This master’s thesis describes the influence of conformity on friction in rolling bearings. The coefficient of friction is measured on an experimental machine - Mini Traction Machine 2 – using ball-on-disc method. The results are plotted in graphs which showing the dependence of the coefficient of friction at spin-to-roll ratio for specific conformity, normal load and speed in the contact area. The influence of load, speed or different lubricant viscosity is verified for a given value of conformity. Experimentally obtained data are compared with the mathematical model developed in MatLab, within this thesis.

This thesis describes the problems of the engine block and crankcase. There is solution of structural design and contains the engineering design of invert six-cylinder engine block with water cooling. Thesis deals with connected equipment and drives. Engineering design is verified by finite elements analysis for the determination of strenght and durability. The ending of thesis analyzes the production methods of designed engine block.

Tato disertační práce se zabývá vlivem mělkých mikro-textur na tření a tloušťku filmu v mazaných nekonformních kontaktech za extrémních podmínek a za podmínek hladovění kontaktu. Měření byla realizována na tribometru v konfiguraci ball-on-disk. Kontakt byl pozorován pomocí vysokorychlostní kamery. Pro stanovení součinitele tření byl využit snímač krouticího momentu. V této studii byly popsány dva typy mikrotextur – mikrovtisky a příčné mikrodrážky. Výsledky naznačují, že za podmínek hladovění vedou mikrovtisky ke snížení tření a to díky nárůstu tloušťky mazacího filmu. Mechanismus doplňování mikrovtisků čerstvým mazivem je pravděpodobně způsoben kapilárními jevy ve vstupní oblasti. Třecí plochy s příčnými mikrodrážkami, jejichž délka byla menší než průměr Hertzova kontaktu, potom obecně vykazovaly lepší tribologické parametry ve srovnání s hladkými povrchy. Příčné mikrodrážky vedly k výraznému nárůstu tloušťky mazacího filmu za podmínek hladovění i za extrémních provozních podmínek (protisměrný pohyb). Numerické simulace přechodových jevů příčných mikrodrážek ukázaly dobrou shodu s experimentálními výsledky.

This thesis deals with the experimental study of lubrication of hip joint replacements. The influence of the synovial fluid composition and the head material to the lubricating film thickness were asssesed by using a pendulum hip joint simulator. Both of these effects were assesed under static and dynamic loading conditions. The experimental results showed that the movement of the head against the cup is unnecessary for the separation of the rubbing surfaces by a layer of adsorbed proteins. Composition of the synovial fluid then significantly influences the thickness of the lubricating film. Two opposite extremes have been observed during tests with two model synovial fluids. The first fluid formed a very strong lubricating film. The second sample almost prevent adsorption of proteins and consequently formed only very thin lubricating film. The influence of the material is noticeable when comparing the results obtained with a metal head and ceramic heads. Metal head formes under the same conditions thicker lubricating film. This evidence may be partly influenced by different diametrical clearances, which were in the case of ceramic heads higher.

This master’s thesis deals with the experimental study of an elastohydrodynamic contact under conditions of insufficient lubricant supply. Starvation level of this type of the contact may be experimentally determined based on the input position of the meniscus, but this way can’t determine all its levels of starvation. Consequent development in the field of tribology achieved theoretical model that can determine at all levels of starvation depending on the thickness of the lubricant film entering the contact, but it is relatively difficult for experimental verification. The main goal of this work is an experimental study and describes the behavior of elastohydrodynamic contact at an exactly defined thickness of the lubricant film at the contact input. The benefit of this work is a validation of that mentioned theoretical model for base oils and greases made from them, and mutual comparison of their behavior.

