The purpose of this diploma thesis is to describe the influence of input parameters (rolling speed, load, temperature, dynamic viscosity and pressure coefficient of the lubricant) on film thickness in point and elliptical contacts using optical interferometry. Regression based film thickness formula has been obtained using universal form of non-dimensional parameters of entrainment speed U, load W and material G. Equations were also complemented by the function of ellipticity k. New regression formulas for central and minimum film thickness have been compared with existing EHL thickness equations. These film thickness measurement and new regression formulas have applicability to our understanding of the performance and more effective design of lubricated gears from polymeric materials.

This diploma thesis deals with the design of linear axis for heavy machine tool. The thesis describes the definition of heavy machine tool and its basic construction nodes. The next chapter describes the components of the linear feed assemblages, the basic principles of use and their advantages and disadvantages. On the basis of this research part there are selected variants of the solution and in the last part of the thesis there is a design of the axis X of the gantry machine tool. Part of the work is a 3D model of the proposed feed assemblages and part of the drawing documentation.

The thesis deals with the design and construction of headstocks of a turning centre. The aim is to design a spindle with an output of 20 kW and a maximum speed of 5000 1/min. The research part of the thesis is focused on the description of the basic parameters of the headstock and turning centres needed for the construction of the headstock and contains an analysis of the available spindles on the market. The next part of the thesis deals with the selection and calculation of cutting conditions and the necessary parameters. Analytical calculations are then verified using FEM analysis. At the end of the thesis, a 3D model was developed and headstock drawing documentation.

Plastics contribute 2 GTons to the global carbon footprint, today, several countries have set targets to achieve carbon neutrality. Plastics, being a major contributor to global carbon footprint, would need to be reduced significantly from our daily life to achieve that or a way needs to be devised to recycle them. A big bottleneck in this process is to reduce the consumption of thermosetting plastics or to reduce the emissions associated with plastic and move towards economical and environmentally safe plastics having a longer lifespan and efficient recyclability. Fused filament fabrication (FFF) is the most commonly used 3D printed technology available today. Its applications range from production of prototypes to hollow shafts, and fully functional commercial components. This technology is revolutionary in a sense that it offers advantages such as cheaper raw materials, high degree of customizability, production in smaller batches at lower costs, decrease in material wastage, rapid prototyping, and complex geometry. A number of thermoplastic polymers can be used with FFF technology to produce parts, in addition research is on going to print materials not commonly used for FFF process. Polyoxymethylene (POM) could be a viable option for utilization as FFF basestock for the production of tribologically functional components. POM is an engineering thermoplastic that offers high resistance to wear, low friction, excellent impact resistance, and good chemical resistance. These properties render it suitable for production of gear wheels and low load bearings. It is currently processed using traditional manufacturing methods such as injection and compression moulding, while its printability has received very little attention in the openly available literature. An attempt has been made in this thesis to fill up this research gap by providing insight into POM filament quality, and the thermal, mechanical, and tribological behaviour of POM printed parts. The influence of overfill and layer height on the bulk properties of the printed samples, its play with counterface surface roughness and applied load has also been investigated.

This diploma thesis is devoted to problems of crankshaft plain bearings at five-cylinder in-line engine. Document body describes behaviour of plain bearings under various working conditions. To needs of the hydrodynamic bearings simulations is created the cranktrain virtual model. Next part of hereof document deals with problems of bearing shell design. Is created survey of the bearing materials and shortly described technological processing of shell bearing. To understand complicated problems hydrodynamic lubrication is derived Reynolds differential equation and foreshadowed succession calculation dynamically loaded bearings. In final parts of this thesis are presented most interesting results obtained from computational analysis.

The wheel-rail contact is at the core of all research related to vehicle-track interaction. This tiny interface governs the dynamic performance of rail vehicles through the loads it transmits and, like any high stress concentration zone, it is subjected to serious damage phenomena. Thus, a clear understanding of the rolling contact between wheel and rail is key to realistic vehicle dynamic simulation and damage analyses. In a multi-body-system simulation package, the essentially demanding contact problem should be evaluated in about every millisecond. Hence, a rigorous treatment of the contact is highly time consuming. Simplifying assumptions are, therefore, made to accelerate the simulation process. This gives rise to a trade-off between accuracy and computational efficiency of the contact models in use. Historically, Hertz contact solution is used since it is of closed-form. However, some of its underlying assumptions may be violated quite often in wheel-rail contact. The assumption of constant relative curvature which leads to an elliptic contact patch is of this kind. Fast non-elliptic contact models are proposed by others to lift this assumption while avoiding the tedious numerical procedures. These models are accompanied by a simplified approach to treat tangential tractions arising from creepages and spin. In this thesis, in addition to a literature survey presented, three of these fast non-elliptic contact models are evaluated and compared to each other in terms of contact patch, pressure and traction distributions as well as the creep forces. Based on the conclusions drawn from this evaluation, a new method is proposed which results in more accurate contact patch and pressure distribution estimation while maintaining the same computational efficiency. The experience gained through this Licentiate work illuminates future research directions among which, improving tangential contact results and treating conformal contacts are given higher priority. / <p>QC 20130911</p>

