Due to the rapid technological developments in the car industry and the high quality demands of customers, manufacturers and researchers focus on the reduction of surface roughness making use of various surface topography measurement systems. This master thesis focuses on development of a waviness measurement system (WMS) at Volvo Cars where light from different heights and angles illuminates the surface of an extended object in order to acquire images with different intensities due to shadowing effect and reflection. With this, surface irregularities and imperfections can be detected both in polished and unpolished surfaces for improving the car panels in the manufacturing process.  The initial WMS idea was to illuminate the surface at different heights from the four corners of a dark room using 20 flash lights and a camera positioned exactly on the top of the surface in the middle of the room. The first light goes on and the image is acquired. This procedure continues for all flash lights in 19s.The acquired images were evaluated by Matlab application. With the new WMS system flash lights are replaced by 32 RGB COB LED lights using the DMX512 protocol to communicate with them. The system runs in 9s which is half the time of the old WMS system. New LabView and Matlab codes were adjusted to the new parameters and devices. In the end, measurements were taken with different surfaces, exposure times and color lights. Details of the new devices and software are analyzed in this thesis.

Profile waviness is one of the main causes for scrapped parts in precision bore grinding. Although efforts have been made to reduce its occurrence, the problem has not been eliminated completely. In production, the identification of a few scrapped parts in a lot of several thousands often requires expensive manual processes. Grinding machines used to produce these parts are usually equipped with measurement gage heads having tactile probes. Until now, these in-process gages have been used to measure only the average diameter of the part. This research focused on the use of these tactile probes to measure bore waviness in precision-ground parts. The first objective was to develop a post-process machine that performs automated measurement of the bore profile and is capable of detecting waviness. The machine was built using the same measurement system and the same roll-shoe centerless fixture as the grinding machines used for the production of the parts. The machine was designed and set up such that disturbances of the measurement are minimized. It was shown that the machine reaches accuracies close to those obtained by manually operated roundness machines. The cycle time is approximately 4 seconds per part compared to several minutes for manually operated roundness machines. As a second objective, the possibility of measuring waviness directly in the grinding machine was evaluated. Feasible design modifications to reduce the effect of disturbances are very limited in grinding machines, since interference with the grinding process must be avoided. Therefore, analytical methods were developed to reduce these effects and partly restore the original profile. The main disturbances that were addressed are errors due to irregular sampling of the profile, to the frequency response behavior of the gage heads, and to motion of the workpiece center relative to the gage heads. The post-process machine was used as a development and test platform for the analytical methods. To further verify these methods, tests were also conducted in an industrial grinding machine.

The diploma thesis deals with the issue of bearings noisiness. The bearings noisiness appears as a negative phenomenon in all the mechanical devices that generate any kind of movement. Analysis of this phenomenon enables to analyse the technical condition of the bearing and predict its defects as well. The theoretical part of the thesis is devoted to the vibration diagnostics and noisiness diagnostics, which are deeply linked. The practical part of the thesis deals with the real problem of the bearing’s noisiness in the engineering company. The main asset of this thesis is a design and successful implementation of the measures, which reduce noisiness of the selected type of the bearing.

<p>Paper that is subjected to moisture undergoes dimensional changes. It expands during moistening and shrinks during drying. When the paper is under tension between rollers, the effects are complex since shrinkage and expansion are restricted in the width direction. Waves can then appear on the paper web. This can be a problem in heatset web offset printing. The problem is known as waviness or fluting. The printed papers exhibit a wavy shape, which is visually disturbing due to light reflections which create glossy streaks. The aim of the work described in this thesis was to develop a method suitable for studying the moisture- and tension-induced waviness. Experiments were carried out on a laboratory scale to study how such waves develop during moistening and drying. The experimental setup was based on a modified tensile tester. A CCD camera and image analysis based on the STFI-OptiTopo technique was used to characterise the waviness. Moistening and drying were achieved by changing the surrounding air humidity. The method was used to study the effect of moisture uptake by the paper, and to evaluate the effect of tension on the waviness. It was found that increasing moisture resulted in a higher waviness amplitude, but that the web tension controlled the wavelength of the waviness. A high tension gave rise to a shorter wavelength. The measured wavelength was compared with a previously suggested model and the predicted wavelength was about twice as high as the measured wavelength.</p> / <p>When paper becomes damp it can develop waves which can be a problem with heatset web offset printing. Paper with waves may have glossy streaks after printing. Laboratory experiments studied the effect of moisture uptake by the paper. Readings were taken at a range of air humidities. The effect of tension on the waviness was also measured. The waviness was characterised using a charge coupled device (CCD) camera and the STFI-Packforsk OptiTopo technique to analyse the images. When the humidity was increased the amplitude of the waves increased. A high tension resulted in shorter wavelengths. Results from a previous model were used as a comparison.</p>

