The following paper will illustrate the development of a multiflex chain in hybrid construction. The aim of this novel chain variant is to improve the stiffness and strength in comparison to conventional plastic slide chains. A two part multiflex chain with a chain pitch of 33.5 mm and a structural width of 83 mm was used as the basis for the development of the hybrid multiflex chain. The hybrid multiflex chain is supposed to be integrated in already existing layouts of chain conveyors. The load bearing structure of the single chain links is manufactured in the metal die cast procedure while taking the constructive, production related, and operational aspects into consideration and subsequently covered in the injection molding process with plastics commonly used for multiflex chains. The evaluation of the improved stiffness and strength takes place in the course of extensive test series. / In der folgenden Abhandlung wird die Entwicklung einer Multiflex-Kette in Hybridbauweise erläutert. Mit dieser neuartigen Kettenvariante soll eine Steifigkeits- und Festigkeitssteigerung gegenüber den konventionellen Kunststoffgleitketten erzielt werden. Als Ausgangsbasis für die Entwicklung der hybriden Förderkette dient eine zweiteilig ausgeführte Multiflex-Kette mit der Teilung von 33,5 mm und einer Baubreite von 83 mm. Die hybride Förderkette soll in bestehende Layouts von Kettenförderern integriert werden können. Unter Beachtung konstruktiver, fertigungstechnischer und betrieblicher Aspekte wird die lasttragende Struktur der einzelnen Kettenglieder im Metalldruckgussprozess gefertigt und anschließend mit einem, für Multiflex-Ketten üblichen Kunststoff im Spritzgießprozess ummantelt. Die Evaluierung der Steifigkeits- bzw. Festigkeitssteigerung erfolgt im Rahmen umfangreicher Versuchsreihen.

The objectives of this research were to investigate the wear that occurs on the surface of a Hardcoat anodized die-cast aluminum surface, which was sliding against a composite rubber belt. This research investigated known wear theories and the results for previous testing to understand the mechanisms that were likely occurring in this application. These theories indicated that the wear occurring may be reduced by changing the hardness of the materials involved. Archard's equation gave tangible evidence of this fact, but related to the base material and not a surface coating. It was hypothesized that Hardcoat anodizing would follow the theory of Archard's equation and increase the wear resistance of 390 die-cast aluminum when sliding against a composite rubber belt. Standardized wear tests were implemented in order to test this theory. The results of the wear tests indicated that the wear resistance of the Hardcoat anodized coating did not follow the wear theories and wore at a higher rate than the base material surfaces. This is likely due to the phenomenon seen by Jiang and Arnell where the surface roughness influenced the wear rate of DLC coatings. They found that there existed a transition point where the wear rate of the surface increased with an increase of surface roughness. The Hardcoat anodized surface was rougher than the surface of the base material due to alloy materials and the processing characteristics of 390 Aluminum die-casting material. Subsequently the Hardcoat anodized surface wore at a higher rate than did the base surface. A case study was conducted on an ATV to investigate the accuracy of the results from the laboratory testing. This case study showed a significant localized wear groove in the stock CVT drive sheave with little wear occurring elsewhere. The Hardcoat anodized CVT drive sheave did not show evidence of a significant localized wear groove as the stock sheave but indicates that wear occurred more evenly across the surface. This wear is evident due to visible aluminum through the Hardcoat layer. In addition, there was a ridge at the outer diameter of the sheave where the belt could not wear the surface. Both of these items indicated that significant wear occurred on the surface, but the presence of a localized wear groove is non-existent.

There are a need for reducing the weight of vehicles, one solution is to implement cast lightweight materials such as the high pressure die cast AM50 magnesium alloy. The weldability of this cast alloy is poor and to implement the use of the alloy commercially a welding process is needed that limits the porosity of the weld. The aim of this thesis is to study the effect of the welding parameters on the porosity in the weld, for three laser welding methods. The welding methods examined are single spot and twin spot laser using either a beam splitter or separate optics. The microstructure of the base material are also examined in order to evaluate relations between the components of the microstructure and the porosity in the weld. It was concluded that the hydrogen in the base material was the main reason for the observed porosity in the weld and that the material contains high pressure gas. The welding parameters did not influence the porosity for the single beam laser process, however, for the dual beam processes the welding parameters could affect the amount of pores. It was found that a double weld reduced the amount of pores and that the size and distribution of the secondary phase particles would benefit from the treatment. The cleaning of the samples prior to welding increased the porosity, however, non-cleaned samples contained more oxide inclusions. The results indicate that a twin beam process could reduce the porosity in the weld of the AM50 alloy. / Det finns ett behov av att reducera vikten på fordon, en lösning är att implementera gjutna lätta material såsom formsprutad AM50-magnesiumlegering. Svetsbarheten hos denna gjutna legering är dålig och för att kommersiellt kunna använda legeringen krävs en svetsprocess som begränsar svetsens porositet. Syftet med detta examensarbete är att studera svetsparametrarnas effekt på svetsens porositet för tre lasersvetsmetoder. De svetsmetoder som undersöks är enkelpunkts och dubbelpunktslaser där antingen en stråldelare eller separat optik använts. Basmaterialets mikrostruktur undersöks också för att utvärdera sambandet mellan mikrostrukturen och porositeten i svetsen. Man drog slutsatsen att väte i basmaterialet var huvudorsaken till den observerade porositeten i svetsen och att materialet innehåller gas under högt tryck. De undersökta svetsparametrarna påverkade inte porositeten för processen med en laserstråle, men för dubbelstråleprocesserna kan svetsparametrarna påverka mängden porer. Det visade sig att en svets utförd med två strålar minskade mängden porer och att storleken och fördelningen av sekundärfaspartiklarna gynnas av behandlingen. Prover som rengjordes före svetsning hade ökad porositet, men icke-rengjorda prover innehöll mer oxidinneslutningar. Resultaten indikerar att en dubbelstråleprocess kan minska porositeten då AM50-legeringen lasersvetsas.

