<p><a href="">This work investigates the effect of surface features such as roughness, pits, and cracks on the tribological and fatigue behavior of machine components. It comprises of three main investigations: (i) effect of roughness on non-contacting fatigue, (ii) lubricated contact fluid structure interaction (FSI) behavior in presence of surface cracks, and (iii) the equivalence between non-contacting and contacting fatigue and the effect of roughness.</a></p><p>For the first investigation, a novel microstructure-based approach was developed to model surface roughness. It used a finite element fatigue damage model to predict the effects of roughness on tensile fatigue. AISI 4130 steel specimens with different surface finishes were fabricated and tested in axial fatigue using an MTS machine. The experimental results demonstrated the detrimental effect of roughness on fatigue lives, which was predicted by the model accurately.</p><p>In the second investigation, a partitioned CFD-FEM based FSI solver was developed using Ansys Multiphysics software to model and investigate elastohydrodynamically lubricated contacts typical in gears and cylindrical roller bearings. The FSI model relaxes Reynolds assumptions, and uses Navier-Stokes equations to determine the lubricant flow and utilizes finite element method to model the structural response. The FSI model was evaluated for robustness under various operating conditions. The effect of material plasticity, subsurface features, etc. were also investigated. The model was then extended to investigate the effects of surface cracks in rolling/sliding EHL line contacts. Using CFD based approach enabled the investigation of surface cracks with inclined geometries, overcoming the limitations of standard Reynolds-based solvers. The effects of crack geometry parameters such as crack location, crack length, crack width, crack tip radius and crack orientation on fluid pressure distribution were studied. This investigation identified the crack geometries that affect the contact fatigue behavior by predicting the location and severity of stress concentrations in the material.</p><p>Finally, the relationship between contacting fatigue and non-contacting fatigue was investigated. A test rig was designed and developed to simulate rolling contact fatigue (RCF) surface damage. Experimental investigation revealed that the RCF surface damage stress-life (SN) results can be predicted using torsional fatigue results 10 times faster. A computational contact mechanics model was developed to incorporate the effect of roughness in this prediction, and corroborated against experimental RCF results at different roughness levels.</p>

Environmentally friendly lubricants are in demand in response to the rising concerns and restrictive legislation that surround the use of mineral oil lubricants. One area of importance is understanding the service life of the environmentally friendly base oils of these non-toxic, biodegradable and renewable alternatives. The service life of a lubricant is directly influenced by its degradation behavior, especially oxidation.  In this research, selected environmentally friendly base oils; Glycerol, Rapeseed oil, Polypropylene glycol, Polyethylene glycol, Bis(di-2-ethyl hexyl) sebacate, Squalene and reference mineral oil; paraffin,  were subjected to thermo-oxidative ageing at 150oC. The changes in the chemical structures of the samples were followed using Spectroscopic, chromatographic, rheological and corrosivity studies. Tribological tests were also carried out to quantify the changes in these lubricants. The results obtained showed that the thermal oxidation affected the physicochemical properties and the lubricating ability of the base oils. However, each base oil degraded distinctly to the accelerated ageing conditions.

Electric machines are widely used in for instance the automotive industry in electric vehicles and in wind turbines. The electrical machines have mechanical bearings as an integral part used to transmit power and load. In addition, the main function includes reducing friction between interacting surfaces. However, it is one of the most failing machine elements in these machines. To improve operational sustainability and reduce maintenance costs, understanding bearing failure mechanisms under electrical influence is important. One of the main reasons of bearing failure is linked to high frequency power switches typically used to enhance electric machines’ efficiency. The increase in switching rate induces more frequent common mode voltage fluctuations making the system vulnerable to bearing currents. A small voltage difference of a few ten volts can induce significant electric stress on the bearing depending on the lubricant film thickness and related tribological parameters. The electric charge build-up leads to electric current conduction (arc discharge which happens when the voltage exceeds the breakdown voltage) ultimately damaging the bearing. There are different mitigation strategies which are used to restrict bearing currents through grounding or using completely insulative bearings such as ceramic ones. However, at the moment, there are no satisfactory solutions and there is a need for efficient and economical solutions to the problem. On the other hand, various filters are used to reduce the amplitude and its frequency of bearing currents, but they only partly solve the problem. Similarly, the insulative surface coatings provides high electrical resistance but start acting as capacitors. At a sufficiently high voltage difference, the current passes through the system. Therefore, mitigation strategies are still being explored to improve system performance and service-life. To understand the bearing discharge activity and electrical breakdowns, an electrified ball bearing rig is developed with the ability of testing different electrical properties of lubricants and running conditions. To be able to characterize the electrical properties of a bearing, two electrical circuits are designed. Experimental tests are carried out with PAO-15 and an electrical conductivity-enhanced PAO-15/P-SiSO lubricant with addition of ionic liquids. The influence of different tribological parameters such as rotational speed and viscosity are compared with respect to discharge activity. In addition, two fully formulated experimental oils are compared and evaluated in terms of their electrical performance. The bearing is found to be in different states showing electric-field dependent insulation breakdown ranging from resistive to resistive-capacitive to capacitive states. The electric characterization shows a difference between the boundary, mixed and full film lubrication regimes. Conclusively, the electrical behavior of a mechanical bearing is characterized experimentally to understand discharge problem and roadmap solution opportunities.

