Vehicle modeling and simulation have fast become the easiest and cheapest method for vehicle testing. No longer do multiple, intensive, physical tests need be performed to analyze the performance parameters that one wishes to validate. One component of the vehicle simulation that is crucial to the correctness of the result is the tire. Simulations that are run by a computer can be run many times faster than a real test could be performed, so the cost and complexity of the testing is reduced. A computer simulation is also less likely to have human errors introduced with the caveat that the data input into the model and simulation is accurate, or as accurate as one would like their results to be. Simulation can lead to real tests, or back up tests already performed. The repeatability of testing is a non-issue as well. Tire models are the groundwork for vehicle simulations and accurate results cannot be conceived without an accurate model. The reason is that all of the forces transmitted to and from the vehicle to the ground must occur at the tire contact patches. This presents the problem of obtaining a tire model. Tire companies do not readily give out tire data since the tire industry is still as much "black art" as it is science. For tire data one must begin with a testing apparatus. The test rig must be accurate and must have been validated before results can be used. This thesis presents the process of the design and construction of a portable tire test rig. It then will discuss tire testing procedures and validation techniques. The resulting data shows good correlation between test data and known tire test data from flat track testing provided by a tire manufacturer. Then, a simple rollover study of a military truck will be compiled in TruckSim. Lastly, a control method for the rollover case will be designed and implemented. The results of the roll control simulation are positive. The study shows an increase in dynamic roll stability due to the implementation of the control algorithm. / Master of Science

Swerea KIMAB is one of Europe’s leading institutes for metallic materials and excels in many different areas. KIMAB’s main advantage is its open internal structure where all groups and projects can share information and knowledge between the sections. After moving to new premises it was noted that the surface fatigue test rig that had been used had started to leak oil and was no longer suitable for new projects. Because surface fatigue testing will be of importance in the future for the development of new alloys that will replace existing alloys in for example gears, this thesis was created as a foundation for how a new test rig should be acquired.This thesis goal is to describe KIMAB’s requirements in a test rig and to do a market screening over existing solutions for test rigs. Thereafter a designed concept shall be developed for KIMAB’s specific requirements and describe how it should be made. These different parts will be the ground for how KIMAB should continue in the acquisition of a new rig.The base of the thesis is a literature study in surface fatigue, its mechanics and how these can be affected to give the desired test scenario. This information is used to make a market screening for suitable test rigs that fulfils the requirements. Thereafter a concept generation is made and evaluated during a meeting on KIMAB. The chosen concept will then be designed to be user friendly, robust and as reliable as possible.When the final concept is done and quotes from manufacturers have been gathered for most of the parts in the design, a time and cost estimation was made to give the reader the chance of deciding which alternative is the most suitable for KIMAB. This choice has to be made with regard to future projects and how the market will develop for the ordering of surface fatigue testing. / Swerea KIMAB är ett av Europas ledande institut för metalliska material med spetskompetens inom ett flertal områden. KIMAB’s stora fördel är dess öppna interna struktur där alla grupper och projekt kan dela information och kunskap emellan avdelningarna. Efter att KIMAB flyttade till nya lokaler uppmärksammades det att den kontaktutmattningsrigg de använt under flera år började läcka olja och inte längre var optimal för dagens projekt. Eftersom kontaktutmattning kommer att bli ett viktigare inslag i framtiden då nya legeringar kommer att ersätta befintliga i exempelvis kugghjul, så skapades detta examensjobb som en grund för hur en ny rigg skall införskaffas.Detta examensjobb har som mål att beskriva KIMAB’s behov i en testrigg samt att göra en marknadsundersökning efter befintliga riggar. Därefter skall ett förslag designas på hur en testrigg som är anpassas just för KIMAB’s behov skall kunna byggas. Dessa delar skall sedan ligga som grund för hur KIMAB skall gå vidare i införskaffandet av en ny rigg.Examensarbetets grund ligger i en litteraturstudie i kontaktutmattningsskador samt mekanismerna bakom dessa skador och hur de kan påverkas i ett test scenario. Denna kunskap användes för att undersöka marknaden efter lämpliga riggar som kan uppfylla kraven. Därefter skapades ett antal koncept som utvärderades under ett möte på KIMAB. Det koncept som valdes har därefter designats för att vara så användarvänligt och tillförlitligt som möjligt.När konceptet var färdigställt och prisuppgifter hämtats in på merparten av delarna så har en kostnads och tidskalkyl utförts för att låta läsaren avgöra vilket alternativ som passar bäst för KIMAB. Detta val måste baseras på framtida projekt och hur marknaden ser ut för beställning av kontaktutmattningsprover.