Paper that is subjected to moisture undergoes dimensional changes. It expands during moistening and shrinks during drying. When the paper is under tension between rollers, the effects are complex since shrinkage and expansion are restricted in the width direction. Waves can then appear on the paper web. This can be a problem in heatset web offset printing. The problem is known as waviness or fluting. The printed papers exhibit a wavy shape, which is visually disturbing due to light reflections which create glossy streaks. The aim of the work described in this thesis was to develop a method suitable for studying the moisture- and tension-induced waviness. Experiments were carried out on a laboratory scale to study how such waves develop during moistening and drying. The experimental setup was based on a modified tensile tester. A CCD camera and image analysis based on the STFI-OptiTopo technique was used to characterise the waviness. Moistening and drying were achieved by changing the surrounding air humidity. The method was used to study the effect of moisture uptake by the paper, and to evaluate the effect of tension on the waviness. It was found that increasing moisture resulted in a higher waviness amplitude, but that the web tension controlled the wavelength of the waviness. A high tension gave rise to a shorter wavelength. The measured wavelength was compared with a previously suggested model and the predicted wavelength was about twice as high as the measured wavelength. / When paper becomes damp it can develop waves which can be a problem with heatset web offset printing. Paper with waves may have glossy streaks after printing. Laboratory experiments studied the effect of moisture uptake by the paper. Readings were taken at a range of air humidities. The effect of tension on the waviness was also measured. The waviness was characterised using a charge coupled device (CCD) camera and the STFI-Packforsk OptiTopo technique to analyse the images. When the humidity was increased the amplitude of the waves increased. A high tension resulted in shorter wavelengths. Results from a previous model were used as a comparison.

no / Hot spots are high thermal gradients on the disc surface during brake events which can cause the undesired phenomena of thermal judder and drone. The origin of hot spotting has been presented by various theories such as Thermo elastic instability (TEI) and progressive waviness distortions (PWD). However, majority of the numerical models based on these theories mainly concentrated on solid disc rather than ventilated disc which is the most commonly used nowadays. According to the experimental work done by the authors, disc geometry factors such as vents and pins also have correlations with hot spot distribution; these phenomena are difficult to be predicted analytically. Thus a convenient 2D asymmetric finite element simulation has been performed in order to obtain the correlations observed in experiments. Further parameter studies investigated factors such as uneven initial temperature, vents, pins and pad length. The results have been correlated with the experimental data and demonstrate the contribution of geometric factors in the generation of hot spots and hot judder.

