A challenge in engineering coupling design is the understanding of performance of contact geometry for a given application. “Wear” is one of a number of mechanical failures that can occur in mechanical coupling design. “Fretting wear” occurs where surfaces in contact are subjected to oscillating load and very small relative motion over a period of time. Fretting has been observed in many mechanical interactions and is known to be a reason for failure in many designs. Recent evidence suggests that fretting wear occurs at the taper junction of modular total hip replacements and leads to failure of the implants. Experimental testing to determine the wear behaviour that occurs in mechanical devices is time consuming, expensive and complicated. Computational wear modelling is an alternative method which is faster and cheaper than real testing and can be used in addition to testing to help improve component design and enhance wear characteristics. Developing an algorithm that can accurately predict fretting wear considering linear wear, volumetric wear and surface wear damage is the main focus of this thesis. The thesis proposes a new computational methodology incorporating published wear laws into commercial finite element code to predict fretting wear which could occur at the taper junction of total hip replacements. The assessment of wear in this study is solely based on mechanical wear (fretting) as being the primary mechanism causing surface damage. The method is novel in that it simulates the weakening of the initial taper ‘fixation’ (created at impaction of the head onto the stem in surgery) due to the wearing process. The taper fixation is modelled using a contact analysis with overlapped meshes at the taper junction. The reduction in fixation is modelled by progressive removal of the overlap between components based on calculated wear depth and material loss. The method has been used for three different studies to determine surface wear damage, linear and volumetric wear rates that could occur at taper junction of total hip replacements over time. The results obtained are consistent with those found from observation and measurement of retrieved prostheses. The fretting wear analysis approach has been shown to model the evolution of wear effectively; however, it has been shown that accurate, quantitative values for wear are critically dependant on mesh refinement, wear fraction and scaling factor, wear coefficient used and knowledge of the device loading history. The numerical method presented could be used to consider the effect of design changes and clinical technique on subsequent fretting wear in modular prosthetic devices or other mechanically coupled designs.

abstract: The demand for miniaturized components with feature sizes as small as tens of microns and tolerances as small as 0.1 microns is on the rise in the fields of aerospace, electronics, optics and biomedical engineering. Micromilling has proven to be a process capable of generating the required accuracy for these features and is an alternative to various non-mechanical micro-manufacturing processes which are limited in terms of cost and productivity, especially at the micro-meso scale. The micromilling process is on the surface, a miniaturized version of conventional milling, hence inheriting its benefits. However, the reduction in scale by a few magnitudes makes the process peculiar and unique; and the macro-scale theories have failed to successfully explain the micromilling process and its machining parameters. One such characteristic is the unpredictable nature of tool wear and breakage. There is a large cost benefit that can be realized by improving tool life. Workpiece rejection can also be reduced by successfully monitoring the condition of the tool to avoid issues. Many researchers have developed Tool Condition Monitoring and Tool Wear Modeling systems to address the issue of tool wear, and to obtain new knowledge. In this research, a tool wear modeling effort is undertaken with a new approach. A new tool wear signature is used for real-time data collection and modeling of tool wear. A theoretical correlation between the number of metal chips produced during machining and the condition of the tool is introduced. Experimentally, it is found that the number of chips produced drops with respect to the feedrate of the cutting process i.e. when the uncut chip thickness is below the theoretical minimum chip thickness. / Dissertation/Thesis / Masters Thesis Engineering 2015