Hot stamping of aluminium alloys allows for increased formability, decreased springback and the possibility of integrating age-hardening heat treatments into the process. However, it can be challenging due to the occurrence of material transfer of aluminium onto the tool, as aluminium is prone to adhesion even at low temperatures. Hence, lubrication is always necessary when forming aluminium, but lubricants can still fail, leading to direct interaction between tool and workpiece and thus material transfer. This phenomenon reduces the efficiency of the process, as interruptions are necessary for the refurbishment of the tools. Understanding of how material transfer takes place is important in order to find new or improved solutions, in terms of lubrication and surface engineering, to prevent adhesion. Nevertheless, current research in high temperature tribology of aluminium, mainly in terms of material transfer mechanisms, is very limited, as many of the works focus on lubricated conditions and do not look into the fundamental interactions between aluminium alloys and tool steels. In this context, the aim of this work is to investigate the mechanisms behind the occurrence of aluminium alloy transfer onto tool steel during sliding at high temperature and in dry conditions. A hot-strip drawing tribometer was used to perform tests at room temperature, 300°C, 400°C, and 500°C, directly after solubilizing the aluminium alloy at 520°C. Two different topographies for the tool steel were used: ground and polished. Material transfer characterization was performed mainly through scanning electron microscopy. It was found that grinding marks (ground tool steel) and carbides (polished tool steel) act as initiation sites for the transfer to occur. Temperature plays a role on the growth mechanisms of the transfer films during sliding, as thermal softening of the aluminium alloy is the dominant factor in determining the growth direction of the transfer layers. A growth towards the trailing edge (shearing and smearing of the transferred aluminium) or a growth towards the leading edge (build-up of transferred aluminium, leading to a thicker and more localized transfer material).

Tato dizertační práce je zaměřena na studium deformace nerovnosti uvnitř elastohydrodynamicky mazaného (EHD) kruhového kontaktu. Práce se zabývá studiem přechodu příčné nerovnosti přes kontaktní oblast, která je modelována pomocí numerických metod. Model dále uvažuje nenewtonské chování maziva. Použitý matematický model se skládá z parciální diferenciální rovnice druhého řádu pro řešení tlaku a integro-diferenciální rovnice pro řešení elastických deformací. Pro řešení tohoto modelu je použitá takzvaná multigrid (vícesíťová) metoda. Práce obsahuje popis matematického modelu EHD kontaktu a aplikované numeriké metody. Výsledky simulací jsou porovnány s experimentálně stanovenýma hodnotama tloušťky mazacího filmu. Deformace nerovnosti uvnitř kontaktní oblasti je studována pro různé provozní podmínky (střední rychlost, poměr proklzu) a různá vlastnosti maziva.

