Materials can flow down a slope in a wide range of geophysical and industrial contexts, including lava flows on volcanoes and thin films on coated surfaces. The aim of my research is to provide quantitative insight into these forms of motion and their dependence on effects of the topography, the volume and the rheology of the flowing structure. Numerous different problems are investigated through mathematical models, which are developed analytically and confirmed by laboratory experiments. The initial advance of long lava flows is studied by considering the flow of viscous fluid released on sloping channels. A scaling analysis, in agreement with analog experiments and field data, offers a practical tool for predicting the advance of lava flows and conducting hazard analysis. A simple and powerful theory predicts the structure of flows resulting from any time-dependent release of fluid down a slope. Results obtained by the method of characteristics reveal how the speed of the advancing front depends importantly on the rate of fluid supplied at an earlier time. Viscous flows on surfaces with different shapes are described by similarity solutions to address problems motivated by engineering as well as geophysical applications. Pouring viscous fluid out of a container can be a frustratingly slow process depending on the shape and the degree of tipping of the container. The discharge rate of the fluid is analysed in simple cases, shedding light on how containers can be emptied most quickly in cosmetic and food industries. In a separate study motivated by coating industries, thin films are shown to evolve with uniform thickness as they drain near the top of a horizontal cylinder or sphere. The leading edge eventually splits into rivulets as predicted theoretically and confirmed by experiments. Debris flows can develop levees and trigger avalanches which are studied by considering dense granular flows down a rough inclined plane. Granular materials released down a slope can produce a flowing structure confined by levees or trigger avalanches at regular intervals, depending on the steady rate of supply. The experimental results are discussed using theoretical ideas of shallow granular flows. Finally, materials flowing in long and slender ducts are investigated theoretically to better understand the digestive and urinary systems in biology. The materials are pumped in an elastic tube by translating waves of muscular contraction and relaxation. The deformation of the tube is predicted by solving a free-boundary problem, a similar mathematical exercise to predicting the moving boundaries of materials spreading on slopes.

Manufacturing by mechanical machining has historically benefited from the use of cutting fluid. Cutting fluids help to reduce temperature, friction, flush away chips, and hence prolong tool life and improve machining performance. However, uncontrolled use of cutting fluid raises concern in respect of cost and environmental burden. For these reasons, dry machining is used in conjunction with high speed machining to reduce cycle times and simultaneously deliver a greener process. However, for some workpiece materials full implementation of dry machining is not economically viable due to the absence of the essential cooling and lubricating functions delivered by cutting fluids. The most feasible bridging technology is minimum quantity lubrication (MQL) where a very small flow rate of coolant/lubricant is delivered to the cutting zones. In terms of machinability, the application of MQL is promising. However, most studies conducted on MQL focused on the feasibility of MQL application and show-casing the technical benefits. No studies had been identified in literature systematically investigating the relationship between cutting conditions and MQL with the goal of optimising the process. Moreover, the presumed environmental benefits of MQL have not been systematically assessed because Life Cycle Analysis (LCA) derived evaluation models do not explicitly model the impact of machining conditions such as feedrates, cutting velocities and depth of cut.The motivation for this PhD work was to select the optimum machining process variables for maximising effectiveness of MQL, to explore process improvements and to assess the environmental credentials of the process in relation to other forms of cutting environments. In this work, high speed, end milling tests on tool steel were undertaken and 1) Taguchi methods were used to optimise the process, 2) the sensitivity of tool wear to nozzle position was evaluated and 3) the environmental burden of dry, MQL and flood coolants were evaluated based on direct energy needs and process outputs. A fluid soaking device was used to assess the amount of fluid collected or presumed to be delivered to the cutting zone for different nozzle orientations.The Taguchi process optimisation suggested that in HSM the size effect, brought about by a low chip thickness, should be considered in the search for an optimum process window for HSM. A significant and novel finding of this PhD was the dominance of MQL nozzle positioning. The study clearly showed that when machining hardened steel at a high cutting speed and RPM the tool life could be significantly increased by 50% by adjusting the position of the nozzle toward the rake face in relation to the end-milled face. The work opens up new science and provides recommendations as to where to align the nozzle when end milling tool steel at high cutting speeds. The fluid trapping and the blade-wiping angle are key parameters that influenced the effective delivery of MQL when high spindle revolutions per minute are used. These results from the fluid soaking device were found to correlate strongly with observed machining performance evaluations.In terms of modelling, the PhD developed an improved and more generic direct energy model that can be used to determine the environmental burden for direct electrical energy requirements and the energy embodied in other process material outputs. This model addresses the system boundary and activity that within the control of the manufacturing plant. The model was used to evaluate the environmental performance of dry, flood and MQL fluids. The impact of these results and models in optimising environmental performance was also illustrated.The work in this PhD is important to industry in that it contributes to the optimisation of MQL and gives an assessment of the environmental impact. The PhD developed new and significantly important machining science in the positioning of nozzles in MQL machining at higher speeds.