Obtaining an enhanced lifespan for mechanical transmissions has become a challenge in diverse application sectors. Micropitting as a contact fatigue mechanism has seriously jeopardized the well-being of rolling-sliding elements present for instance in gearboxes. Additivation through copper nanoadditives has demonstrated promising results in preventing contact fatigue. There is a need to assess the influence of copper nanoadditives on micropitting and mild wear before contemplating employing them in real transmission gearboxes. Consequently, this research work aims to acquire knowledge of the tribological behavior of rolling-sliding contacts additivated with a copper nanoadditive, emphasizing the influence of two different copper nanoadditive concentrations (0.3% and 3%) on wear and micropitting as failure mechanisms. Tests were performed using a micropitting test rig. Micropitting and wear were analyzed at different slide-to-roll ratios (1%, 5%, and 30%), different load conditions (1.5 GPa and 2.5 GPa), and different temperatures (60 °C and 100 °C), for all versions of the studied lubricant. There was no change in friction behavior between the versions of the oil additivated with the copper nanoadditive and its original version. Furthermore, it was found a reduction of micropitting for the 3% version of the studied oil in some operating conditions, and a reduction of the average wear volume for this same concentration in all studied operating conditions. On the other hand, it was found that the 0.3% version of the studied oil promoted wear with an increasing slide-to-roll ratio when compared with the original version of the studied oil. A higher reduction in wear was obtained for the 0.3% version of the studied oil with an increasing temperature when compared with the 3% version. These results indicate that copper nanoadditives exhibit the potential to reduce micropitting in non-conformal rolling-sliding contacts typically found in gears and rolling-element bearings.

The objective of this thesis work was to develop a method to detect early damage on small planetary gear sets that are installed in Atlas Copco nutrunners. The project has gone through several stages of product development, from idea to working product and signal analysis. Currently, Atlas Copco have a test rig for testing these planetary gears, this rig has been proven to be insufficient at detecting faults during an ongoing test. A new tailored test rig was therefore designed and manufactured. Low noise and low amount of vibration was of interest when designing the rig. Four concepts was thought of and evaluated through simulations using Matlab and Simulink. Most of the components of the rig were manufactured in the workshop at Atlas Copco in Nacka. Methods fo rmeasuring torsional, transverse and acoustic vibration was implemented and analyzed. There are many different parameters considering fault of fixed shaft gears. However, these are not easily applicable on a planetary gear because of the nature of its design. Therefore, special techniques are required. Two “new” parameters were tested (NSDS,FRMS [Lei. et al.]) with positive results. Pitting of individual gear members could befound.