<p>Demand for lightweight, cost-effective, structural components is driving the development of continuous fiber thermoplastic tow preforms, also known as 3D-tow or tow reinforcements, to add material performance to hybrid-molded structures as an alternative to metal components. Tow reinforcements offer the performance advantages of continuous fiber composites within molded structures. The tow reinforcements also feature more tailorability of performance compared to fabric or organo-sheet reinforced hybrid-molded structures, improving their potential for design optimization. However, the added complexity of 3D-tow reinforcement structure requires the development of unique design principles and computer aided engineering (CAE) methodologies to effectively design components which meet manufacturing and performance requirements. </p> <p><br></p> <p>A systematic evaluation of design considerations was performed comparing parts manufactured with various design features, configurations, and materials. Choosing the structural profile and balance of material properties was shown to be an important component of achieving the desired performance especially where the tow reinforcement must work in conjunction with the overmolding material to provide structural performance. </p> <p><br></p> <p>By experimentally testing representative structures with features found on automobile components and molded sports equipment, performance was evaluated for a range of material combinations and reinforcement content. Tow reinforcements were made from continuous glass or carbon fiber reinforced PA6 prepreg tape and injection overmolded with unfilled or glass fiber filled PA6 adding a shear web and rib structures. Tow reinforcement significantly reduced warpage, and in tensile loading, demonstrated potential for 340\% strength increase over parts without tow. However, three-point bend performance was dominated by the overmolding material. High strain to break overmolding materials are recommended to avoid premature overmolding material cracking. </p> <p><br></p> <p>Tensile performance of tow reinforced structures is not accurately captured by conventional modeling processes. When wrapped around load introduction points, the fibers of a thick tow traverse a shorter distance at the inner radius than the outer radius leading to waviness on the inner region of each wrap. The Hsaio and Daniel model was used to predict local elastic properties of the wavy fiber composite and spatially varying material properties were applied to 3D finite element models of a suspension link. Neglecting fiber waviness overpredicted experimental tensile stiffness and strength by 36\% and 33\% respectively while modeling waviness overpredicted stiffness and strength by only 9\% and 14\% respectively. Tow wrap configuration, waviness propagation, and material parameters have significant effect on tensile performance while the tow has little effect on compressive performance.</p> <p><br></p> <p>In addition to fiber waviness, tow bundles also spread to reconcile path length differences. A method for accounting for tow spread orientations was developed and combined with fiber waviness modeling techniques. The effects of simulating the resulting fiber orientations and effective elastic properties was used to model representative beams in tension and bending load cases and compared to previous experimental results. Accounting for fiber waviness in tension demonstrated greatly improved part stiffness predictions. Spread tow bundles improved predicted strength and stiffness over simulations where tow was constrained to a uniform cross section. Increased tow reinforcement increased bending stiffness, but failure behavior was significantly influenced by the overmolding material.  </p> <p><br></p> <p>The studies in this work identified key performance attributes of 3D-tow reinforced hybrid composite structures. Design principles and modeling techniques were developed in this work, providing improved performance predictions which brings the technology closer to widespread adoption. </p>

L'ondulation pli est un défaut majeur qui peut apparaître dans certains matériaux composites tels que le CFRP. Des mesures de vitesse et atténuation ultrasonore permettent la détection, mais pas l'identification, de l'ondulation pli. Dans la présente étude, il est démontré que pour identifier cette ondulation pli, il est important de prendre en compte la déviation du faisceau ultrasonore. Deux méthodes différentes, A²Scan et C²Scan, permettent de détecter et mesurer cette déviation. D'une part, de l'écart produit un comportement asymétrique dans les réponses obtenues à des angles d'incidence oblique. Ce phénomène se manifeste à travers l'étude des domaines d'angles d'incidence, qui peuvent normalement être superposés. D'autre part, la technique de C²Scan permet la mesure de la déviation du champ acoustique transmis. Dans les deux cas, l'étude de la déviation induite révèle sa sensibilité à la présence d'ondulation plis. Ces méthodes ont été validées expérimentalement et leur utilisation potentielle, en fonction de l'épaisseur de la pièce, ainsi que sont industrialisation par ultrasons laser sont discutées. / Ply waviness is a major defect, which can appear in certain composite materials such as CFRP. Attenuation and ultrasound velocity measurements allow the detection, but not the identification, of ply waviness. In the present study it is shown that in order to identify this ply waviness, it is important to take the deviation of the ultrasonic beam into account. Two different methods,A²Scan et C²Scan , allowing such deviations to be detected are proposed. On the one hand, the deviation produces an asymmetrical behaviour in the responses obtained at oblique incidence angles. This phenomenon is revealed through the study of incidence angle ranges, which can normally be superimposed. On the other hand, the double scanning technique allows the deviation of the energy maxima of the transmitted acoustic field to be determined. In both cases, the study of induced deviation reveals that it is sensitive to the presence of ply waviness. These methods have been experimentally validated and their potential use, depending on the thickness of the workpiece and industrialization by laser ultrasonic means are discussed.