Die vorliegende Arbeit beschreibt den Einsatz von Hochleistungskeramiken im Bereich der Gleitlagertechnik. Dabei liegt der Fokus auf das keramikgerechte Design, welches die umge-bende Struktur mit einbezieht. Insbesondere die Einbettung aber auch der Bolzen sind durch konstruktive Maßnahmen zu adaptieren, sodass eine möglichst geringe Zugspannung unter Last im keramischen Werkstoff entsteht. Parameterstudien mit Hilfe der FEM erlauben die Aufstellung von Anforderungen an das Design nach dem Kriterium des Spannungsminiums und in Abhängigkeit der Lagergröße und -belastung sowie des verwendeten keramischen Werkstoffes. Eine experimentelle Validierung des keramikgerechten Designs bestätigt eine statische und dynamischer Tragfähigkeit bis mindestens 150 N/mm². Weiterhin wird ein Weg eines fluidfreien und wartungsfreien Tribologiesystems für keramische Werkstoffe aufgezeigt, das einen geringen Reibwert von kleiner 0,1 und einen nicht messbaren Verschleiß aufweist. Optimierungspotenzial besteht hinsichtlich des erreichbaren Gleitweges. Abschließend wird eine Berechnungsvorschrift zur Dimensionierung eines keramischen Gleitlagers gegeben.:Abbildungsverzeichnis VIII Tabellenverzeichnis XI Symbole und Abkürzungen XII 1 Einleitung und Zielsetzung 1 2 Stand der Technik und Wissenschaft 3 2.1 Technische Merkmale und Marktanalyse heutiger Gleitlager 3 2.2 Keramische Werkstoffe 7 2.3 Hochleistungskeramik in hochbeanspruchten Gleitanwendungen sowie Präzisierung der Aufgabenstellung und angewandten Methoden 14 3 Berechnungsmethoden für keramische Werkstoffe 18 3.1 Spannungszustand im keramischen Bauteil 18 3.2 Zulässige Spannung und Sicherheitsbeiwert für keramische Werkstoffe 20 3.3 Lebensdauerbestimmung mittels Messmethoden 24 4 Mechanisches Design eines keramischen Gleitlagers (mechanische Lebensdauer) 26 4.1 Verbindungselement Koppelstange und typische Lastsituationen 26 4.2 Konstruktive Voraussetzungen für eine rein elastische Beanspruchung 27 4.3 Parameterstudien zu konstruktiven Einflussgrößen und deren Auswirkung auf die mechanische Beanspruchung 30 4.3.1 Einfluss der Fertigungsqualitäten des Lagersitzes 31 4.3.2 Einfluss der Gleitlagerbuchsen- und Einbettungssteifigkeit 32 4.3.3 Einfluss der Bolzenballigkeit 36 4.3.4 Einfluss der Einbettungsbauform 36 4.3.5 Einfluss der Lagerbelastung und des Nenndurchmessers 40 4.3.6 Einfluss der Lagerluft 41 4.3.7 Weitere Parameterstudien 42 4.4 Ableitung von Konstruktions- und Werkstoffanforderungen 43 4.5 Experimentelle Festigkeitsuntersuchung 45 4.5.1 Prüfstandsvorrichtungen 46 4.5.2 Proben zur Festigkeitsuntersuchung und Messprogramm 47 4.5.3 Statische und dynamische Tragfähigkeit keramischer Gleitlager 49 5 Design eines fluidfreien und reibwertreduzierten Tribologiesystems (tribologische Lebensdauer) 51 5.1 Allgemeine und keramische Tribologie 53 5.2 Zusammenfassung tribologischer Kennwerte einer Si3N4-Stahl-Paarung 57 5.3 Möglichkeiten zur Reibwert- und Verschleißreduzierung 59 5.4 Experimentelle Analyse des Tribologiesystems 65 5.4.1 Tribologiesystem und Abbruchkriterien 65 5.4.2 Tribologische Proben und Messprogramm 69 5.4.3 Ergebnisse zum Reibwert und zum erzielbaren Gleitweg 74 5.4.4 Verschleißzustände und tribologisches Verhalten 78 5.4.5 Diskussion der tribologischen Ergebnisse 83 6 Berechnungsvorschrift zu rein elastisch beanspruchten Gleitlagerbuchsen nach