Erasteel Kloster i Långshyttan är en stålindustri som bland annat valsar tråd och tunna band.Kvalitén på det valsade stålet undersöks med en elektromagnetisk sensor. Denna sensorkalibreras med hjälp av en testrigg där sensorerna testas med olika provpinnar med defekter.Provpinnarna förs fram och tillbaka genom sensorn som undersöks, vilken ger utslag på dentillkopplade datorn. Dessa utslag används sedan för att kalibrera inställningarna hossensorerna samt för att testa om de fungerar. Syftet med följande studie är att undersöka förbättringsmöjligheterna hos denna testrigg samtta fram ett lösningsförslag på en förbättrad konstruktion. Den nuvarande testriggens problemidentifieras genom en intervju och observationer. Olika konceptidéer togs fram, undersöktesoch diskuterades med företagets krav samt de nuvarande problemen som grund. Olikakomponenter, exempelvis drivenhet och glidskenor som passar ändamålet identifieras. Medhjälp av dessa framställs sedan flera förbättringskoncept, vars egenskaper jämförs gentemot Erasteels önskemål. Resultatet av studien blev en modell av en ny testrigg, ritad i Solidworks. Denna modell bestårav en sammanställning av de delkoncept som uppfyllt flest krav på bästa sätt, vilket harbestämts med hjälp av en Pughs konceptvalsmatris. Denna nya modell löser de problem somidentifierats hos den gamla testriggen samtidigt som den blir mer användarvänligt. Dettagjordes genom att drivenheten konstruerades om samt att den gamla motorn ersattes med enlinjärmotor. Även sensorns hållare modifierades för att kunna förflyttas medan sensorn är påplats, vilket förenklar bytet av provpinnen. Det nya testriggsförslaget kommer sedan utgöraunderlaget vid konstruktionen av en ny testrigg hos Erasteel. / Erasteel Kloster in Långshyttan is a steelwork that among other things hot rolls iron. The quality of the rolled iron is inspected by an electromagnetic sensor. This sensor is calibrated using a test rig and a test material with a defect. This test material is moved back and forth through the sensor, which gives different outputs depending on the fault. These outputs are then used to calibrate the sensor settings. This study aims to examine possible improvements of the currently used test rig as well as to develop a proposal for an improved rig. The current problems are identified from interviews and observations. Different concept ideas were developed, examined, and discussed with the companies wishes and the identified problems as a foundation. Different fitting components such as drive units and linear rails which can be purchased have been identified. Various improvement concepts were created based on the old test rig, while the identified problems and the wishes of Erasteel were taken into consideration. This work resulted in a new model of a test rig, made with Solidworks. The design is created with the concepts that satisfy the companies demands in the best way, which was evaluated with the Pugh concept matrix. The final proposal solves all identified problems which are associated with the old rig, while at the same time being more user friendly. This new rig will be the basis for the new machine which will be built at Erasteel.

Det här examensarbetet skildrar en konceptstudie och kostnadsuppskattning av enuniversell testrigg för växellådor. Arbetet har genomförts på uppdrag av SwepartTransmission AB och har resulterat i koncept- och komponentförslag samtkostnadsuppskattning av ett universellt test system av växellådor. / This degree project cover a concept study and cost analyses of a universal test rig forgears. The project has been performed for Swepart Transmission AB and has resultedin a concept and component suggestion as well as cost analysis of a universal testsystem for gears.