Orientador: Katia Lucchesi Cavalca Dedini / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-26T18:02:41Z (GMT). No. of bitstreams: 1 Tsuha_NataliaAkemiHoshikawa_M.pdf: 4686995 bytes, checksum: aeef3d6d2e979e94d873690470d3d153 (MD5) Previous issue date: 2015 / Resumo: Mecanismos camos-seguidores são extremamente importantes em equipamentos modernos, amplamente utilizados em motores de combustão interna e máquinas que exigem movimentos complexos com repetibilidade e confiabilidade. O camo é um corpo sólido e seu perfil em conjunto com o tipo do seguidor define um movimento que pode ser muito difícil, ou mesmo impossível, de reproduzir com outros mecanismos. O projeto do par camo-seguidor envolve muitas variáveis a serem consideradas. Para um deslocamento desejado, fatores, como tensão e desgaste superficial, devem ser minimizados. Para isso, é importante estudar as características do filme de óleo no contato, já que esse reduz o atrito entre o camo e o seguidor. Portanto, o objetivo desta dissertação é analisar o mecanismo desde a sua cinemática, desenho do perfil, curva de força, até a determinação das condições de lubrificação (distribuição de pressão e espessura de filme). O tipo de lubrificação mais comum em camos é a elastohidrodinâmica (EHD), a qual considera tanto a dinâmica do filme de óleo quanto a deformação no contato gerada devido às grandes pressões no lubrificante. Como as equações do modelo EHD não são lineares, foram aplicados métodos numéricos com malha cuja discretização é variável ¿ Métodos Multiníveis (Multigrid e Integração Múltipla Multiníveis ¿ MLMI). A principal dificuldade de estudar lubrificação em camos é decorrente da alteração dos parâmetros do equacionamento durante sua rotação. O raio de curvatura, a velocidade tangencial ao contato e a força são variáveis durante o ciclo e tanto dependem da modelagem dinâmica do mecanismo quanto estão relacionados a sua velocidade de rotação. Para este trabalho, foram comparadas as condições de lubrificação EHD durante um ciclo de operação do camo para os seguidores de face plana e de rolete, ambos em movimento de translação, e a duas velocidades de rotação distintas do camo / Abstract: Cam-follower mechanisms are extremely important in modern equipments, widely used in automotive engines and machinery that requires complex motion with repeatability and reliability. A cam is a solid body and its shape in conjunction of follower¿s type defines a movement that can be too difficult or even impossible to reproduce with others mechanisms. The project of cam-follower pair involves many variables to consider. For a desired displacement, factors such as tension and surface wear must be minimized. Thus, it is important to study the oil film characteristics in the contact, since it reduces friction between the cam and the follower. Therefore, the objective of this dissertation is to analyze the mechanism starting from its kinematics, profile design, force curve, until the determination of the lubrication conditions (pressure distribution and film thickness). The most common type of lubrication in cams is the elastohydrodynamic (EHD), which considers both the dynamics of the oil film and the contact deformation created due to high pressures in the lubricant. Due to the nonlinearity of the equations of the EHD model, numerical methods are necessary with variable mesh discretization ¿ Multilevel Methods (Multigrid and Multilevel Multi-Integration ¿ MLMI). The main difficulty of studying lubrication in cams results from the change of the equation parameters along its rotation. The radius of curvature, the contact tangential velocity and the force are variable over the cycle and depend on the dynamic modeling of the mechanism and the rotation speed. For this work, the EHD lubrication conditions were compared over the operating cam cycle for the flat faced and the offset roller followers, both in translation motion, and in two different rotation speeds of the cam / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestra em Engenharia Mecânica