dem Spannungsminimum 85 7 Zusammenfassung und Diskussion der Ergebnisse 90 8 Ausblick 93 Literaturverzeichnis 95 Anlagenverzeichnis 97 / This paper describes an application of ceramics in the plain bearing technology. The main issue is the specific ceramic design including the surrounding structure. Especially the embedding as well as the bold have to be adapted to minimize the tensile stress of the ceramic in operation. Parametric studies based on FEM allowing to define the design requirements depending on the criteria of minimum stress, size of bearing, bearing load and ceramic material. Experiments verify the ceramic design regarding to a static and dynamic load rating of 150 N/mm². Furthermore an opportunity is shown to create a fluid free and maintenance-free tribology system for ceramics which has a coefficient of friction less than 0,1 and a not measurable wear. The sliding distance limit has to be optimize. In summary it is given a calculation regula-tion to dimension a ceramic plain bearing.:Abbildungsverzeichnis VIII Tabellenverzeichnis XI Symbole und Abkürzungen XII 1 Einleitung und Zielsetzung 1 2 Stand der Technik und Wissenschaft 3 2.1 Technische Merkmale und Marktanalyse heutiger Gleitlager 3 2.2 Keramische Werkstoffe 7 2.3 Hochleistungskeramik in hochbeanspruchten Gleitanwendungen sowie Präzisierung der Aufgabenstellung und angewandten Methoden 14 3 Berechnungsmethoden für keramische Werkstoffe 18 3.1 Spannungszustand im keramischen Bauteil 18 3.2 Zulässige Spannung und Sicherheitsbeiwert für keramische Werkstoffe 20 3.3 Lebensdauerbestimmung mittels Messmethoden 24 4 Mechanisches Design eines keramischen Gleitlagers (mechanische Lebensdauer) 26 4.1 Verbindungselement Koppelstange und typische Lastsituationen 26 4.2 Konstruktive Voraussetzungen für eine rein elastische Beanspruchung 27 4.3 Parameterstudien zu konstruktiven Einflussgrößen und deren Auswirkung auf die mechanische Beanspruchung 30 4.3.1 Einfluss der Fertigungsqualitäten des Lagersitzes 31 4.3.2 Einfluss der Gleitlagerbuchsen- und Einbettungssteifigkeit 32 4.3.3 Einfluss der Bolzenballigkeit 36 4.3.4 Einfluss der Einbettungsbauform 36 4.3.5 Einfluss der Lagerbelastung und des Nenndurchmessers 40 4.3.6 Einfluss der Lagerluft 41 4.3.7 Weitere Parameterstudien 42 4.4 Ableitung von Konstruktions- und Werkstoffanforderungen 43 4.5 Experimentelle Festigkeitsuntersuchung 45 4.5.1 Prüfstandsvorrichtungen 46 4.5.2 Proben zur Festigkeitsuntersuchung und Messprogramm 47 4.5.3 Statische und dynamische Tragfähigkeit keramischer Gleitlager 49 5 Design eines fluidfreien und reibwertreduzierten Tribologiesystems (tribologische Lebensdauer) 51 5.1 Allgemeine und keramische Tribologie 53 5.2 Zusammenfassung tribologischer Kennwerte einer Si3N4-Stahl-Paarung 57 5.3 Möglichkeiten zur Reibwert- und Verschleißreduzierung 59 5.4 Experimentelle Analyse des Tribologiesystems 65 5.4.1 Tribologiesystem und Abbruchkriterien 65 5.4.2 Tribologische Proben und Messprogramm 69 5.4.3 Ergebnisse zum Reibwert und zum erzielbaren Gleitweg 74 5.4.4 Verschleißzustände und tribologisches Verhalten 78 5.4.5 Diskussion der tribologischen Ergebnisse 83 6 Berechnungsvorschrift zu rein elastisch beanspruchten Gleitlagerbuchsen nach dem Spannungsminimum 85 7 Zusammenfassung und Diskussion der Ergebnisse 90 8 Ausblick 93 Literaturverzeichnis 95 Anlagenverzeichnis 97

