Pulse width modulation (PWM) voltage source converters (VSC) are one type of motor drives that have become popular because they enable precise control of speed and torque in medium voltage motors. However, these drives are known to have adverse effects on the insulation system particularly on conductive armour tape (CAT) and semi-conductive stress grading tape (SGT). These tapes, which are crucial components of the insulation system, control the surface electrical stresses in the stator slot and in the end portion of the form-wound coils outside the grounded stator. The material properties of CAT and SGT and the methods by which they are applied on form-wound motor coils are traditionally designed for power frequency, or a 60 Hz sinusoidal voltage. However, because of the high frequencies associated with the repetition rate and the fast rise time of the PWM pulses, elevated electrical and thermal stresses develop in these tapes, which can lead to premature insulation failure. Little research has been conducted with respect to understanding the mechanism of dielectric heating as a function of frequency and repetitive pulse characteristics. The material characterization of CAT and SGT is a vital part of an investigation of the performance of the stress relief system at high frequencies. In this study, the anisotropic dielectric properties of CAT and SGT have been measured in dc and ac and in low and high electric fields. The laboratory experiments for determining the material characteristics are discussed and the results analyzed. According to the ac space charge limited field (SCLF) theory, the maximum ac tangential component of the electric field in a nonlinear resistive SGT on medium voltage form-wound motor coils can be predicted from the field dependent electrical conductivity and the frequency. However, the SCLF theory cannot predict the total electric field (vector sum of the tangential and normal components) in the air adjacent to the surface of the tapes. Simulations of the electric field using a finite element method (FEM), is one of the best ways of finding the resultant electric field distribution in the air space adjacent to the SGT. However, prior to this study, researchers simplified the modelling of the stress relief system to avoid the convergence problems that develop due to the nonlinearity of the SGT conductivity as a function of the electric field, and also because of the geometry and dimensions of the tapes when their depths are orders of magnitude smaller than the other dimensions associated with form-wound coils. For modelling the stress grading (SG) system at power frequency and at the rated voltage, the dc isotropic conductivity of the SGT and CAT has also been extensively investigated. However, relatively little work has been done with respect to the ac electrical behaviour of these materials and dc modelling cannot reflect the effects of high-frequency stresses on the machine insulation. In this study, comprehensive transient FEM modelling has been developed in order to simulate the insulation system with nonlinear field dependent materials. The actual dimensions of the components are applied in the model, and the appropriate material parameters for the FEM simulations are extracted from the experimental test results. One crucial point that has not been considered in previous studies is the effect of the component of the electric field that is normal to the surface of the coil. In most studies, only the tangential component of the electric field is considered; however, in this study, both components and the resultant electric field are computed. The surface tangential field is calculated with reference to the gradient of the surface potential as measured with an electrostatic voltmeter. It is shown that this technique can provide a reasonable estimate for the tangential field along the SG system, but not without limitations, which are discussed in detail. Based on laboratory work and analytical analysis, this research has successfully determined the relationship between the thermal effect of the PWM voltage and the other repetitive fast pulses, such as square wave and impulse voltages. The influence of the pulse characteristics on the development of stresses has also thoroughly investigated, and the results are presented. A coupled electric and thermal model that incorporates the finite element method (FEM) is used as a means of studying thermal stresses and determining appropriate remedies. However, using transient analysis as an approach for finding the temperature profile associated with high repetitive impulses (1-10 kHz) and fast rise times (~200 ns) is both difficult and impractical. According to these considerations, an alternative method has been developed from stationary analyses based on two sinusoidal voltages of different frequencies. The frequency and amplitude of these sinusoids are measured relative to the switching frequency, signal power, and nonlinearity of the system, and the results of the simulation are then verified experimentally, thus showing the efficacy of this method. This research also concluded that a capacitive SG system with conductive foil embedded in the groundwall insulation can be a practical alternative to a conventional SGT of form-wound coils in inverter fed motors. The performance of the capacitive SG scheme is independent of frequency and can therefore provide the required mitigation of the stress caused by repetitive fast pulses. The results of the evaluation of this system with respect to qualification tests demonstrate the effectiveness of the system.