Die Arbeit untersucht den Einfluss von von radialen, im Zahngrund auslaufenden Schmierölbohrungen auf die Zahnfußtragfähigkeit außenverzahnter Stirnräder durch theoretische und experimentelle Untersuchungen. Es werden Formeln entwickelt, die ohne zeitaufwändige Berechnungen eine sichere Beurteilung des Einflusses von Schmierölbohrungen auf die Zahnfußtragfähigkeit ermöglichen. Dazu wird ein Einflussfaktor Y_OeB ermittelt, welcher die einfache Integration in vorhandene Berechnungsstandards erlaubt. Als Vorlage dient dabei die Berechnung der Zahnfußtragfähigkeit nach DIN 3990 / ISO 6336, die durch diesen Faktor ergänzt werden kann. Neben experimentellen Versuchen zum Einfluss der geometrischen Größen Zahnfußausrundungsradius und Bohrungsdurchmesser werden auch verschiedene Parameter wie die Kranzdicke, zusätzliche Torsionsbelastungen (z. B. an Sonnenwellen), die Wärmebehandlung und die Belastungsart (Schwell- oder Wechsellast) berücksichtigt. Darüber hinaus betrachtet die Arbeit das Verhalten verschiedener Werkstoffe bei Vorhandensein einer Schmierölbohrung. Sie liefert des Weiteren einen Erklärungsansatz zum Einfluss der Schmierölbohrungen auf die Zahnfußtragfähigkeit auf Basis der Veränderung der Eigenspannungsverteilung im Zahnfußgebiet durch die radiale Bohrung und bietet dafür auch ein Modell zur qualitativen Berechnung der Eigenspannungsverteilung auf Basis der FE-Methode an.:1 EINLEITUNG 1 1.1 WISSENSCHAFTLICHE PROBLEMSTELLUNG 1 1.2 ZIELSETZUNG 1 2 STAND DER TECHNIK UND DER BISHERIGEN FORSCHUNG 3 2.1 KERBEN UND KERBWIRKUNG 3 2.1.1 Einzelkerben 3 2.1.2 Mehrfachkerben 4 3 PRÄZISIERUNG DER AUFGABENSTELLUNG 6 4 NUMERISCHE UNTERSUCHUNGEN DER ZAHNRÄDER 7 4.1 GRUNDLAGEN DER FINITE ELEMENTE METHODE 7 4.2 FEM-MODELLBILDUNG – ELEMENTTYPEN 8 4.3 PARAMETERSTUDIE – GRUNDLEGENDE UNTERSUCHUNGEN 10 4.3.1 Variation der Umfangslage der Bohrung 17 4.3.2 Zusammenfassung der Parametervariationen 19 4.4 UNTERSUCHUNGEN ZUM EINFLUSS DER ZAHNBREITE 22 4.5 UNTERSUCHUNG DES SPANNUNGSGRADIENTEN 23 4.6 EINFLUSS EINER FASE AM AUSLAUF DER BOHRUNG IM ZAHNGRUND 25 4.7 SCHMIERÖLBOHRUNG UND VERZAHNUNGSMODIFIKATIONEN 27 5 EXPERIMENTELLE UNTERSUCHUNGEN 28 5.1 ALLGEMEINE VORBEMERKUNGEN 28 5.1.1 Versuchsvorrichtung für Schwelllastversuche 30 5.1.2 Prüfvorrichtung für Wechsellastversuche 31 5.2 KONTROLLE DER BREITENLASTVERTEILUNG 33 5.2.1 Lastverteilung am Zahnkopf 34 5.2.1.1 2D-Kontaktrechnung – Ermittlung des Hebelarmes unter Last 35 5.2.1.2 3D-Kontaktrechnung – Breitenlastverteilung am Zahnkopf 36 5.3 AUSWERTUNG DER VERSUCHE 38 5.3.1 Zeitfestigkeitsgebiet 38 5.3.1 Dauerfestigkeitsgebiet 39 5.4 ERGEBNISSE DER EXPERIMENTELLEN UNTERSUCHUNGEN 42 5.4.1 Geometrievariationen 42 5.4.2 Untersuchung anderer Parameter 43 5.4.3 Einfluss des Werkstoffes 47 5.4.4 Ergebnisse der Wechsellastversuche 51 5.5 STREUUNG DER MESSERGEBNISSE 53 5.6 ERGEBNISSE DER WERKSTOFFTECHNISCHEN UNTERSUCHUNGEN 54 5.6.1 Ergebnisse für 18CrNiMo7-6 54 5.6.2 Ergebnisse für 16MnCr5 55 5.6.3 Ergebnisse für 42CrMo4 55 5.6.4 Ergebnisse für 31CrMoV9 55 5.6.5 Untersuchung des Bruchbildes 56 5.7 UNTERSUCHUNG DES EIGENSPANNUNGSZUSTANDES 57 5.7.1 Experimentelle Untersuchungen 57 5.7.2 Theoretische Untersuchung der Verteilung der Eigenspannungen 60 5.7.2.1 Ringmodell 62 5.7.2.2 L-Modell 66 5.7.2.3 Zahnlückenmodell 70 5.7.2.4 Zahnradsegmentmodell 73 6 ZUSAMMENFASSUNG 77 7 AUSBLICK 80 8 LITERATUR 84 9 ABBILDUNGSVERZEICHNIS 89 10 TABELLENVERZEICHNIS 91 11 ANHANG 92