Wear condition modelling is a research topic which lately has increased in popularitydue to its significance to the railway industry. Large sums are spent on maintenanceof the network every year, which has generated a demand for understanding and predictingwear mechanisms in a multitude of components within both railway vehiclesand infrastructure. To acquire this knowledge, using a simulation software to predictwear and maintenance needs, is a cheap and dependable option. This thesis sets outto create a wear modelling software for the catenary-pantograph interaction, which intheory could enlighten railway operators of the condition of their infrastructure. This research contains an extensive literature review on the subject of wear modelling,analysing different strategies and theories of the wear mechanism and desired modelproperties. Thereafter, an attempt to recreate a model for a representative Swedishcase was conducted; implementing parameters of a typical Swedish rail vehicle to awear rate formula, recreating a passage of a pantograph sliding along the catenary.The output was a wear rate as a function of time, a determination of life expectancyfor the infrastructure and a worn profile of the catenary wire after one year of operation. The model, named AWEAR, was deemed functional for determining wear mechanismtendencies and behaviour for a few cases of alternating parameters. However, sinceno validation could be performed due to a lack of resources, the validity of the outputvalues could not be confirmed - thus leaving calibration of the model to future work.In conclusion, AWEAR needs to be calibrated for future research but does contain amultitude of enhancement opportunities proposed in this thesis. While not completelyfunctional, the software was deemed a useful foundation for future projects and mightresult in a product that aids operators maintaining their infrastructure.Keywords: Wear modelling, catenary pantograph interaction, mechanism, / Slitagemodellering är ett forskningsområde som den senaste tiden har ökat i popularitetpå grund av dess betydelse till järnvägsindustrin. Stora summor spenderas på underhållav nätverket varje år, vilket har genererat en efterfågan på att förstå och förutspåslitage i en mängd olika komponenter inom både spårfordon och infrastruktur.För att uppnå vetskapen, är att använda simulering till att förutspå slitage och underhållsbehov, ett billigt och tillitsfullt alternativ. Detta arbete söker att skapa ett slitagemodelleringsprogram för interaktionen mellan pantograf och kontaktledning, vilket iteorin skulle kunna upplysa järnvägsoperatörer om skicket på deras infrastruktur. Denna forskning innehåller en genomgående litteraturstudie inom ämnet slitagemodellering, där det olika strategier och teorier analyseras om slitagemekanism och önskade modellegenskaper. Därefter görs ett försök på att återskapa en modell för ettrepresentativt svenskt fall; där parametrar för svenska järnvägsfordon och svensk infrastruktur implementeras i en ekvaktion för att simulera en passage av en pantografglidandes längst med en kontaktledning. Resultatet var en slitagenivå som funktionav tiden, ett fastställande av förväntad livslängd på infrastrukturen och en modelleradprofil av kontaktledningen efter ett år i tjänst. Modellen, döpt till AWEAR, ansågs funktionabel till att identifiera tendenser inomslitagemekanism och beteende för ett fåtal fall av alternerande parametrar. Då ingenjämförelse med resultat och data från riktiga scenarion genomfördes på grund utav enbrist på resurser, kunde resultaten från modellen inte bekräftas och därmed lämnadeskalibreringen åt framtida arbete. Sammanfattningsvis behöver AWEAR kalibrerasför framtida forskning men innehåller därtill en mängd olika förbättringsmöjligheterföreslagna i denna rapport. Även om modellen hitills inte är fullkomligt funktionabel,kan den skapade mjukvaran anses vara nyttigt grundmaterial för framtida projekt. Islutändan kan detta därmed

L’allègement des véhicules automobiles imposés par des nouvelles règlementations remettent en question le choix des matériaux et des designs dans le développement des nouvelles pièces mécaniques dans l’industrie automobile. Pour les rotules de suspension, cet allègement a pour conséquence l’augmentation de l’intensité du chargement subi par ces organes qui assurent la stabilité du véhicule et sa tenue sous différentes conditions de roulage : virage, freinage brusque, franchissement d’obstacles, etc.. Sous un chargement intense, des phénomènes d’endommagement d’origines mécanique, thermique et tribologique peuvent apparaitre dans le contact conforme de la rotule. La caractérisation et la modélisation de ces phénomènes en fonction du chargement incident ont particulièrement été abordées dans ce travail de thèse. Des essais d’endommagement ont été réalisés sur des rotules automobiles fournies par le partenaire industriel VT2i afin d’appréhender l’influence des sollicitations intenses et répétées sur la dégradation de la fonction rotule d’un véhicule. La reproduction de ces phénomènes sur des éprouvettes ont permis d’identifier les lois de comportement des matériaux constituant la rotule et de définir leur fonctionnement optimal selon les cahiers des charges établis par les clients de VT2i. Une modélisation de l’endommagement du contact pivot-coussinet de la rotule a été proposée et confrontée aux résultats d’essais expérimentaux. La bonne adéquation des résultats de la modélisation avec ceux des essais montre la pertinence de la démarche adoptée. Cette dernière consiste à (i)- analyser la cinématique de la rotule de suspension en fonction du chargement imposé, (ii)- identifier l’évolution du champ de contraintes pendant les phases de roulage, (iii)- calculer le champ de glissements dans le contact et enfin (iv)- évaluer la contribution des différents modes d’endommagement dans la dégradation totale de la rotule. La modélisation