Cement hydration is the result of a series of simultaneous chemical reactions occurring during the production of concrete. An excessive amount of heat is generated, which consequently may give rise to thermal stresses and cause early age cracks in concrete that may affect its structural integrity, and load bearing capacity. Incorporating fly ash into the concrete mixture has shown to be an efficient method to reduce the temperatures developed during early age hydration, especially for massive concrete structures. Fly ash does additionally affect the concrete's development of compressive strength, tensile strength and Young's modulus. The MahanaKhon tower's mat foundation is divided into 14 layers, with fly ash incorporated in the concrete mix. A finite element model was developed of the mat foundation with COMSOL Multiphysics to simulate the developed temperatures and thermal stresses during curing. The simulations were carried out as parametric studies with different strain reference temperatures. The simulated temperatures were compared with existing temperature measurements that were conducted in three different elevations in each concrete layer. The result of the temperature analyses showed that the measured temperatures were generally larger than the simulated ones, which may have been the result of the numerical model's heat conductivity and convective heat transfer coeffcient not reflecting the actual case. Furthermore, the numerical model did not take into account the effects of solar radiation, which would most likely have increased the temperature of the concrete. The maximum simulated temperatures were mostly found in the center level of the concrete, followed by the lower level, and the lowest at the top. It was also observed that the maximum temperatures in some of the mat foundation layers could exceed 70 °C, which is generally considered high since the risk of delayed ettringite formation may arise. The large temperature is partially a result of not using cooling methods, such as cooling pipes, but also due to the high initial and ambient temperatures. The result of the thermal stress analyses showed that no tensile stresses arose when the strain reference temperature, Tref, was specified to 30 °C, corresponding to the mean ambient temperature. This is due to the concrete temperature not falling below Tref, and the concrete will therefore be in expansion and only be subject to compressive stresses. Increasing Tref to 50 °C, which was considered a reasonable estimation, resulted in developed tensile stresses in all mat foundation layers, where the majority of the mat foundation layers showed a risk of superficial surface cracks. The maximum tensile stresses were found at the final time of the simulations, which was expected, since the temperatures were at their lowest as a result of removing the curing insulation. Finally, setting Tref to 70 °C, corresponding to the maximum temperature during hardening, increased the induced tensile stresses considerably, due to the large temperature gradient between Tref and the concrete temperature. The maximum stresses were, as expected, located at the top level and caused by internal restraint. The second largest tensile stresses were found in the center level, also subject to internal restraint. The lowest tensile stresses were located in the lower level, subject to external restraint. / Cementhydratation är resultatet av en serie kemiska reaktioner som sker under tillverkningen av betong. Stora mängder värme genereras, vilket följaktligen kan ge upphov till termiska spänningar och orsaka tidig sprickbildning som påverkar betongens hållfasthet, och bärförmåga. Inkludering av flygaska i betongblandningen har visat sig vara en effektiv metod avsedd att minska temperaturerna som utvecklas under hydratationen i ung betong, särskilt i massiva betongkonstruktioner. Flygaska påverkar också betongens utveckling av tryckhållfasthet, draghållfasthet och elasticitetsmodul. MahanaKhon towers bottenplatta är uppdelad i 14 lager, där flygaska inkluderades i bottenplattans betong. En finit elementmodell av bottenplattan skapades i COMSOL Multiphysics, där de utvecklade temperaturerna och termiska spänningarna i den unga betongen simulerades under bottenplattans härdningsfas. Simuleringarna genomfördes som parameterstudier