This thesis presents a study of inter-bar current effects on induction motors with die-cast aluminium and die-cast copper rotors. The parasitic effects introduced by these currents are analyzed and possible solutions to these problems are presented. This is realized by developing analytical tools for the simulation of inter-bar current effects. The methods used are verified by measurements on prototype machines. It is shown that the inter-bar currents can have a considerable effect on the motor starting performance, which can result in a reduced pull-out torque. At rated operation, this is seen as increased harmonic rotor currents, having a negative effect on the motor performance. Results from calorimetric measurements show, that the efficiency gained when substituting a skewed die-cast aluminium rotor with a skewed die-cast copper rotor, is less than the theoretical expectation. It is shown that this is a result of a reduced power factor for the copper rotor. High inter-bar currents are believed to be the origin of this effect, increasing the harmonic content in the rotor magnetomotive force. This would be seen as an increased rotor leakage reactance. Results from locked-rotor tests, and simulations using measured values of inter-bar resistance, support this theory. It is shown, that these negative effects are suppressed to a negligible level by the use of an unskewed rotor, but to the expense of a large synchronous torque at a low speed. By using a modulated rotor concept, having an asymmetrical rotor slot distribution, an unskewed rotor is designed to reduce this parasitic torque. Measurements on a prototype machine show that the modulated rotor suppresses both the inter-bar currents and the synchronous torque, resulting in an improved starting performance, without any significant change of the motor efficiency. The presented results strengthen the potential of the modulated rotor concept, introducing new possibilities for the reduction of negative effects appearing in induction machines. / <p>QC 20130320</p>

This thesis is focused on defects occurring in products made by high pressure die casting of aluminum alloys. The theoretical part includes introduction to high pressure die casting technology and description of individual defects, causes and corrective procurations. The practical part focuses on the determination of the defect on the pre-selected casting, which is cast in the foundry ALW INDUSTRY, s.r.o. Based on the identification of the defect, there is a corrective procuration to reduce its occurrence.

The following paper will illustrate the development of a multiflex chain in hybrid construction. The aim of this novel chain variant is to improve the stiffness and strength in comparison to conventional plastic slide chains. A two part multiflex chain with a chain pitch of 33.5 mm and a structural width of 83 mm was used as the basis for the development of the hybrid multiflex chain. The hybrid multiflex chain is supposed to be integrated in already existing layouts of chain conveyors. The load bearing structure of the single chain links is manufactured in the metal die cast procedure while taking the constructive, production related, and operational aspects into consideration and subsequently covered in the injection molding process with plastics commonly used for multiflex chains. The evaluation of the improved stiffness and strength takes place in the course of extensive test series. / In der folgenden Abhandlung wird die Entwicklung einer Multiflex-Kette in Hybridbauweise erläutert. Mit dieser neuartigen Kettenvariante soll eine Steifigkeits- und Festigkeitssteigerung gegenüber den konventionellen Kunststoffgleitketten erzielt werden. Als Ausgangsbasis für die Entwicklung der hybriden Förderkette dient eine zweiteilig ausgeführte Multiflex-Kette mit der Teilung von 33,5 mm und einer Baubreite von 83 mm. Die hybride Förderkette soll in bestehende Layouts von Kettenförderern integriert werden können. Unter Beachtung konstruktiver, fertigungstechnischer und betrieblicher Aspekte wird die lasttragende Struktur der einzelnen Kettenglieder im Metalldruckgussprozess gefertigt und anschließend mit einem, für Multiflex-Ketten üblichen Kunststoff im Spritzgießprozess ummantelt. Die Evaluierung der Steifigkeits- bzw. Festigkeitssteigerung erfolgt im Rahmen umfangreicher Versuchsreihen.