In real life, immediately after joint replacement, the artificial joint is actually bathed in blood (and clotted blood) instead of synovial fluid. Blood contains large molecules and cells of size ~ 5 to 20 2m suspended in plasma and considered to be a non-Newtonian (pseudoplastic) fluid with density of 1060 Kg/m3 and viscosity ~ 0.01 Pas at shear rates of 3000 s-1 (as obtained in this work). The effect of these properties on friction and lubrication is not fully understood and, so far to our knowledge, hardly any studies have been carried out regarding friction of metal-on-metal bearings with various clearances in the presence of lubricants such as blood or a fluid containing macromolecules such as hyaluronic acid (HA) which is a major component of synovial fluid increasing its viscosity and lubricating properties. In this work, therefore, we have investigated the frictional behaviour of a group of Smith and Nephew Birmingham Hip Resurfacing implants with a nominal diameter of 50mm and diametral clearances in the range ~ 80 2m to 300 2m, in the presence of blood (clotted and whole blood), a combination of bovine serum (BS) with hyaluronic acid (HA) and carboxymethyl cellulose (CMC, as gelling agent) adjusted to a range of viscosities (~0.001-0.2 Pas), and bovine serum with CMC adjusted to a similar range of viscosities. These results suggested that reduced clearance bearings have the potential to generate high friction especially in the presence of blood which is indeed the in vivo lubricant in the early weeks after implantation. Friction factors in higher clearance bearings were found to be lower than those of the lower clearance bearings using blood as the lubricant. Similar trends, i.e. increase in friction factor with reduction in diametral clearance, were found to be also the case using a combination of BS+CMC or BS+HA+CMC as lubricants having viscosities in the range 0.1-0.2 and 0.03-0.14 Pas, respectively. On the other hand, all the lubricants with lower viscosities in the range 0.001-0.0013 and 0.001-0.013 Pas for both BS+CMC and BS+HA+CMC, respectively, showed the opposite effect, i.e. caused an increase in friction factor with increase in diametral clearance. Another six large diameter (50mm nominal) BHR deflected prostheses with various clearances (~ 50-2802m after cup deflection) were friction tested in vitro in the presence of blood and clotted blood to study the effect of cup deflection on friction. It was found that the biological lubricants caused higher friction factors at the lower diametral clearances for blood and clotted blood as clearance decreased from 2802m to 502m (after deflection). The result of this investigation has suggested strongly that the optimum clearance for the 50 mm diameter MOM BHR implants to be ¿1502m and <2352m when blood lubricant used, so as to avoid high frictions (i.e. avoid friction factors >0.2) and be able to accommodate a mixed lubrication mode and hence lower the risk of micro- or even macro-motion specially immediately after hip implantation. These suggested optimum clearances will also allow for low friction (i.e. friction factors of <0.2-0.07) and reasonable lubrication (dominantly mixed regime) for the likely cup deflection occurring as a result of press-fit fixation. / Smith & Nephew Orthopaedics Ltd.

Total hip joint prostheses made of CoCrMo heads versus ultra high molecular weight polyethylene (UHMWPE) cups have a limited lifetime, mainly due to the wear of the UHMWPE cups as a result of high friction between the articulating surfaces leading to osteolysis and implant loosening with revision surgery becoming inevitable in more active patients. Tribology plays an important role in developing the design, minimizing wear and reducing friction of hip joint prostheses in order to improve their long-term performance, with good lubricating properties. Metal-on-metal hip resurfacing prostheses have shown significantly lower wear rates compared with conventional metal-on-polyethylene implants and thus osteolysis is potentially reduced leading to increased lifetime of the prosthesis. Nevertheless, excessive wear of metal-on-metal joints leads to metal ion release, causing pseudo-tumours and osteolysis. An alternative approach to such bearings is the use of newly developed carbon fiber-reinforced poly-ether-ether-ketone (CFR PEEK) acetabular cups articulating against ceramic femoral heads due to their better wear resistance compared to UHMWPE. In this study, therefore, friction and lubrication properties of large diameter, as cast, Co-Cr-Mo metal-on-metal hip resurfacing implants with various diameters and clearances have been investigated and compared to those of the newly developed zirconia toughened alumina (ZTA) ceramic femoral heads articulating against carbon fiber reinforced poly-ether-ether-ketone (CFR PEEK) acetabular cups with different diameters and clearances. Friction hip simulator was used to measure frictional torque and then friction factors were calculated along with Sommerfeld numbers leading to Stribeck analysis and hence the lubricating mode was also investigated. This involved using lubricants based on pure bovine serum (BS) and diluted bovine serum (25 vol. %BS+75 vol. %distilled water) with and without carboxymethyl cellulose (CMC) (as gelling agent). Standard Rheometer was used to measure lubricant viscosity ranged from 0.0014 to 0.236 Pas at a shear rate of 3000 . Pure bovine serum, diluted bovine serum without CMC and with CMC (25BS+75DW+0.5gCMC and +1gCMC) showed pseudoplastic flow behaviour up to shear rate of ¿139 above which a Newtonian flow with significant increase in shear stress was observed. The viscosity flow curves for the 25BS+75DW+2gCMC, +3.5gCMC and +5gCMC showed only shear thinning up to a shear rate of 3000 . The shear rate application modified the flow behaviour of bovine serum from a pseudoplastic to a Newtonian flow depending on its purity and CMC content. This will cause a different frictional behaviour depending on joint diameter and clearance, as seen in this work. The experimental data were compared with theoretical iv predictions of the lubricating regimes by calculating theoretical film thickness and lambda ratio. The metal-on-metal Biomet ReCaps showed similar trends of Stribeck curves, i.e. friction factors decreased from ~0.12 to ~0.05 as Sommerfeld numbers increased in the range of viscosities ~0.001-0.04Pas indicating mixed lubrication regimes above which the friction factor increased to ~0.13 at a viscosity of 0.236Pas. The Stribeck analyses suggested mixed lubrication as the dominant mode with the lowest friction factor in the range ~0.09 - ~0.05 at the physiological viscosities of ~0.01 to ~0.04 Pas and that such joints can be used for more active patients as compared to the conventional total hip replacement joints with 28mm diameter. The Stribeck curves for all ZTA ceramic-on-CFR PEEK components illustrated a similar trend with BS fluids showing higher friction factors (in the range 0.22-0.13) than the diluted BS+CMC fluids (in the range 0.24-0.05). The friction tests revealed boundary-mixed lubrication regimes for the ZTA ceramic-on-CFR-PEEK joints. The results, so far, are promising and suggest clearly that the newly developed ZTA ceramic femoral heads articulating against CFR PEEK cups have similar friction and lubrication behaviour at optimum clearances to those of currently used metal-onmetal hip resurfacing implants at the range of viscosities 0.00612 to 0.155Pas. These results clearly suggest that the ZTA ceramic-on-CFR-PEEK joints showed low friction at the physiological viscosities of ~0.01Pas in the range ~0.1-0.05, suggesting that these novel joints may be used as an alternative material choice for the reduction of osteolysis. The result of this investigation has suggested that the optimum clearance for the 52mm diameter MOM Biomet ReCaps could be ~170¿m. However, 48 and 54mm joints showed lower friction due to clearances to be >200¿m. For the 52mm ZTA ceramic-on-CFR-PEEK joints the optimum clearance seems to be ¿ 630¿m radial clearance. These results suggested that increased clearance bearings have the potential to generate low friction and hence no risk of micro- or even macro-motion for the ceramic-on-CFR-PEEK joints. This study found no correlation between theoretical predictions and experimental data for all metal-onmetal and ZTA ceramic-on-CFR PEEK bearings at the physiological viscosity (0.0127Pas). However, at lubricant viscosity of 0.00157Pas, the theoretical prediction of lubrication regime correlated well with the experimental data, both illustrating boundary lubrication. As expected, a decrease in viscosity resulted decrease in the film thickness.