med olika referenstemperaturer. De simulerade temperaturerna jämfördes vidare med befintliga temperaturmätningar som utfördes i tre olika elevationer i varje gjutetapp. Resultaten av temperaturerna visade att de uppmätta temperaturerna var generellt högre än de simulerade, vilket bland annat kan bero på att betongens värmeledningsförmåga, samt konvektiva värmeöverföringskoefficient inte återspeglade det aktuella fallet. Den numeriska modellen tog inte heller hänsyn till effekten av solinstrålning, som sannolikt skulle ökat betongens temperatur. De maximala temperaturerna hittades mestadels i betongens mittnivå, följt av den lägre nivån och slutligen lägsta nivåerna vid toppen. Det observerades även att de maximala temperaturerna i bottenplattan kunde överstiga 70 °C, vilket generellt anses vara högt då risken för fördröjd ettringitbildning kan uppstå. De höga temperaturerna beror delvis på avsaknad av kylmetoder, såsom kylrör, men även på den höga initialtemperaturen och omgivningstemperaturen. Resultaten av spänningsanalysen påvisade att inga dragspänningar uppstod när referenstemperaturen Tref denierades till 30 °C, som motsvarar den genomsnittliga omgivningstemperaturen. Detta förklaras av att betongen kommer att vara i expansion och följaktligen endast utsättas för tryckspänningar. Efter att Tref ökats till 50 °C, vilken ansågs vara en rimlig estimering i denna studie, uppstod dragspänningar i alla lager i bottenplattan, där vissa utsattes för risk för ytsprickor. De maximala dragspänningarna uppstod vid simuleringarnas slut, vilket var förväntat då temperaturerna var som lägst vid den tidpunkten till följd av att isoleringen avlägsnades. Slutligen höjdes Tref till 70 °C, vilket motsvarar den maximala temperaturen i bottenplattan under härdning. De inducerade dragspänningarna ökade avsevärt på grund av den stora temperaturgradienten mellan Tref och betongtemperaturen. Samtliga lager utsattes i detta fall för risk för genomgående sprickor. De maximala dragspänningarna påträffades på toppnivån och orsakades av inre tvång. De näst största dragspänningarna fanns i mitten av plattan och var också resultatet av inre tvång. De lägsta dragspänningarna påträffades vid plattans lägre nivå, som utsattes för yttre tvång.

Le but de cette thèse pluridisciplinaire est d’étudier le problème de l’interaction fluide-structure à partir du point de vue mathématique et physique. Des problèmes d’interaction d’un fluide visqueux avec une structure élastique décrivent, par exemple, des interactions entre le manteau terrestre et de la croûte terrestre, le sang et la paroi vasculaire dans un vaisseau sanguin, etc. En génie l’interaction fluide visqueux-structure apparaît lors de la formation de solution colloïdale quand un laser passe à travers le fluide influençant le substrat (ablation laser dans un liquide). Fusion sélective au laser (FSL) est utilisée pour étudier le comportement des contraintes résiduelles en dépendance des propriétés thermoélastiques et mécaniques du matériau et des formes variées des cordons rechargés. A partir du point de vue mathématique le système couplé “flux fluide visqueux – plaque mince élastique” en 3D lorsque l’épaisseur de la plaque, E, tend vers zéro, tandis que la densité et le module de Young du matériau élastique sont d’ordre 1 et E-3, respectivement, est considéré. Le solide est couché par le fluide qui occupe un domaine épais. La modélisation multi-échelle est effectuée pour la partie élastique. Le développement asymptotique complet est construit lorsque E tend vers zéro. L’existence, la régularité et l’unicité de la solution pour le problème initial sont étudiées au moyen de techniques variationnelles. La méthode de décomposition asymptotique partielle du domaine est appliquée pour le système couplé. L’erreur de la méthode est évaluée / The goal of this multi-disciplinary thesis is to study the fluid-structure interaction problem from mathematical and physical viewpoints. Viscous fluid-structure interaction problems describe, for example, interactions between the Earth mantle and the Earth crust, the blood and the vascular wall in a blood vessels, etc. In engineering viscous fluid-structure interaction appears during colloidal solution formation when a laser pierce through the fluid influencing the substrate (laser ablation in a