Das Trag- und Verbundverhalten textiler Bewehrungen wurde in den vergangen Jahren umfassend experimentell untersucht. Die dabei gewonnenen Erkenntnisse stützen sich jedoch fast ausschließlich auf einaxiale Beanspruchungszustände. Grundsätzlich können aus dem Vergleich von Versuchen an Rovings und an textilen Bewehrungsstrukturen Rückschlüsse auf den Einfluss der Quer- und Stützfäden und der verschiedenen Bindungstechniken auf das einaxiale Tragverhalten von Textilbeton getroffen werden. Offen bleibt jedoch, inwieweit sich die gefundenen Gesetzmäßigkeiten auf mehraxiale Beanspruchungssituationen übertragen lassen. Dadurch werden Fragen bezüglich des Tragverhaltens textiler Bewehrungen unter mehraxialen Zugbeanspruchungen aufgeworfen, welche die Motivation für die vorliegende Arbeit liefern. Die hierzu durchgeführten experimentellen Untersuchungen umfassen 84 Einzelversuche und wurden in einem speziell für zweiaxiale Zugbeanspruchungen entwickelten Versuchsaufbau durchgeführt. Als textile Bewehrungen kamen zwei verschiedene Gelegearten aus AR-Glas und Carbon zum Einsatz. Die Ergebnisse konnten die bisher ausschließlich an einaxialen Dehnkörpern gewonnenen Erkenntnisse über das Tragverhalten textiler Bewehrungen grundsätzlich bestätigen. Für den Übergang von Zustand I zum Zustand II konnte eine Abhängigkeit der Erstrissspannung vom Spannungsverhältnis nachgewiesen werden. Die Merkmale der Zustände IIa und IIb zeigen hingegen keine signifikante Abhängigkeit vom Verhältnis aus Längs- und Querzugspannung. Darüber hinaus haben offenbar durch Querzug induzierte bewehrungsparallele Risse keine maßgeblichen Auswirkungen auf das Verbundverhalten der Rovings in Längsrichtung. Eine wesentliche Erkenntnis aus den biaxialen Zugversuchen mit Carbon betrifft den Einfluss der Welligkeit. Es wurde deutlich, dass der Abbau der Welligkeit in beschichteten textilen Bewehrungen hochgradig lastabhängig ist. In zahlreichen Versuchen mit Carbon kam es innerhalb des Zustands IIb zu Delamination, einem bisher in diesem Umfang nicht beobachteten Effekt. Die Erkenntnisse hinsichtlich des Abbaus der Welligkeit wurden im Anschluss auf das Tragverhalten von AR-Glas übertragen und führten zu einer Neubewertung des bei AR-Glas beobachteten Steifigkeitsdefizits im Zustand IIb. Weiterhin wurde der Einfluss der Orientierung der Bewehrung unter einaxialer Beanspruchung an scheibenartigen Probekörpern untersucht. Es zeigte sich, dass die untersuchten Bewehrungen aus AR-Glas hinsichtlich der Tragfähigkeit bei schiefwinkliger Beanspruchung deutlich unempfindlicher reagieren als Bewehrungen aus Carbon. Für die Reduktion der effektiven Faserbruchspannungen wurde ein mathematisches Modell vorgestellt, welches eine getrennte Beschreibung der geometrischen Einflüsse sowie alle sonstigen, die Faserbruchspannung reduzierenden Effekte erlaubt. / The load bearing and bond behaviour of textile reinforcements has been comprehensively studied experimental in recent years. The findings are based almost exclusively on uniaxial loading. Generally, from the comparison of tests on rovings and fabrics conclusions can be drawn about the influence of transverse and supporting threads and different binding patterns on the uniaxial load-bearing behaviour. However, it remains open, to what extend the found principles are applicable to multi-axial loading situations. This raises questions about the load bearing behaviour under multi-axial tension loading, which provide motivation for this work. For the experimental studies on 84 specimens a specially developed test setup for biaxial tensile loading was used. Two different types of textile reinforcements made from AR-glass and carbon fibres were examined. The results generally approve the findings on the structural behaviour of textile reinforcements exclusively derived from uniaxial tests. A relationship between first cracking stress level and biaxial stress ratio has been found. The characteristics of the cracking phases and during stabilized cracking, however, show no significant dependencies on the ratio of longitudinal and transverse tensile stresses. Furthermore, parallel cracks induced by transverse tensile stresses have no significant impact on the bond behaviour of longitudinal rovings. An essential result from biaxial tensile tests with carbon is the strong influence of waviness. It became clear that the reduction of waviness in coated textile reinforcement is highly load-dependent. In numerous experiments with carbon reinforcement delamination occurred during stabilized cracking – an effect, that has been observed in this large scale for the first time. The findings regarding the reduction of the waviness were subsequently applied to AR-glass and led to a revaluation of the known stiffness deficit in the phase IIb. Furthermore, the influence of reinforcement orientation has been studied on discoidal specimens under uni-axial loading. It was found that the load bearing capacity of carbon reinforcement is much more sensible to load orientation than AR-glass. A mathematical model was presented, which allows the separate description of geometric factors and as well as all other effects that reduce the fibre tensile strength.

