Análisis de la influencia de los diferentes parámetros de diseño en la aparición de fatiga superficial en contactos mecánicos

La fatiga superficial es uno de los principales problemas en las transmisiones mecánicas y es uno de los focos de atención de las investigaciones de los últimos anos en Tribología. La disminución de viscosidad de los lubricantes para la mejora de la eficiencia, el aumento de las potencias a transmitir, el aumento de la vida de los componentes o la mejora de su fiabilidad han supuesto que los fenómenos de fatiga superficial hayan cobrado especial relevancia, especialmente los fenómenos de pitting y micropitting en cajas multiplicadoras/reductoras de grandes potencias de aplicación, por ejemplo, en el sector eólico. Como todo fenómeno de fatiga, el pitting y micropitting son debidos a la aplicación de cargas ciclicas. Su aparición depende de las presiones y tensiones cortantes en el contacto entre dos superficies que al encontrarse en rodadura y deslizamiento varian con el tiempo. La principal consecuencia de la fatiga superficial es la aparición de hoyuelos de diferente magnitud segun la escala del fenómeno (pitting o micropitting) en la superficie del material. La aparición de estos hoyuelos provoca la perdida de material, induce vibraciones y sobrecargas en el elemento que finalmente acaba fallando. Debido a la influencia de la presión y tensión cortante en el contacto, la aparición de fatiga depende fuertemente del lubricante que se encuentre entre las dos superficies y de las condiciones de funcionamiento en las cuales este trabajando. Cuando el contacto trabaja en condiciones de lubricacion mixta-elastohidrodinamica tiende a aparecer micropitting debido a las altas tensiones localizadas en las proximidades de las asperezas, mientras que si el régimen es de lubricación completa el tipo de fatiga superficial suele ser pitting debido a las tensiones mas suavizadas y menos concentradas. En esta Tesis Doctoral se han analizado todos estos factores de influencia que controlan el pitting y el micropitting prestando especial atención al efecto del lubricante. Para ello, se ha dado un enfoque conjunto a ambos fenómenos resolviendo las ecuaciones involucradas en el contacto elastohidrodinamico no-Newtoniano (la ecuación de Reynolds, la deformación elástica de los sólidos y la reologia del lubricante) para conocer la presión y la tensión cortante en el contacto. Conocidas estas, se resuelve el campo de tensiones en el interior del material y, finalmente, se aplican criterios de fatiga multiaxial (Crossland, Dang Van y Liu-Mahadevan) para conocer si el material falla o no falla. Con la metodología desarrollada se ha analizado el efecto sobre las tensiones y la aparición de la fatiga superficial del coeficiente viscosidad-presion, de la compresibilidad, del espesor especifico de película y de la fricción así como de la influencia de las propiedades a fatiga del material y de las condiciones de funcionamiento (radios de contacto, velocidad, deslizamiento, carga y temperatura). Para la validación de los resultados se han utilizado resultados teóricos y experimentales de otros autores junto con normas internacionales de amplia utilización en el mundo industrial, entre otras, para el diseño y calculo de engranajes. A parte del trabajo realizado por simulación y cálculo de los diferentes modelos desarrollados, se ha realizado un importante trabajo experimental que ha servido no solo para validar la herramienta desarrollada sino que además ha permitido incorporar al estudio factores no considerados en los modelos, como los aditivos del lubricante. Se han realizado ensayos de medida del coeficiente de fricción en una maquina de ensayo puntual con la que se ha validado el cálculo del coeficiente de fricción y se ha desarrollado un proceso de mejora del coeficiente de fricción mediante texturizado superficial en contactos puntuales elastohidrodinamicos mediante fotolitografia y ataque quimico. Junto con los ensayos de medida de fricción en contacto puntual se han realizado ensayos de fricción y fatiga superficial en contacto lineal mediante una maquina de discos que ha permitido evaluar la influencia de diferentes aditivos (modificadores de fricción, antidesgaste y extrema-presion) en la aparición de fatiga superficial (pitting y micropitting) y la fricción en el contacto. Abstract Surface fatigue is one of the most important problems of mechanical transmissions and therefore has been one of the main research topics on Tribology during the last years. On the one hand, industrial demand on fuel economy has led to reduce lubricant viscosity in order to improve efficiency. On the other hand, the requirements of power and life of machine elements are continuously increasing, together with the improvements in reliability. As a consequence, surface fatigue phenomena have become critical in machinery, in particular pitting and micropitting in high power gearboxes of every kind of machines, e.g., wind turbines or cranes. In line with every fatigue phenomena, pitting and micropitting are caused by cyclic loads. Their appearance depends on the evolution of pressures and shear stresses with time, throughout the contact between surfaces under rolling and sliding conditions. The main consequence of surface fatigue is the appearance of pits on the surface. The size of the pits is related to the scale of the fatigue: pitting or micropitting. These pits cause material loss, vibrations and overloads until the final failure is reached. Due to the great influence of the pressures and shear stresses in surface fatigue, the appearance of pits depends directly on the lubricant and the operating conditions. When the contact works under mixed regime (or under elastohydrodynamic but close to mixed regime) the main fatigue failure is micropitting because of the high pressures located near the asperities. In contrast, when the contact works under elastohydrodynamic fully flooded conditions the typical fatigue failure is pitting. In this Ph.D. Thesis, the main factors with influence on pitting and micropitting phenomena are analyzed, with special attention to the effect of the lubricant. For this purpose, pitting and micropitting are studied together by solving the equations involved in the non-Newtonian elastohydrodynamic contact. Thus, pressure and shear stress distributions are found by taking into account Reynolds equation, elastic deflection of the solids and lubricant rheology. Subsequently, the stress field inside the material can be calculated and different multiaxial fatigue criteria (Crossland, Dang Van and Liu- Mahadevan) can be applied to predict whether fatigue failure is reached. The influences of the main parameters on pressure and surface fatigue have been studied, taking into account the lubricant compressibility and its viscosity-pressure coefficient, the specific film thickness, the friction coefficient and the fatigue properties of the contacting materials, together with the operating conditions (contact radius, mean velocity, sliding velocity, load and temperature). Several theoretical and experimental studies of different authors have been used to validate all the results obtained, together with international standards used worldwide in gear design industry. Moreover, an experimental stage has been carried out in order to validate the calculation methods and introduce additional influences not included previously, e.g., lubricant additives. The experimentation includes different friction tests in point contacts performed with a tribological equipment in order to validate the results given by the calculations. Furthermore, the reduction and optimization of the friction coefficient is analyzed by means of textured surfaces, obtained combining photolithography and chemical etching techniques. Besides the friction tests with point contact, friction and surface fatigue tests have also been performed with line contact in a tribological test rig. This equipment is also used to study the influence of different types of additives (friction modifiers, anti-wear and extreme-pressure additives) on surface fatigue (pitting and micropitting).