The objective of this Master's thesis is to find, using genetic algorithm (GA), an optimal profile for lubricating gap of a thrust bearing of a turbocharger. Compared to the analytical profile, the optimal profile is expected to have minimized friction for an equivalent load capacity. Friction minimization is one way to increase the efficiency of the thrust bearing; it reduces the friction losses in the bearing. An initial problem was given: a thrust bearing with Load capacity 1000 N, inner and outer radii of 30mm and 60mm respectively, rotor speed of 45000 rpm and angle of running surface of $0.5^0$. Lubricant properties were also provided for the initial problem: oil density of $ 840 kg/m^3$, dynamic viscosity $(\eta)$ of 0.01 Pa.s With this data, the numerical solution of the Reynolds equation was computed using MATLAB. To obtain more information, the minimum lubricating gap thickness was also computed using MATLAB. With this information, the shape of the analytical profile, and its characteristics were found. The analytical profile was then used a guide to create a general profile. The general profile thus obtained is then optimized using GA. The characteristics of the generated profile is then computed and compared to that of the analytical profile.

No description available.

This thesis deals with tests of forming operations, which are used to determine coefficient of friction. In the theoretical part of thesis, the individual tests are described in details, with the greatest emphasis on the upsetting test. In the experimental part of thesis was perform upsetting test on the cylindrical and ring samples. Coefficient of friction of the cylindrical samples was determined by a calculation method and ring samples were evaluated using diagram of calibration. The thesis includes comparison of the result received on lubricant and unlubricated samples and method for determined coefficient of friction. Graphite Delta 144 was used as a lubricant. This result show that the lubricant has a positive effect on forming process.

The thesis focuses on the optimization of the central lubrication system for the lubrication of rolling bearings of rolling mills in the operation continuous wire rod mill. The work is divided into theoretical and practical part. The first part of the theoretical work is focuses on the search of rolling and tribodiagnostics. The next part focuses on the description of modern central lubrication systems, explanation of their principle and practical use. The practical part explains the function of the old lubrication system for rolling mill bearings with an analysis of its problems. Next is described the technical design of a new central lubrication system, its application into operation and its actual commissioning are described. The last part of the thesis is the conclusion and evaluation of the benefits of the new central lubrication system compared to the old one.

Articular cartilage is a highly organized, anisotropic tissue lining the ends of bones within synovial joints. Composed primarily of water, collagens, proteoglycans and chondrocytes which synergistically give rise to the tissue's mechanical and tribological properties. Fluid pressurization and resistance to fluid flow within the porous extracellular matrix of cartilage, coupled with the low hydraulic permeability of the tissue endow the tissue with a viscoelastic response to loading and aid to reduce the coefficient of friction between articulating surfaces, with the pressurized fluid supporting 95% of applied loads. Experiencing millions of articulations throughout an average lifetime, articular cartilage possesses distinct biotribological properties. These require effective lubrication, mediated by the synergistic interaction between fluid and boundary lubricants, to provide a low coefficient of friction and prevent wear at the cartilage surface. Osteoarthritis is the progressive deterioration of articular cartilage and synovial joint structure and function, leading to softer and wear prone tissue on account of altered biochemical composition of the extracellular matrix. Plain radiography remains the most accessible tool and the current standard of care to visualize musculoskeletal diseases and injuries (e.g., osteoarthritis), but cannot directly visualize soft tissues or cartilage, and diagnoses are based solely on boney changes, which occur in the later stages of the disease. Coupled with no way to quantitatively assess tissue health prior to irreversible deterioration, there remains no cure for osteoarthritis. Integral to OA pathology are concomitant changes in the biochemical composition of synovial fluid that result in deterioration of rheological properties, contributing to increased cartilage wear. To address both the lack of quantitative diagnosis methods and lack of chondroprotective therapies, this dissertation presents a dual faceted approach to quantitatively image articular cartilage health, coupled with lubrication strategies to improve cartilage lubrication, and preserve cartilage tissue. This dissertation describes the synthesis of tantalum oxide nanoparticles of varying surface charges for use as contrast agents for rapid, minimally invasive, non-destructive, and quantitative contrast-enhanced computed tomography to assess both the biochemical content and biomechanical integrity of articular cartilage. Ex vivo contrast enhanced computed tomography attenuation using the nanoparticle contrast agent reveals correlations between attenuation and the mechanical and biochemical properties of the tissue. The lubrication strategy described within this dissertation involves introducing a rolling ball element between two surfaces to reduce friction. In this strategy, either single, globular macromolecules or nanoparticles are employed as ball bearings between articulating surfaces to reduce friction when asperities on the surfaces are in direct contact. Rheological characterization and construction of classical Stribeck curves using the lubricant formulations reveal that introducing the rolling element reduces the coefficient of friction during boundary lubrication, while leaving the rheological properties of the base fluid intact. Ex vivo cartilage mechanical testing involving shear deformation under varying speeds and loads reveal improved biotribological performance compared to pure synovial fluid or saline.