Demanding applications, as well as the push to eliminate the need for fossil-fuel based lubricants, create the need for the development of high-performance polymers. Polyphenylene Sulfide (PPS) is an example of a high-performance polymer and has a high service temperature, good dimensional stability, and excellent chemical resistance. However, it has a low impact strength and is very brittle in neat form. Another high-performance polymer, Polytetrafluoroethylene (PTFE), provides low friction in dry sliding conditions and can deposit polymer transfer films onto the counterface but exhibits high wear rates in neat form. To take advantage of the desirable characteristics of both polymers, PPS/PTFE-based composites were produced through the Injection Molding process. The individual disadvantages of these polymers were further improved by incorporating the following fillers: SCF, GO and CNT. The tribological performance under dry sliding conditions and two different loads were investigated as well as the microhardness and degree of crystallinity of the materials. The DSC results showed that the incorporation of reinforcements did not significantly alter the total degree of crystallinity in the material. PPS/PTFE and the composites have significantly lower specific wear rates and coefficient of friction values compared to neat PPS and PTFE. The composites have higher microhardness and friction coefficient values (60N and 100N) compared to PPS/PTFE. For both loads, composites SCFCNT, 5SCF and 10SCF had the lowest specific wear rates recorded where a synergistic effect between SCF and CNT has been observed. The filler loading content did not affect the friction performance of the composites in both loads. However, for composites with SCF as the only reinforcement, the increase in wt% content of SCF increased the specific wear rate at 60N and decreased the specific wear rate at 100N. SEM images of the pin surfaces show that the governing wear mechanisms in the polymer blend and composites are abrasive and adhesive wear. The reduction of the specific wear rate values is also accompanied by the improvement in the uniformity of the observed transfer film formation.

Cette thèse vise à contribuer à la caractérisation, à l’aide de modélisation et d’expérience, de la dynamique de bulle en microfluidique. Deux régimes d’écoulements rencontrés en microfluidique sont étudiés, le régime bubbly flow et le régime Taylor flow. En particulier, la première partie de cette thèse traite de la dynamique d’un écoulement de type bubbly flow dans un microcanal rectiligne de section circulaire en présence de surfactants. Le code de calcul numérique JADIM est utilisé. Une méthode numérique permettant, d’une part, de simuler le transport de surfactants le long d’une interface qui bouge et qui se déforme, et d’autre part, de simuler l’effet Marangoni crée par une distribution inhomogène de ces surfactants sur cette interface, est implémentée et validée. Les simulations effectuées avec ce code concernant la dynamique d’un écoulement de type bubbly flow montrent par exemple que, le confinement créé par les parois du microcanal résulte en une distribution des surfactants sur la surface des bulles qui est fondamentalement différente d’une distribution rencontrée dans le cas d’une bulle qui se déplace dans un liquide de dimension infinie. En effet, les surfactants s’accumulent en des locations spécifiques sur la surface des bulles et créent des forces de Marangoni locale, qui influencent drastiquement la dynamique des bulles. Dans certains cas, les surfactants peuvent même engendrer une désintégration de la bulle, un mécanisme qui est rationalisé par un bilan de force à l’arrière de la bulle. La méthode numérique implémentée dans cette thèse est également utilisée pour un problème pratique concernant la production artisanale de Mezcal, une boisson alcoolisée produite au Méxique. La seconde partie de cette thèse traite de la dynamique d’un écoulement de type Taylor flow, à l’aide d’expérience et de modélisation. Une méthode expérimentale permettant de mesurer l’épaisseur du film de lubrification qui se forme entre une bulle de Taylor et les parois du microcanal est développée. Cette méthode requiert uniquement une image « brightfield » de la bulle. En plus de la mesure de l'epaisseur du film de lubrification, la méthode permet aussi de mesurer la profondeur du microcannal. Enfin, l'utilisation de la méthode proposée couplée à la mesure de la vitesse de translation de la bulle permet de déduire la tension de surface de celle-ci. Dans le dernier chapitre de cette thèse, l'influence des effets gravitaires sur la dynamique des écoulements de Taylor est quantifiée. Quoique souvent négligée en microfluidique, il est montré que les effets gravitaires peuvent avoir un impact significatif sur la dynamique des écoulements de Taylor. Ces impacts sont quantifiés à l'aide d'expériences et de modélisations. Ce travail a été réalisé à la Princeton University avec Professeur Howard A. Stone pendant un séjour de 7 mois. / This thesis aims at contributing to the characterization of the dynamics of bubbles in microfluidics through modeling and experiments. Two flow regimes encountered in microfluidics are studied, namely, the bubbly flow regime and the Taylor flow regime (or slug flow). In particular, the first part of this thesis focuses on the dynamics of a bubbly flow inside a horizontal, cylindrical microchannel in the presence of surfactants using numerical simulations. A numerical method allowing to simulate the transport of surfactants along a moving and deforming interface and the Marangoni stresses created by an inhomogeneous distribution of these surfactants on this interface is implemented in the Level set module of the research code. The simulations performed with this code regarding the dynamics of a bubbly flow give insights into the complexity of the coupling of the different phenomena controlling the dynamics of the studied system. Fo example it shows that the confinement imposed by the microchannel walls results in a significantly different distribution of surfactants on the bubble surface, when compared to a bubble rising in a liquid of infinite extent. Indeed, surfactants accumulate on specific locations on the bubble surface, and create local Marangoni stresses, that drastically influence the dynamics of the bubble. In some cases, the presence of surfactants can even cause the bubble to burst, a mechanism that is rationalized through a normal stress balance at the back of the bubble. The numerical method implemented in this thesis is also used for a practical problem, regarding the artisanal production of Mezcal, an alcoholic beverage from Mexico. The second part of the thesis deals with the dynamics of a Taylor flow regime, through experiments and analytical modeling. An experimental technique that allows to measure the thickness of the lubrication film forming between a pancake-like bubble and the microchannel wall is developed. The method requires only a single instantaneous bright-field image of a pancake-like bubble translating inside a microchannel. In addition to measuring the thickness of the lubrication film, the method also allows to measure the depth of a microchannel. Using the proposed method together with the measurment of the bubble velocity allows to infer the surface tension of the interface between the liquid and the gas. In the last chapter of this thesis, the effect of buoyancy on the dynamics of a Taylor flow is quantified. Though often neglected in microfluidics, it is shown that buoyancy effects can have a significant impact on the thickness of the lubrication film and consequently on the dynamics of the Taylor flow. These effects are quantified using experiments and analytical modeling. This work was performed at Princeton University with Professor Howard A. Stone during a seven month stay.