Finite volume modelling of an icefield with subglacial lake

Momentum, mass and energy balance laws provide the tools for the study of the evolution of an icefield covering a subglacial lake. The ice is described as a non-Newtonian fluid with a power-law constitutive relationship with temperature- and stress-dependent viscosity (Glen?s law) [1]. The phase transition mechanisms at the air/ice and ice/water interfaces yield moving boundary formulations, and lake hydrodynamics requires equation reduction for treating the turbulence.

Superplasticity and superplastic forming ability of a Zr-Ti-Ni-Cu-Be bulk metallic glass in the supercooled liquid recgion

The superplastic deformation behavior and superplastic forming ability of the Zr41.25Ti13.75Ni10Cu12.5Be22.5 (at.%) bulk metallic glass (BMG) in the supercooled liquid region were investigated. The isothermal tensile results indicate (hat the BMG exhibits a Newtonian behavior at low strain rates but a non-Newtonian behavior at hiqh-strain rates in the initial deformation stage. The maximum elongation reaches as high as 1624% at 656 K. and nanocrystallization was found to occur during the deformation process. Based cm the analysis on tensile deformation. a gear-like micropart is successfully die-forged via a superplastic forgings process. demonstrating that the BMG has excellent workability in the supercooled liquid region. (C) 2004 Elsevier B.V. All rights reserved.

Hydrodynamics and mass transfer coefficient in activated sludge aerated stirred column reactor: Experimental analysis and modeling

The aerated stirred reactor (ASR) has been widely used in biochemical and wastewater treatment processes. The information describing how the activated sludge properties and operation conditions affect the hydrodynamics and mass transfer coefficient is missing in the literature. The aim of this study was to investigate the influence of flow regime, superficial gas velocity (U-G), power consumption unit (P/V-L), sludge loading, and apparent viscosity (pap) of activated sludge fluid on the mixing time (t(m)), gas hold-up (epsilon), and volumetric mass transfer coefficient (kLa) in an activated sludge aerated stirred column reactor (ASCR). The activated sludge fluid performed a non-Newtonian rheological behavior. The sludge loading significantly affected the fluid hydrodynamics and mass transfer. With an increase in the UG and P/V-L, the epsilon and k(L)a increased, and the t(m), decreased. The E, kLa, and tm,were influenced dramatically as the flow regime changed from homogeneous to heterogeneous patterns. The proposed mathematical models predicted the experimental results well under experimental conditions, indicating that the U-G, P/V-L, and mu(ap) had significant impact on the t(m) epsilon, and k(L)a. These models were able to give the tm, F, and kLa values with an error around +/- 8%, and always less than +/- 10%. (c) 2005 Wiley Periodicals, Inc.

Hydrodynamics and mass transfer coefficient in three-phase air-lift reactors containing activated sludge

This study was to investigate the impacts of operating conditions and liquid properties on the hydrodynamics and volumetric mass transfer coefficient in activated sludge air-lift reactors. Experiments were conducted in internal and external air-lift reactors. The activated sludge liquid displayed a non-Newtonian rheological behavior. With an increase in the superficial gas velocity, the liquid circulation velocity, gas holdup and mass transfer coefficient increased, and the gas residence time decreased. The liquid circulation velocity, gas holdup and the mass transfer coefficient decreased as the sludge loading increased. The flow regime in the activated sludge air-lift reactors had significant effect on the liquid circulation velocity and the gas holdup, but appeared to have little impact on the mass transfer coefficient. The experimental results in this study were best described by the empirical models, in which the reactor geometry, superficial gas velocity and/or power consumption unit, and solid and fluid properties were employed. (c) 2006 Elsevier B.V. All rights reserved.