Lubricants additives are inseparable component of modern high-tech lubricants. Viscosity index improvers additives play uncoverable role in a branch of boundary lubrication. They are designed to ensure sufficient oil film thickness in low speeds of frictional surfaces motion. This thesis deal with effect of specific viscosity index improvers additives on boundary lubrication film formation in elliptical contact. The purpose of this work is also checking the effect of concentration changing these additives on lubricantion film thickness formation.

<p>Rolling contact fatigue (RCF) is the primary mode of failure in tribological contacts like rolling-element bearings (REBs), gears, and cam-follower systems. RCF processes have a crack initiation phase followed by a propagation and coalescence phase, resulting in spalls that lead to catastrophic failure. Crack initiation is a highly localized process that is strongly influenced by the inhomogeneity of the material microstructure. Therefore, a microstructure-sensitive model is required to simulate the damage evolution and failure due to RCF loading. This document presents the development of a microstructure-based finite element (FE) framework for RCF, which accounts for the inhomogeneity of bearing steel microstructure by using an explicit definition of polycrystal topology and material anisotropy. The granular topology of the bearing steel microstructure is described using randomly generated Voronoi tessellations. A cubic elastic material definition with a random spatial orientation is specified for each Voronoi grain to simulate the material anisotropy. The Voronoi grains generated using this approach were used to model the critically stressed microstructural volume in RCF loading. A domain size study was conducted to estimate the minimum number of grains that need to be contained by the critically stressed volume such that the macroscopic material response of the polycrystalline aggregate matches the linear elastic material properties of bearing steel. The estimated critically stressed volume was then embedded into a semi-infinite domain for the FE simulation of RCF line contact loading. The RCF domains developed were then subjected to a moving Hertzian pressure over the surface to simulate a bearing load cycle. A boundary averaging scheme was used to estimate the effective stresses along the grain boundaries of the Voronoi cells. Due to the anisotropy of the polycrystalline material, local stress concentrations occur at the grain boundaries as compared to isotropic models. The resolved grain boundary stresses were used to predict critical locations for RCF crack initiation, which closely match observations from RCF bench test data. Since RCF failures typically exhibit subsurface locations for the first crack initiation, the model uses the critical resolved shear stress (RSS) reversal along the grain boundaries and the corresponding subsurface location of the maxima as the driving parameters for RCF fatigue failures. The parameters from the model were fit into a Weibull distribution to estimate the stochasticity in initiation life. The Weibull predictions corroborate well with experimentally measured RCF life scatter. The framework was then extended using a coupled damage mechanics - cohesive element method (DM-CEM) to individually model the crack initiation and propagation phases in RCF. An explicit definition of the grain boundaries was incorporated using cohesive elements. Damage is initiated at the grain boundaries by degradation of the cohesive elements and the rate of damage/degradation is used to characterize the evolution of fatigue life. The rate of damage was calculated at each grain boundary using a fatigue damage law based on the RSS reversal parameter. The model is able to simulate the crack initiation and the propagation/ coalescence phases in RCF, with distinct life estimates for each phase. This model framework is further extended to investigate the effects of lubrication conditions in RCF by integrating an elastohydrodynamic lubrication (EHL) model to simulate the pressure load with the DM-CEM model. Further improvements to the fatigue life predictions using the DM-CEM model are made by coupling it with a crystal plasticity (CP) based submodel approach to predict the crack initiation life in RCF. CP-based metrics are used to correlate the microplasticity developed under RCF loading with the formation of fatigue micro-cracks and the corresponding initiation life estimations. The resulting final spall patterns and RCF life estimates were found to match well with experimental data available in the open literature.</p> <p><br></p>