The natural hip joint in healthy people has a very low friction with very little (or no) wear. It works as a dynamically loaded bearing and is subjected to about 1-2 million cycles of loading per year. The applied load is the body weight which is tripled when walking and even higher during other activities such as running and jumping. Unfortunately these joints are not always healthy due to various causes such as fractures or disease leading to severe pain which necessitates joint replacement. Currently, the orthopaedic industries are working towards developing an ideal artificial hip joint with low wear, low friction, good lubrication, better fixation/stability and biocompatibility. Many different designs and materials have been investigated with some promising new implants which can be used depending on patients¿ individual need (large or small joint), activity and age. In this work, two types of artificial hip joints were tested for friction and lubrication studies: Metal-on-Metal (MoM) Biomet hip resurfacing ReCaps with large diameters (>35-60 mm) and different diametral clearances (~ 60-350 µm), and Zirconia Toughened Alumina (ZTA) heads against carbon-fibre-reinforced poly-ether-ether ketone (CFR PEEK) cups with different diameters (>35-60 mm) and diametral clearances (60-1860 µm). Seven serum-based lubricants with different viscosities were used with and without carboxy methyl cellulose (CMC) additions as gelling agent to increase viscosity depending on the CMC content. The maximum load applied was 2000 N for the stance phase with a minimum load of 100 N for the swing phase. A Pro-Sim friction hip simulator was used to investigate the frictional torque generated between the articulating surfaces so as the friction factor can be calculated. Stribeck analysis was then employed to assess the mode of lubrication. For the metal-on-metal hip resurfacing joints, the friction factors were in the range 0.03-0.151 and those for the ZTA ceramic heads versus CFR PEEK cups were in the range 0.006-0.32. Stribeck analyses showed mainly mixed lubrication for both MoM and ZTA ceramic-on-CFR PEEK joints. The experimental results were in agreement with most of the theoretical calculations suggesting mixed lubricating regimes at low viscosities and moving on to fluid film lubrication at higher viscosities. Joints with larger-diameters, lower clearances and lower surface roughness exhibited a higher lambda ratio suggesting improved lubrication. Viscosity flow curves for the serum-based lubricants having viscosity ¿ 0.00524 Pas showed non-linear relationship between viscosity and shear rate indicating non-Newtonian flow with pseudoplastic or shear-thinning characteristic, i.e. viscosity decreased as shear rate increased up to shear rates of ~ 1000 s-1. However, at shear rates greater than 1000 s-1 Newtonian flow became dominant with almost constant viscosity, i.e. a linear relationship between shear stress and shear rate. On the other hand, viscosity flow curves for the lubricants with viscosity ¿ 0.0128 Pas showed non-Newtonian behaviour up to a shear rate of 3000 s-1 with shear-thinning characteristic. / Ministry of Higher Education, Libya