liquid). Selective laser melting (SLM) is used to study the behavior of residual stresses depending on the thermoelastic and mechanical properties of the material and on various forms of reloaded beads. From mathematical point of view the coupled system “viscous fluid flow-thin elastic plate” in 3D when the thickness of the plate, E, tends to zero, while the density and the Young’s modulus of the plate material are of order 1 and E-3, respectively, is considered. The plate lies on the fluid which occupies a thick domain. The multi-scale modeling is performed for the elastic part. The complete asymptotic expansion is constructed when E tends to zero. The existence, the regularity and the uniqueness of the solution for the original problem are studied by means of variational techniques. The method of asymptotic partial domain decomposition is applied for the coupled system. The error of the method is evaluated

Induction Assisted Single Point Incremental Forming (IASPIF) is a die-less hot sheet metal forming. The IASPIF does not apply characteristic complex tooling like those applied in deep drawing and bending. In this thesis, induction heating was used to heat up the sheet while simultaneously forming with a tool. The research goal is to improve the formability of high strength steels by heating. The IASPIF consists of non-complicated set up that allows induction heating to be utilized through the coil inductor moved under the sheet and synchronized with the forming tool that moves on the upper side of the sheet. The advanced high strength steel alloys, DP980, DP600 and 22MnB5 steels, were investigated. The influence of induction heating on formability was evaluated by the maximum wall angle that can be achieved in a single pass. Additionally, tool diameter and tool feed rate was also varied. The most influencing parameters were tool feed rate, induction power, and the profile depth. A new forming strategy was also developed by control the heating temperature through coupling the formed profile depth with a successively increased tool feed rate. The forming forces of DP980 steel sheet, were reduced from 7 kN to 2.5 kN when forming process was performed at room and elevated temperature, respectively. Stretching stresses were developed during forming process causing a high reduction in the resulting wall part thickness. New findings in this investigation were the reverse relationship between the step-down depth and the thickness reduction percentage. The smaller the tool diameter, the better was the formability. The finite element simulation of the investigated forming process showed that the increase in heating temperature has a direct effect on rising the plastic strain from 0.2 at room temperature to 1.02 at 800 ◦ C. The maximum true strain achieved in the resulting wall part thickness was determined by FEM simulations and validated with experimental trials. The part shape accuracy was measured and the highest deflection was founded when the part was formed by the highest step-down depth. Moreover, the minimum deflection in the part shape was achieved by utilizing a high induction power in the experiments. Finally, the resulting mechanical properties of the 22MnB5 alloy sheet material were tailored during IASPIF. For this purpose, the sheets were locally heated by induction during the forming process and subsequently quenched at different rates. As a result, the produced tailored parts consist of three different regions, which consist of a ductile, transitional and hardened region. The proposed procedure allows forming and quenching at the same time without transfer and thus, process time was reduced. / Die induktionsgestützte, inkrementelle Blechumformung (englisch: Induction Assisted Single-Point Incremental Forming IASPIF) ist Warmumformprozess, bei dem keine komplexen Werkzeuge wie beim Tiefziehen und Biegen benötigt werden. Inhalt dieser Arbeit ist die inkrementelle Umformung eines Bleches mit gleichzeitig ablaufender induktiver Erwärmung. Das Forschungsziel bestand in der Verbesserung der Umformbarkeit von hochfesten Stahlwerkstoffen wie DP600, DP980 und 22MnB5 durch eine gezielte partielle Erwärmung. Der prinzipielle Aufbau des Versuchsstandes besteht aus einem Spuleninduktor, der unterhalb des umzuformenden Blechs platziert ist, und der synchron mit dem Werkzeug – einem Drückdorn – während des Umformvorganges verfährt. Ein wesentlicher Untersuchungsschwerpunkt bestand in der Ermittlung der Einflussgrößen auf den untersuchten IASPIF-Prozess. Für die Bewertung der Umformbarkeit wurden hierbei der maximal erreichbare Teilwandwinkel und die Profiltiefe, die in einem Umformdurchgang herstellbar waren, ermittelt und ausgewertet. Darüber hinaus konnten im Rahmen der Arbeit die Induktionsleistung des Generators, der Werkzeugdurchmesser und die Werkzeugvorschubgeschwindigkeit als relevante Prozessparameter identifiziert werden. Im Ergebnis der durchgeführten Untersuchungen zeigten die Werkzeugvorschubgeschwindigkeit und die Induktionsleistung einen wesentlichen Einfluss auf die erreichbare Profiltiefe. Aufbauend auf den erzielten Ergebnissen konnte eine prozessangepasste Umformstrategie entwickelt werden, bei der eine konstante Erwärmungstemperatur durch das Koppeln der momentanen Profiltiefe mit einer sukzessiv steigenden Werkzeugvorschubgeschwindigkeit erreicht wird. Weiterhin ließen sich die Kräfte bei der Umformung eines Stahlbleches aus DP980 von 7 kN (bei Raumtemperatur) auf 2,5 kN (bei erhöhter Temperatur) reduzieren. Aufgrund des mit einem Streckziehvorgang vergleichbaren Spannungszustandes während des Umformprozesses war eine starke Verringerung der resultierenden Wanddicke zu beobachten. Als neue Erkenntnis in dieser Untersuchung konnte die umgekehrte Beziehung zwischen der Zustelltiefe und dem Dickenreduktionsprozentsatz abgleitet werden. Aus der Finite - Elemente - Simulation des vorgestellten Umformprozesses wurde erkennbar, dass die Erhöhung der Erwärmungstemperatur einen direkten Einfluss auf die plastische Dehnung von 0,2 (bei Raumtemperatur) auf 1,02 (bei 800 °C) hat. Mittels der numerischen Simulation und der nachfolgenden experimentellen Validierung erfolgte darüber hinaus die Bestimmung der maximalen wahren Dehnung, die in der resultierenden Wanddicke erreicht wurde. Bei den Versuchen mit der größten Zustellung ließ sich durch die Bestimmung der Teileformgenauigkeit die höchste Abweichung von der Sollgeometrie CAD Modell feststellen. Abschließend wurde nachgewiesen, dass der IASPIF Prozess auch zur Einstellung maßgeschneiderter Bauteileigenschaften wie der resultierenden mechanischen Eigenschaften des Blechmaterials aus 22MnB5 einsetzbar ist. Zu diesem Zweck wurden die Bleche während des Umformprozesses lokal induktiv erwärmt und anschließend zur Einstellung des gewünschten Gefüges bei unterschiedlichen Abkühlgeschwindigkeiten abgeschreckt.

Sélectionner des traitements de surface pour l’industrie nécessite de prendre en compte :les propriétés à conférer au substrat, la nature et la géométrie de celui-ci et les caractéristiques du milieu extérieur. Certaines combinaisons de ces paramètres rendent difficile la sélection d’un traitement unique, d’où le recours à des multitraitements de surface. Dès lors, se posent les questions suivantes :<p>- Utiliser des multitraitements de surface peut se faire en scindant les différentes requêtes en sous-ensembles, de manière à ce que chaque traitement réponde à l’un d’eux. Dans quel ordre ces requêtes doivent-elles être introduites par rapport au substrat ?<p>- Comment sélectionner les traitements de surface répondant à chaque requête individuelle ?<p>- Comment classer des multitraitements en termes d’adéquation au problème posé ?<p>Dans ce travail, les première et troisième questions sont abordées, en explorant les requêtes concernant habituellement les dispositifs de moulage de l’aluminium :<p>- Résistance aux contraintes d’origine thermique.<p>- Résistance à la corrosion par les métaux fondus.<p>- Résistance au frottement.<p>L’analyse de la bibliographie relative aux traitements de surface utilisés dans ces systèmes a été analysée et des « architectures »-types ont été identifiées (chapitre 3). On prévoit, par exemple, un traitement conférant la résistance à la fatigue superficielle, ainsi qu’un revêtement étanche et résistant à l’aluminium fondu. Une barrière thermique est parfois préconisée.