a permis de mettre en place un outil d’aide à l’optimisation du contact pivot-coussinet de la rotule et la conception de nouvelles géométries répondant aux contraintes techniques sévères du marché pour notre partenaire industriel / Car weighting from new guidelines challenges material and design engineering in new automotive applications. For suspension ball joints, products weighting consequences are the increase of thermomechanical loading supported by the parts which ensure car stability and road handling (curves, hard braking, obstacle crossing, etc.). Under such loadings, the damage of ball joints are due to mechanical, thermical and tribological aspects that can occur in the conformal contact interface. Characterization and modelling of such phenomenon under different thermomechanical loading has been particularly studied. Damage tests performed on automotive ball joint made by our industrial partner VT2i led to understand the influence of intense and repeated solicitation on the part degradation. The analysis of the same phenomenon tested on material probe test gives information about its behavior and define convenient application regime for each VT2i customer demand. A damage modelling in suspension ball joint contact interface has been proposed and compared to damage tests performed on real ball joints. This good adequation between experimental and modelling results confirmed the pertinence of the proposed modelling approach which consists in (i) analyzing kinematical behavior under different loadings of suspension ball joints, (ii) identifying the stress field evolution during the driving phases, (iii) evaluating the sliding distance field in the contact interface, and last (iv) evaluating the damage mode contributions to the total degradation of the ball joint. The modelling allowed to develop an assistance tool for optimization and design of new ball stud/ball socket contact and geometries of suspension ball joints, responding to the severe technical specifications of the automotive market for our industrial partner VT2i

La qualité des pièces découpées pour les industries électroniques et micromécaniques est appréciée via trois critères principaux : le niveau de bavure, l’aspect du bord découpé et la précision dimensionnelle. Or, l’étude de la qualité des pièces découpées ne peut se faire sans une compréhension de l’usure des poinçons. Ainsi, des méthodes de mesure en continu et in situ de l’usure ont été mises au point et validées, soit l’activation superficielle et la mesure par double réplique. Ainsi, il a été possible de suivre l’influence d’un certain nombre de paramètres du procédé sur l’évolution de l’usure lors du découpage. Par ailleurs, nous avons mis au point une méthode de quantification de la bavure sur la totalité du contour découpé. Il a ainsi été possible d’étudier l’évolution de la bavure au cours de la découpe. L’aspect des bords découpés a été examiné grâce à des relevés topographiques permettant le suivi de son évolution. Ainsi, une corrélation entre la cinétique d’usure des poinçons et l’apparition de la bavure a été établi. De plus, une simulation expérimentale de l’usure des poinçons a été entreprise. Un dispositif expérimental de tribométrie a été conçu et installé sur la ligne de presse, simulant les conditions de frottement d’un poinçon sur une tôle. Il a permis d’évaluer l’abrasivité des tôlesminces vis-à-vis des poinçons. Par ailleurs, une modélisation numérique de l'opération de découpage par éléments finis a été entreprise, permettant d’approcher le profil d’usure d’un poinçon de géométrie cylindrique. Et par conséquent la possibilité de prédire son évolution en fonction du nombre de pièces découpées devient accessible en fonction des paramètres du procédé / The blanked parts quality for electronic and amicromechanical industry is assessed using threemain criterions: the burr amount, the appearance ofthe cut edge and dimensional accuracy. However, thestudy of the quality of the blanked pieces can not bedone without an understanding of the punches wear.Thus, methods for continuous and in-situ wearmeasurements have been developed and validated:Thin Layer Activation and measurement by doublereplica. Thus, it was possible to follow the influenceof process parameters on the wear evolution duringblanking.In addition, we have developed a method forquantifying the burr on the entire blanked contour. Itwas thus possible to study the evolution of the burrduring blanking. The appearance of the cut edges wasexamined by means of topographic survey for monitoringits evolution. Thus, a correlation between the kinetics ofpunches wear and the appearance of the burr has beenestablished. In addition, an experimental simulation ofpunches wear was undertaken. An experimentaltribometry was designed and installed on the press line,simulating the conditions of friction of a punch on onesheet. It evaluated the abrasiveness of thin sheets againstthe punches.Additionally, a numerical modelling of blanking wasundertaken to approach the wear profile of a punch ofcylindrical geometry. And therefore the ability to predictits evolution contingent on the number of blanked pieces becomes available depending on process parameters