High strength aluminum alloys have for a long time been a popular material utilized in the automotive and aerospace sector due to coveted mechanical properties in terms of weight, strength, fatigue, and corrosion. However, tribological mechanisms such as tribo-film formation and material transfer during the metal cutting manufacturing process of aluminum impose significant reduction of machining and tool-life performance. Additionally, environmental aspects associated with metal cutting manufacturing has got more interest and pushed cutting tool development in new directions to meet increased customer demands. One possible way of achieving this, is the implementation and utilization of diamond based cutting tools which has been shown to perform well in machining of high strength aluminum. However, in depth knowledge regarding the tribological properties of diamond based cutting tools is currently lacking. Thus, the aim of this master thesis has been to investigate the refined tribological characteristics and properties of WC-Co cemented carbide cutting tools coated with synthetically grown CVD diamond. Tribological testing methods, such as frictional scratch/sliding, pin-turning, contact-zone temperature measuring, and longitudinal turning have been conducted to acquire extensive amount of research material in the form of test samples and data information. Furthermore, pin-turning tests were performed using a newly developed Tribojan pin-turning equipment and the performance of this was evaluated as a subgoal task. Specimen sample analysis have primarily been performed through LOM and SEM/EDS microscopy techniques. The results acquired from testing, microscopy analysis and data set evaluation have showed promising results in terms of frictional characteristic and material transfer properties regarding CVD diamond coated surfaces. The average CoF of CVD diamond sliding against an Alumec 89 aluminum alloy surface were somewhat lower as compared with similar sliding of a conventional uncoated WC-Co cemented carbide material. Furthermore, the frictional behavior and characteristic of CVD diamond appears to be more consistent and regular over longer sliding distances. The contact interaction between the CVD diamond coated surface and Alumec 89 appears to have a more abrasive nature due to the rough surface structure and material properties of the coating. The corresponding tribo-pair contact interaction with WC-Co cemented carbide shows more adhesive tendencies. Additionally, the contact-zone temperature development during pin-turning is shown to be somewhat lower during CVD diamond/Alumec 89 surface interactions. Regarding material transfer properties, CVD diamond are shown to perform well when interacting with high-strength aluminum. The amount of material adherence is significantly reduced on CVD diamond coated surfaces. During longitudinal turning using CVD diamond coated cutting tools, no significant wear was observed. On the other hand, evidence of both adhesive and abrasive wear was observed during turning using conventional uncoated WC-Co cemented carbide tools. Finally, tribological mechanisms acting during Tribojan pin-turning tests was shown to be relatively comparable with an actual machining operation, which indicate that the testing method perform well as compliment to standard frictional sliding and machining testing. / Höghållfasta aluminiumlegeringar har länge varit ett populärt material inom bil- och flygindustrin på grund av deras eftertraktade mekaniska egenskaper när det gäller vikt, styrka, utmattning och korrosion. Däremot medför tribologiska fenomen, så som tribofilmbildning och materialöverföring under metallskärande tillverkningsprocesser för aluminium, en betydande minskning av prestanda hos utrustning och skärverktygens livslängd. Dessutom har miljöaspekterna i samband med metallskärande tillverkning fått ökat intresse och därmed drivit utvecklingen av skärverktyg i nya riktningar för att uppfylla kundernas ökade krav. Ett möjligt sätt att uppnå detta är att införa och använda diamantbelagda skärverktyg, vilka har visat sig fungera bra vid bearbetning av höghållfast aluminium. Dock saknas det för närvarande djupgående kunskaper om de tribologiska egenskaperna hos dessa diamantbaserade skärverktyg. Syftet med detta examensarbete har därför varit att undersöka de förfinade tribologiska egenskaperna hos WC-Co skärverktyg av hårdmetall belagda med syntetiskt odlad CVD-diamant. Tribologiska testmetoder, så som friktionsskrapning/glidning, pinnsvarvning, temperaturmätning i kontaktzonen samt longitudinell svarvning, har genomförts för att samla in analysmaterial i form av prover och datainformation. Dessutom utfördes pinnsvarvningstesterna med hjälp av en nyutvecklad så kallad Tribojan-utrustning, vars prestanda har utvärderats som ett delmål i projektet. Analyser av provexemplar har huvudsakligen utförts med hjälp av mikroskopitekniker så som LOM och SEM/EDS. Resultaten från provning, mikroskopianalys och utvärdering av data har visat lovande resultat när det gäller friktions och materialöverföringsegenskaper för CVD-diamantbelagda ytor. Den genomsnittliga CoF för CVD-diamant som glider mot en yta av aluminiumlegeringen Alumec 89 var något lägre jämfört med motsvarande glidning av konventionellt WC-Co hårdmetallmaterial. Dessutom verkar friktionsbeteendet hos CVD-diamant vara mer konsekvent och regelbunden över längre glidsträckor. Kontaktinteraktionen mellan ytor av CVD-diamant och Alumec 89 verkar också ha en mer abrasiv karaktär på grund av diamantbeläggningens grova ytstruktur och materialegenskaper. Motsvarande kontaktinteraktion mellan Alumec 89 och obelagd WC-Co hårdmetall visar däremot mer adhesiva tendenser. Dessutom tenderar temperaturutvecklingen i kontaktzonen under pinnsvarvning vara något lägre vid ytinteraktioner mellan CVD-diamant och Alumec 89. När det gäller materialöverföringsegenskaperna visar sig CVD-diamant fungera bra vid interaktion med höghållfast aluminium. Materialets vidhäftning minskar betydligt på diamantbelagda ytor. Vid kontinuerlig longitudinell svarvning med diamantbelagda skärverktyg observerades inget betydande slitage. Å andra sidan hittades tecken på både adhesivt och abrasivt slitage under svarvning med konventionella obelagda WC-Co hårdmetallverktyg. Slutligen visade det sig att de tribologiska mekanismerna som verkade under Tribojan-pinnsvarvning vara relativt jämförbara med faktisk bearbetning, vilket tyder på att testmetoden fungerar bra som komplement till friktions och svarvtester.