMT6 Ford Getrag transmission (six speeds plus reverse) with a DW10b, 4-cylinder, 4-stroke, 2.0 litres diesel engine. This particular rattle condition is fundamentally similar to any other where an engaged gear is pertained (drive, over-run or float), with the 1st or 2nd gear engaged at a very low engine speed. The numerical models include an initial single degree of freedom (DoF) simulation. It comprises either of the engaged gear pair under Hertzian contact conditions or of a loose gear pair under hydrodynamic regime of lubrication. Once the validity of this model is established and correlated with the results obtained from a single gear pair test rig, simulations of increasing complexity can be envisaged. A 7 DoF numerical model is, therefore, developed. The Hertzian contact model still prevails for the engaged gear pair, whereas an analytical hydrodynamic solution is implemented for the remaining 6 loose gear wheels and Petrov s law is applied to the needle bearings retaining the gear wheels. With the aim of accommodating a fully lubricated model of all the tribological conjunctions, an analytical elastohydrodynamic (EHL) Grubin type algorithm is employed. Also, the energy equation is analytically solved for hydrodynamic and elastohydrodynamic conjunctions, based on the assumptions dictated by the Peclet number. Therefore, under hydrodynamic conditions, the energy equation is governed by viscous heating and convective cooling, whereas in the EHL conjunctions the governing terms are viscous and compressive heating, together with conductive cooling. The retaining needle bearings follow the same heat generation mechanism as journal bearings. The effective viscosity, as obtained from the Houpert s equation accounting for pressure and thermal effects, is fundamental for the study of the friction in the contact. The hydrodynamic contacts are only governed by viscous friction, whereas EHL conjunctions exhibit asperity iv interactions as well as viscous effects. The results obtained from this new 7 DoF model are then compared to the experimental measurements taken from the vehicle tests and various purpose-built drivetrain rigs. A metric named Impulsion Ratio is hereby introduced, aiming to shed some light into the predictions obtained by the various models presented. This metric is the ratio of driving over resistive forces acting on each individual gear wheel. Its use is tested to predict single or double-sided rattle scenarios and, therefore, ascertaining higher and lower rattle levels. The 13 DoF model from which these conclusions were obtained includes shafts planar translation and rocking moments. The rolling element bearings supporting the shafts are, therefore, modelled to capture the inherent frequencies arising from their motion. The final model introduces the effects of transient thermo-elastohydrodynamics. This 7 DoF dynamic model accounts for a numerical solution of Reynolds equation with Elrod s cavitation algorithm for simultaneous teeth in mesh. The results obtained validate the previously used Grubin assumption by comparing the predicted central film thickness along the full mesh of one tooth. Also, the effect of starved input conditions and thermal and isothermal solutions are studied.

Le procédé de soudage à l'arc sous atmosphère inerte (TIG) est souvent employé pour des assemblages nécessitant une grande qualité du joint soudé. Les propriétés du joint soudé dépendent essentiellement du cycle thermique imposé par l'opération de soudage, de la composition chimique du matériau métallique et des mouvements convectifs du métal fondu dans le bain de fusion. L'écoulement du métal liquide dans le bain de fusion modifie la distribution de température en son sein et à proximité, ainsi que la forme géométrique du joint. Afin d'améliorer l'opération de soudage TIG, par exemple pour accroitre la productivité ou éviter des défauts rédhibitoires, il est nécessaire de bien comprendre les phénomènes physiques mis en jeu dans le bain de fusion ainsi que l'effet des paramètres opératoires (intensité, hauteur d'arc, gaz …) sur ces phénomènes physiques. Dans le but d'appréhender les phénomènes mis en jeu au cours de l'opération TIG et dans le bain de fusion, un modèle multi-physique 2D axisymétrique a été établi et résolu par la méthode des éléments finis (MEF). Les forces telles que Lorentz (électromagnétique), Marangoni (Tension superficielle), Boussinesq et la force de cisaillement du plasma d'arc ont été prises en compte au niveau du bain de fusion. Le modèle TIG établi est utilisé pour prédire la distribution de température et la distribution des vitesses dans le bain de fusion ainsi que la forme géométrique du bain de fusion. Un protocole expérimental a été développé dans le but de valider le modèle proposé. Pour cela, une opération de soudage TIG stationnaire (pas de mouvement de la