Les garnitures mécaniques sont utilisées dans de multiples applications pour réaliser l'étanchéité autour d'arbres en rotation. Ces composants peuvent fonctionner efficacement pendant plusieurs années en conditions stables, mais leur durée de vie est significativement réduite lorsque les conditions varient. L'objectif de ce travail de recherche est de développer et d’utiliser un banc d'essais et code de calcul pour étudier l'impact de pulsations de pression, d’inversions de pression et du chargement dynamique résultant sur les performances de garnitures mécaniques ayant des faces mésalignées et présentant des défauts de planéité.Le solveur fluide d'un modèle numérique de garnitures mécaniques a été étendu aux conditions transitoires. Un module résolvant la dynamique des forces et des moments a été ajouté afin de prédire le déplacement axial et les déplacements angulaires de la face montée de manière flexible. Afin de caractériser les performances de garnitures, un banc d'essais générant des pulses de pression a été instrumenté et des méthodes de mesure de perte de volume d'huile et d'entrée d'eau mises en place.Des garnitures mécaniques à faces parallèles puis mésalignées, fonctionnant sous pulsations et inversions de pression, ont été testées expérimentalement et simulées. Seules de très faibles augmentations d'eau dans l'huile ont été observées, sans augmentation au cours du temps, et sans fuite d'huile mesurable. Les faibles valeurs d'entrées d'eau sont dues à la faible épaisseur de film et à la courte durée des inversions de pression. Une garniture mécanique expérimentale à fort défaut de planéité a aussi été testée. Contrairement aux autres paramètres, le défaut de planéité semble augmenter significativement la fuite et promouvoir les entrées d'eau et pourrait ainsi être à l'origine de certaines défaillances. / Face seals are mechanical devices used to seal rotating shafts in numerous applications. While they can operate efficiently under steady conditions for years, they tend to fail prematurely when operating in severe, or rapidly varying conditions. The focus of this research work is the development and use of an experimental and a numerical method to investigate the impact of pressure pulses, pressure inversions and induced dynamic loading on the performance of mechanical face seals exhibiting face misalignment and waviness.The fluid solver of a state-of-the art face seal numerical model was extended to transient conditions and a module solving the dynamics for the axial and angular degrees of freedom of the flexibly-mounted stator added. A system-level experimental setup generating pressure pulses was instrumented and methods to characterise face seal performance in terms of oil volume loss and ingression of water outer-fluid selected and implemented.Face seals, with flat and misaligned faces, operating under pressure pulses and pressure inversions were experimentally tested and simulated. They show only slight increase of water in the oil, no increase over time, and no measurable oil leakage. The low water ingression is due to low film thickness combined with the short duration of pressure inversions. An exploratory face seal of high waviness was also experimentally tested. Contrary to the other parameters, the waviness appears to significantly increase the leakage and promote water ingression and could thus be at the origin of some seal failures.