Nästan alla maskiner och fordon behöver smörjning i någon form. Cellulosatorkar tillverkade av Andritz AB är inte något undantag. Dessa maskiner innehåller en mängd olika komponenter som är i behov av smörjning. För Andritz som har kunder över hela världen uppstår ett problem när dessa kunder söker alternativ till de smörjmedel som Andritz i första hand rekommenderar. Detta arbete har till syfte att kunna ge olika alternativ på smörjmedel oberoende från vilken tillverkare. I arbetet har en lista tagits fram med alternativa smörjmedel från olika smörjmedelstillverkare. Arbetet innefattar även de kritiska faktorer hos smörjmedel som måste uppfyllas för att de ska kunna ersätta varandra. En livstidsanalys, eftersmörjningsintervall och initial fettfyllning för hårt belastade rullager i en av Andritz cellulosatork ingår även i arbetet.

Railway vehicles require a certain level of adhesion between wheel and rail to operate efficiently, reliably, and economically. Different levels of adhesion are needed depending on the vehicle running conditions. In the wheel tread–railhead contact, the dominant problem is low adhesion, as low adhesion on the railhead negatively affects railway operation: on one hand, the vehicle will lose traction resulting in delay when driving on low-adhesion tracks; on the other hand, low adhesion during deceleration will extend the braking distance, which is a safety issue. This thesis examines the influence of several contaminants, i.e., water, oil, and leaves, on the adhesion in the wheel tread–railhead contact. This study will improve our knowledge of the low-adhesion mechanism and of how various contaminants influence adhesion. The thesis consists of a summary overview of the topic and three appended papers (A–C). Papers A and B focus mainly on water and oil contamination examined using two methods, numerical simulation and lab testing. In paper A, real measured wheel and rail surfaces, low- and high-roughness surfaces, along with generated smooth surfaces are used as input to the numerical model for predicting the adhesion coefficient. Water-lubricated, oil-lubricated, and dry contacts are simulated in the model. In the research reported in paper B, scaled testing using a mini traction machine (MTM) was carried out to simulate the wheel–rail contact under lubricated conditions. Two types of disc surfaces of different roughnesses were run at different contact pressures and temperatures. A stylus machine and atomic force microscopy (AFM) were used to measure the surface topography. A study of leaf contamination on the railhead surface, based on field testing, is presented in paper C. Railhead surface samples were cut and the friction coefficient was measured on five occasions over the course of a year. Electron spectroscopy for chemical analysis (ESCA) and glow discharge optical emission spectrometry (GD-OES) were used to detect the chemical composition of the leaf-contamination layer on the railhead surface. The main conclusion of the thesis is that different contaminants reduce the adhesion coefficient in different ways. Oil reduces the adhesion coefficient by carrying the normal force due to its high viscosity. Water can reduce the adhesion coefficient to different degrees depending on the surface topography and water temperature. The mixture of an oxide layer and water contamination may have an essential impact. A leaf-formed blackish layer causes low adhesion by means of a chemical reaction between the leaves and bulk material. The thickness of the friction-reducing oxide layer predicts the friction coefficient and the extent of leaf contamination. / QC 20111123