torche) a été réalisée sur un disque métallique. L'opération a été contrôlée par des mesures de température, par une observation de la formation et de l'évolution de la surface du bain de fusion avec une caméra rapide et un enregistrement des paramètres opératoires (intensité et tension). Toutes les données sont synchronisées entre elles pour permettre une analyse expérimentale pertinente. La confrontation des résultats expérimentaux avec le modèle multi-physique du soudage TIG a fait apparaître une assez bonne adéquation, mais des différences existent, essentiellement liées à la méconnaissance des paramètres décrivant le flux de chaleur utilisé dans la simulation. Le flux de chaleur a été modélisé par une fonction Gaussienne qui nécessite la connaissance du rendement du procédé TIG et la distribution spatiale (ou rayon de la Gaussienne). L'estimation de ces paramètres a été réalisée par une méthode inverse. Cette méthode inverse a consisté à estimer les paramètres inconnus à partir des données expérimentales disponibles. La méthode d'optimisation dite de Levenberg-Marquardt, associée à une technique de régularisation itérative, a été utilisée pour estimer les paramètres. La pertinence et la robustesse de cette méthode ont été validées au travers de plusieurs cas numériques ; soit des cas utilisant des données « exactes » ou des données « bruitées ». Trois types d'erreurs ont été analysés séparément : bruit de mesure, erreur sur la position du capteur et imprécision sur la valeur des propriétés thermophysiques. Les deux dernière erreurs sont celles qui impactent fortement le résultat de l'estimation, essentiellement l'estimation du rendement du procédé TIG. Enfin, une partie des données expérimentales a été utilisée pour résoudre le problème inverse. Les paramètres ont été estimés avec une marge d'erreur inférieure à 10% et ils sont en bon accord avec les valeurs trouvées dans la littérature. / Gas Tungsten Arc Welding (GTAW) process is generally used for assemblies that requires high quality weld joint. The microstructure and the weld joint relies mainly on the thermal cycle due to the welding operation, the chemical composition of the metallic material and the complex flow of molten metal in the weld pool. Moreover the fluid flow in the weld pool play a major role in the temperature distribution and the final weld pool shape. Better understanding of the physical phenomena involved in the welding operation, more exactly in the weld pool, are the fundamental step for improving the GTAW operation, for example increase the productivity or avoid defects. In the present research work, a two dimensional axi-symmetric multiphysics model was established in order to predict the weld pool shape evolution in the frame of a stationary Gas Tungsten Arc Welding using a finite element numerical approach. The weld pool model included various driving forces such as self-induced electromagnetic (Lorentz force), surface tension (Marangoni force), buoyancy and the arc plasma drag force. The stated GTAW model is used for predicting the velocity and temperature distribution in the fusion zone and the final weld pool shape. In order to validate the GTAW model, an experimental set up was defined for synchronizing the acquisition of time dependent data such as temperature, weld pool radius and welding process parameters (current and voltage). Image processing algorithms were developed for the time dependent weld pool size identification from the high speed camera images. Comparison between experimental and calculated data exhibited important discrepancies on the temperature field and weld pool radius. These discrepancies are due to the incoming heat flux from the arc plasma into the work piece. The heat flux was modeled with a Gaussian function itself described with few parameters;two of these required to be estimated: GTAW efficiency and Gaussian distribution.An inverse approach is used for estimating these parameters from the available experimental data: temperature, weld pool radius and macrographs. The Levenberg-Marquardt method is used to solve the inverse heat transfer problem coupled to an iterative process regularization. Afterward the inverse heat transfer problem was investigated through few numerical cases in order to verify its robustness to three sorts of error in the input data (measurement noise, sensor location error and inaccuracies associated with the thermophysical properties). The inverse approach was robust to errors introduced on measurement data. However, errors on the position of sensors or on the knowledge of material thermo-physical properties are problematic on the GTAW efficiency estimation. Finally the inverse problem was solved with experimental measurement. The estimated parameters are in good agreement with the literature. The evaluated error on the estimated parameters is less than 10%.