Powder metallurgy (PM) is usually used in manufacturing parts with complex geometries, such as gears and structural parts. The main attractions of PM are the high rate of material utilization, environmental friendliness of production, economic advantages (especially for complex geometries), and possibility of obtaining lighter components. To find a wide range of applications and compete with regular steel gears, PM gear transmissions should have good transmission efficiency and wear properties. Furthermore, they should have low contact noise and adequate surface fatigue properties. Because of the porosity structure of PM gears both on gear flanks and in the body, the friction and wear properties of PM gear flank contacts differ somewhat from those of regular steel gears.    This doctoral thesis examines the efficiency and wear properties of PM gears. Paper A compares the wear, friction, and damage mechanism properties of two sintered gear materials with those of a standard gear material. Paper B deals with the gear mesh torque loss mechanism of PM and regular steel gears by combining both pin-on-disc frictional and FZG efficiency tests. Paper C comparatively examines the efficiency of PM and regular steel gears by conducting FZG gear efficiency tests. Paper D focuses on the wear and friction properties of PM and regular steel gear materials treated using the triboconditioning process. Paper E studies the friction and wear properties attributable to different pore sizes in PM gear materials.    The results indicate that regular steel meshed with PM gear material and PM meshed with PM gear material are good candidate combinations for gear transmissions. This is because the porosities of PM material can lower the friction coefficient while the wear rate can be the same as or even better than that of regular steel contacts. The triboconditioning process enhances the wear resistance and reduces the friction coefficient of the PM gear material. The friction and wear coefficients of PM meshed with PM gear material display increasing trends with increasing pore size. The friction and wear coefficients of regular steel meshed with PM gear material display decreasing trends with increasing pore size. / <p>QC 20160523</p>

Dirt ingress in hydraulic cylinders is one of the sources that leads to pollution of hydraulic systems. There are already several test rigs to investigate external contamination mechanisms. However, until now only the behavior of the whole sealing system was analyzed. A new testing method to understand the dirt particle transport between a reciprocating motioned rod and a wiper is presented. The new approach aims to avoid known issues such as limited reproducibility and long duration. The paper describes the test rig design and operating principle. First measurement results are shown.

Turbocharging is used as a means to downsize petrol engines, thereby, producing more power for a lower engine size, when compared with a naturally aspirated engine. Due to the presence of a throttle valve in the intake system in petrol engines, flow is restricted at the outlet pipe of the compressor during low load engine operation. For example, during transient tip out tip in maneuvers. Hence, there is a chance of the turbocharger operating in near surge or surge conditions and, thus, generating surge noise. This Thesis describes an experimental and simulation method to predict and measure the turbocharger surge noise. Initially, experimental transient tip-in and tip-out maneuver was performed on a non turbocharged car with a petrol engine. The measured noise level in the intake manifold, at a low frequency of up to 1200 Hz, was analysed and was shown not to represent surge noise. Next, a one dimensional simulation method was applied to simulate the noise of the engine and this demonstrated an increase in the acoustic pressure level in the intake manifold during the tip in and tip out maneuver. However, a surge noise pattern was not observed in the analysis of acoustic pressure signals in the intake system using Short Time Fourier Transform (STFT). The simulation procedure was also used to inform the design of an experimental rig to recreate the surge noise under laboratory conditions. An experimental turbocharger noise rig, designed and built for this purpose, is explained in the Thesis. Important component parts likely to be involved in the surge noise generation such as the intake system, compressor, throttle body, compressor recirculation valve and measurement and control systems were integrated into the test rig. Background noise contributions from the electric motor, AC mains, supercharger pulley, throttle body, inverter fan, throttle body gearing and structural vibration of the supporting structure were identified from the analysed frequency components of the signals from surface microphone measurements taken at the intake system. This helped to clearly identify the surge noise frequency components (3250 Hz) in the STFT analysis. The fundamental mechanism of noise generation was identified using an analysis of the experimental results and a frequency calculation for vortex shedding and the radial acoustic resonances. One of the main conclusions of the Thesis is that the compressor recirculation valve (CRV) open or close position, the CRV delay time and the throttle position are major contributing factors to the cause of the surge noise. Another major conclusion is that the radial acoustic resonance may be a mechanism of surge noise generation. Finally, a passive solution to reduce the surge noise is proposed. A pipe with cross ribs is designed as a passive solution using the radial acoustic resonance calculation and the corresponding nodal patterns. This solution demonstrated a measured intake system noise reduction of up to 10dB under compressor surge conditions.