The mechanical properties achieved with high performance wrought aluminium alloys are superior to cast aluminum alloys. To obtain an intricate shaped component, wrought alloys are commonly subjected to forging followed by subsequent machining operation in the automobile industry. As machining of such high strength wrought aluminium alloys adds to cost, productivity gets affected. Shortening the process by near net shaped casting would tremendously enhance productivity. However, casting of such alloys frequently encounter hot tear defect. Therefore, circumventing hot tear to successfully die cast near net shaped wrought alloy components is industrially relevant. A recent advanced casting process, namely ‘Semisolid Die casting’, is proposed as a likely solution. Hot tearing originates due to lack of liquid flow in the inter-dendritic region. To reduce hot tear susceptibility, fine and non-dendritic grain structure is targeted, amenable for processing by semisolid route. For semisolid processing an adequate freezing range for processing is required. Accordingly A6061 wrought alloy whose composition is tuned with higher silicon and magnesium content within the grade limits, is chosen for the study. With the objective of obtaining fine and non-dendritic microstructured billets, electromagnetic stirring (EMS) and cooling slope (CS) methods are employed. On conducting a parametric study with EMS, a finest possible primary α-Al grain size of about 70 μm is obtained at low stirring time at stirring current levels of 175 A and 350 A, with the addition of grain refiner. CS, on the other hand, rendered a grain of 60 μm at a slope length of 300 mm at a slope angle of 45° with grain refiner addition. Of the two methods, CS billets are chosen for subsequent induction heating. A 3-step induction heating cycle has been devised to attain a temperature of 641°C in the billet on the basis of factors including coherency point, viscosity of the slurry and solid fraction sensitivity with temperature. The billet microstructure is found to be homogenous throughout after quenching in water. The characterization of phase along primary α-Al grain boundary and its composition analysis is done by SEM and EPMA respectively, after billet casting as well as induction heating. In addition, the bulk hardness is determined in BHN. The induction heated billets are semisolid die cast to produce an engine connecting rod used in automobiles. The microstructure is characterized at various locations, and is found to consist of smooth α-Al grains in a background matrix of fine grains formed due to secondary solidification. The component hardness is found to be 66 BHN comparable with A6061 alloy under T4 heat treated condition. X-ray radiography does not confirm presence of surface hot tear, which is the normal defect associated with casting of wrought aluminium alloys. No defects are observed along the constant cross-sectional area of the connecting rod, suggesting that the processing could be suitable for semisolid extrusion.

Ces travaux de thèse portent sur le comportement élastoplastique et la durée de vie sous chargement cyclique d'un alliage cuivre-zinc injecté sous pression. L'apport essentiel de ces travaux de thèse est la mise en évidence d'un écrouissage isotrope qui s'estompe très rapidement dès la première décharge en plasticité. Une analyse qualitative montre que l'évolution de l'amplitude de contrainte est liée à celle de la contrainte interne. Cette étude est multi-échelles, en effet des observations en microscopie électronique à transmission ont permis d'émettre des hypothèses sur l'origine des phénomènes observés lors des essais mécaniques. Les essais de fatigue ont également montré que la durée de vie du matériau dépend fortement des défauts inhérents au procédé de fabrication. L'utilisation d'un modèle multimécanismes simplifié a permis de modéliser le comportement cyclique du matériau étudié, et de prendre en compte l'évolution quasi instantanée de l'écrouissage isotrope. / These research works deal with the investigation of the cyclique and fatigue behaviour of an industrial high-pressure die cast brass. Mechanical tests highlight relatively important changes of elasticity domain during monotonic loading, mainly due to changes of the internal stress. This study was conducted under different scales of observation. TEM observations enabled hypothesis to explain the "original" cyclic behaviour of the alloy. Fatigue tests showed that fatigue life of the material is quite dependent of the presence of defects that may be due to manufacture process. A simplified version of a multi-mechanism model was used to simulate the cyclic behaviour of the study alloy.

This project deals with increasing efficiency of one phase induction motor with permanent split capacitor. We can whole thesis divide into two parts, the first one is basic and the second is interested in analysis and measurement. First part handles with construction of single phase induction motor, explanation of function principle, start and run of motor. Calculating of efficiency including type of losses, which reduce efficiency. Second part concerns analysis losses including moment load characteristic, motor measurement while rotor is locked, with no load operation, measuring mechanical and additional losses. Further there will be measured useful values for creation model for simulation (reactance of windings etc.). Than will be the model created in ANSYS Maxwell with module RMxprt. After analytic calculation in RMxprt and using Finite Element Method (FEM) load characteristics will be compared together. This comparison gives us information about accuracy of model for simulation. Simulation and measurement will be carried out on another engine with high quality ferromagnetic material used for magnetic circuit of motor. Further will be done simulation of motor with modifications shown in previous chapter for high efficiency.