<p>Pour chacune des architectures, des traitements de surface individuels peuvent être sélectionnés. Un « facteur de performance » permettant de classer les solutions par rapport au problème de la fatigue thermique a été construit (chapitre 4) et discuté dans deux situations :<p>- Lorsqu’un revêtement est présent, et que les contraintes d’origine thermique (différence de dilatation thermique couche-substrat) menacent de le rompre lors de l’immersion dans un milieu corrosif à haute température. Des essais de corrosion dans de l’aluminium fondu ont été réalisés sur un acier revêtu par du nitrure de chrome dopé à l’aluminium, synthétisé par déposition physique en phase vapeur (chapitre 5 – collaboration :Inasmet).<p>- Lorsque des variations thermiques rapides menacent de rompre le substrat et la (les) couches. Des essais de fatigue thermique ont été réalisés sur de l’acier à outils pour travail à chaud non traité, boruré ou recouvert d’un multitraitements (zircone yttriée / NiCrAlY / boruration / acier). Le revêtement en zircone yttriée a été obtenu par projection par plasma. L’essai de fatigue thermique a été modélisé et le facteur de performance, discuté (chapitre 6).<p>Au chapitre 7, les architectures-types ont été introduites dans une méthodologie de sélection des multi-traitements de surface, qui a été appliquée dans deux cas :<p>- Celui des moules de fonderie, devant résister à la fatigue thermique et à la corrosion par l’aluminium fondu. Le facteur de performance a été extrapolé à d’autres situations qu’aux chapitres 5 et 6. Les solutions habituellement proposées pour résoudre ce problème sont retrouvées.<p>- Celui de deux pièces en acier frottant l’une contre l’autre en présence d’aluminium fondu.<p><p>To select surface treatments, one must account for the required functional properties, the substrate features and the solicitations the substrate must endure. Certain combinations of these parameters make it difficult to select a single surface treatment, a reason why several successive treatments are preferred. To select them, one needs to determine:<p>- How to divide the several requests into groups and how to stack up these groups from the substrate to the outer surface, so that each treatment deals with one specific group of requests/properties.<p>- How to select individual layers for each group of properties.<p>- How to rank the multi-treatments in terms of relevance for a given application.<p>In this work, one tries to answer the first and the third questions, by studying the case of aluminium foundry, in which the industrial devices frequently face the following solicitations:<p>- Thermal stress (thermal fatigue, thermal expansion mismatch).<p>- Presence of corrosive molten metal.<p>- Sliding wear.<p>In the literature, several “standard” architectures are proposed (chapter 3), like a diffusion layer reducing superficial fatigue plus a corrosion barrier layer. A thermal barrier coating is also sometimes proposed.<p>For each of these architectures, one can select individual treatments. To rank them, one devised a “performance index” for thermal stress (chap.4), which is discussed for two cases:<p>- For large differences between layer and substrate thermal expansion coefficients, when both are put into contact with a high temperature corrosive medium, the layer may be damaged. One discusses this case by examining the corrosion caused by molten aluminium for a steel substrate coated by anticorrosive chromium nitride doped with aluminium. The layer is produced by physical vapour deposition (chap. 5 – cooperation: Inasmet).<p>- Repeated fast surface temperature transients can also damage the substrate and/or the layer by thermal fatigue. One conducted thermal fatigue tests with samples of hot work tool steel, respectively untreated, simply borided and protected by a multilayer. In the last case, top coat is yttria stabilised zirconia, followed by a nickel superalloy and then a borided layer (undercoat). One synthesized the zirconia coating by plasma spray and one modelled the thermal fatigue (chap. 6).<p>In chap. 7, architectures from chap. 2 are introduced in a multi-treatment selection routine, which is applied in two cases:<p>- Foundry moulds for molten aluminium, withstanding both thermal fatigue and corrosion. The devised performance index is extrapolated beyond the tests of chap. 5 and 6 to treatments for this industrial application, thereby quantifying their respective merits.<p>- A foundry device exposed to molten metal and sliding wear.<p><p> / Doctorat en Sciences de l'ingénieur / info:eu-repo/semantics/nonPublished