La friction entre les surfaces mobiles de l’organisme peut être un problème difficile à résoudre, notamment dans les pathologies dégénératives comme l’arthrose ou la sécheresse oculaire. Malgré le développement de nombreux produits pharmaceutiques, les matériaux actuellement utilisés pour protéger les tissus blessés et les dispositifs biomédicaux contre l'usure par frottement sont encore limités dans leurs performances. Il existe un besoin urgent de matériaux injectables capables de protéger ces tissus et dispositifs afin de prolonger leur durée de vie et de traiter efficacement des maladies dégénératives. Parmi les innovations de la dernière décennie, les polymères à structure dite « en brosse » (BBs) se sont révélés prometteurs pour amoindrir les problèmes de friction et d'usure. Inspirés de l’architecture spécifique du protéoglycane 4, l'un des principaux composants lubrifiants du cartilage, les macromolécules BBs sont constituées d’un squelette linéaire et de chaînes latérales formant une brosse dense pouvant maintenir de l’eau sous une pression élevée. Les différentes structures des BBs, selon le squelette et leurs chaînes latérales, conduisent à plusieurs caractéristiques morphologiques et propriétés tribologiques intéressantes dans l’ingénierie tissulaire. Bien que leurs propriétés lubrifiantes aient été prouvées dans plusieurs études, les BBs n’ont à ce jour que peu d’applications. D’une part, la corrélation entre leur structure et leurs propriétés physicochimiques n’est pas encore clairement établie. D’autre part, il manque encore des études relatives à l’efficacité des BBs sur de vrais tissus. Pour pallier ce problème, notre projet vise à caractériser les propriétés physicochimiques et tribologiques des BBs sur différents types de surfaces en fonction de leur structure. La longueur du squelette, la densité de greffage et l’addition du groupe d’ancrage sont les 3 variables principales étudiées dans ce projet. La lubrification ainsi que d’autres propriétés importantes des BBs ont été évaluées sur les surfaces molles des cartilages, des yeux et des lentilles en contact. Les tests tribologiques ont été menés en utilisant un appareil à force de surface (SFA) via l’association du protocole classique et avancé qui l’adapte aux surfaces testées. A côté de la tribologie, l’affinité cinétique, la toxicité, les propriétés antisalissure et anti-inflammatoire des BBs sur les interfaces ont aussi été étudiées dans ce projet via les techniques de LigandTracer et de microscope fluorescent. / Friction between the body's moving surfaces can be a difficult problem to solve, particularly in degenerative pathologies such as osteoarthritis or dry eye. Despite the development of numerous pharmaceutical products, the materials currently used to protect injured tissues and biomedical devices against frictional wear are still limited in their performance. There is an urgent need for injectable materials capable of protecting these tissues and devices in order to extend their life and effectively treat degenerative diseases. Among the innovations of the last decade, polymers with a so-called "brush structure" (BBs) have shown promise in reducing friction and wear problems. Inspired by the specific architecture of proteoglycan 4, one of the main lubricating components of cartilage, BBs macromolecules consist of a linear backbone and side chains forming a dense brush capable of holding water under high pressure. The different structures of BBs, depending on the backbone and their side chains, lead to several morphological features and tribological properties of interest in tissue engineering. Although their lubricating properties have been proven in several studies, BBs have few applications to date. On the one hand, the correlation between their structure and physicochemical properties has not yet been clearly established. On the other hand, studies on the effectiveness of BBs on real tissues are still lacking. To overcome this problem, our project aims to characterize the physicochemical and tribological properties of BBs on different types of surfaces, depending on their structure. Backbone length, graft density and anchoring group are the 3 main variables studied in this project. Lubrication and other important properties of BBs were evaluated on the soft surfaces of cartilages, eyes and contact lenses. Tribological testing was carried out using a Surface Force Apparatus (SFA) via a combination of the classic and advanced protocol, adapting it to the surfaces tested. Alongside tribology, the kinetic affinity, toxicity, anti-fouling and anti-inflammatory properties of BBs on interfaces were also studied in this project via LigandTracer and fluorescent microscopy techniques.

No description available.