Drill String dynamic behaviour during the oil drilling operation, was a major source for the failure of the Bottom Hole Assembly (BHA). The behaviour produced torsional vibration, which underpins the stick slip phenomena. Besides threatening the safety of the oil drilling process, such failure cause interruptions in the drilling operations and incurred high maintenance cost to the oil drilling company. This issue can be resolved with the implementation of the optimum control mechanism while operating the drill string. In this research, an optimum control mechanism was proposed to suppress the torsional vibration as well as mitigate the risk of stick slip phenomenon from occurring. The mechanism was proposed through a series of rigorous research strategies i.e. updated-mathematical equation modelling, experimentation and simulation. As the first step, a mathematical equation model describing system dynamics was derived to set the parameter of investigation. Representing the freedom torsional of the two degrees - conventional vertical drill string, the model was used to predict the frictional Torque On Bit (TOB) through non-linear friction force, denoting the ground-formation behaviour during drilling activity. Using a velocity feedback system, the drill-string oscillation was reduced while gradually increasing its velocity via gain scheduling method - allowing fast response to load disturbance. To avoid the motor torque from exceeding the maximum threshold, a Weight On Bit (WOB) was introduced. This approach remarks the novel contribution of this research. Next, an experiment on the preliminary test rig within a controlled laboratory set up was conducted. The rotary drill rig was assembled to identify the dynamics (i.e. parameters) of an individual part of the drill string. The results obtained were then applied in the drill string operation experiment, to identify the optimum control mechanism that can avoid the torsional vibration. To enable triangulation of results, a simulation was conducted by applying the same parameters obtained from the test rig experiment in the model- which is the optimum control mechanism that was proposed in this research to minimise torsional vibration, as well as reducing the chance of drill-string failure due to stick-slip phenomenon.

The potential for significant performance increases, using ceramic materials in un-lubricated rolling element bearing applications, has been the subject of research over the past two decades. Practical advantages over steel include increased ability to withstand high loads, severe environments and high speeds. However, widespread acceptance has been limited by the inability to predict wear life for ceramic bearing applications. In this thesis, the rolling contact wear of 52100 bearing steel and Over-aged Magnesia-Partially-Stabilised Zirconia (OA-Mg-PSZ) ceramic are examined using a newly developed rolling contact wear test rig. The new wear test rig simulates the system geometry of an un-lubricated hybrid (ceramic and steel) ball bearing. The new wear test rig is versatile in that it allows low cost samples to be utilised resulting in a larger number of samples that can be tested. Wear samples of 52100 bearing steel and OA-Mg-PSZ produced by the new wear test rig were examined for mass loss and wear depth. The wear behavior of both the steel and ceramic material showed a dependence on operating variables time and load. Load was varied between 300N to 790N. Typical mass loss after 1 hour of testing 52100 bearing steel at 790N was 0.03 grams as compared to OA-Mg-PSZ which was 0.001 grams. The rolling contact wear of the OA-Mg-PSZ was an order of magnitude lower than that of the 52100 bearing steel. The wear mechanism for 52100 bearing steel was typical of plastic deformation and shearing near and below the surface of rolling contact. Once cracks extend to reach the surface, thin flat like sheets are produced. In OA-Mg-PSZ the wear mechanism initially is that of plastic deformation on the scale of the surface asperities with asperity polishing occurring followed by lateral cracks and fatigue spallation. Results obtained using the new rolling contact wear test rig led to the establishment of a new equation for wear modeling of 52100 bearing steel and OA-Mg-PSZ ceramic materials.

<p>PolyTech AB in Malmköping manufactures gyro stabilized camera systems or helicopter applications. In this Master´s Thesis a shaker test rig for vibration testing of these systems is designed, implemented and evaluated. The shaker is required to have an adjustable frequency and displacement and different shakers that meet these requirements are treated in a literature study.</p><p>The shaker chosen in the test rig is based on a mechanical solution that is described in detail. Additionally all components used in the test rig are described and modelled. The test rig is identified and evaluated from different experiments carried out at PolyTech, where the major part of the identification is based on data collected from accelerometers.</p><p>The test rig model is used to develop a controller that controls the frequency and the displacement of the shaker. A three-phase motor is used to control the frequency of the shaker and a linear actuator with a servo is used to control the displacement. The servo controller is designed using observer and state feedback techniques.</p><p>Additionally, the mount in which the camera system is hanging is modelled and identified, where the identification method is based on nonlinear least squares (NLS) curve fitting technique.</p>