Development and evaluation of a novel intranasal spray for the delivery of amantadine

The aim of this study was to develop and characterize an intranasal delivery system for amantadine hydrochloride (AMT). Optimal formulations consisted of a thermosensitive polymer Pluronic® 127 and either carboxymethyl cellulose or chitosan which demonstrated gel transition at nasal cavity temperatures (34 ± 1°C). Rheologically, the loss tangent (Tan δ) confirmed a 3-stage gelation phenomena at 34 ± 1°C and non-Newtonian behavior. Storage of optimized formulation carboxymethyl cellulose and optimal formulation chitosan at 4°C for 8 weeks resulted in repeatable release profiles at 34°C when sampled, with a Fickian mechanism earlier on but moving toward anomalous transport by week 8. Polymers (Pluronic® 127, carboxymethyl cellulose, and chitosan) demonstrated no significant cellular toxicity to human nasal epithelial cells up to 4 mg/mL and up to 1 mM for AMT (IC50: 4.5 ± 0.05 mM). Optimized formulation carboxymethyl cellulose and optimal formulation chitosan demonstrated slower release across an in vitro human nasal airway model (43%-44% vs 79 ± 4.58% for AMT). Using a human nasal cast model, deposition into the olfactory regions (potential nose-to-brain) was demonstrated on nozzle insertion (5 mm), whereas tilting of the head forward (15°) resulted in greater deposition in the bulk of the nasal cavity.

Alginates as therapeutic and drug delivery systems

Alginate is widely used as a viscosity enhancer in many different pharmaceutical formulations. The aim of this thesis is to quantitatively describe the functions of this polyelectrolyte in pharmaceutical systems. To do this the techniques used were Viscometry, Light Scattering, Continuous and Oscillatory Shear Rheometry, Numerical Analysis and Diffusion. Molecular characterization of the Alginate was carried out using Viscometry and Light Scattering to determine the molecular weight, the radius of gyration, the second virial coefficient and the Kuhn statistical segment length. The results showed good agreement with similar parameters obtained in previous studies. By blending Alginate with other polyelectrolytes, Xanthan Gum and 'Carbopol', in various proportions and with various methods of low and high shear preparation, a very wide range of dynamic rheological properties was found. Using oscillatory testing, the parameters often varied over several decades of magnitude. It was shown that the determination of the viscous and elastic components is particularly useful in describing the rheological 'profiles' of suspending agent blends and provides a step towards the non-empirical formulation of pharmaceutical disperse systems. Using numerical analysis of equations describing planar diffusion, it was shown that the analysis of drug release profiles alone does not provide unambiguous information about the mechanism of rate control. These principles were applied to the diffusion of Ibuprofen in Calcium Alginate gels. For diffusion in such non-Newtonian systems, emphasis was placed on the use of the elastic as well as the viscous component of viscoelasticity. It was found that the diffusion coefficients were relatively unaffected by increases in polymer concentration up to 5 per cent, yet the elasticities measured by oscillatory shear rheometry were increased. This was interpreted in the light of several theories of diffusion in gels.

Viscosity of aged bio-oils from fast pyrolysis of beech wood and miscanthus:shear rate and temperature dependence

The viscosity of four aged bio-oil samples was measured experimentally at various shear rates and temperatures using a rotational viscometer. The experimental bio-oils were derived from fast pyrolysis of beech wood at 450, 500, and 550 °C and Miscanthus at 500 °C (in this work, they were named as BW1, BW2, BW3, and MXG) in a bubbling fluidized bed reactor. The viscosity of all bio-oils was kept constant at various shear rates at the same temperature, which indicated that they were Newtonian fluids. The viscosity of bio-oils was strongly dependent upon the temperature, and with the increase of the temperature from 30 to 80 °C, the viscosity of BW1, BW2, BW3, and MXG decreased by 90.7, 93.3, 92.6, and 90.2%, respectively. The Arrhenius viscosity model, which has been commonly used to represent the temperature dependence of the viscosity of many fluids, did not fit the viscosity-temperature experimental data of all bio-oils very well, especially in the low- and high-temperature regions. For comparison, the Williams-Landel-Ferry (WLF) model was also used. The results showed that the WLF model gave a very good description of the viscosity-temperature relationship of each bio-oil with very small residuals and the BW3 bio-oil had the strongest viscosity-temperature dependence.

The nitrate to ammonia and ceramic (NAC) process for the denitration and immobilization of low-level radioactive liquid waste (LLW)

Hazardous radioactive liquid waste is the legacy of more than 50 years of plutonium production associated with the United States' nuclear weapons program. It is estimated that more than 245,000 tons of nitrate wastes are stored at facilities such as the single-shell tanks (SST) at the Hanford Site in the state of Washington, and the Melton Valley storage tanks at Oak Ridge National Laboratory (ORNL) in Tennessee. In order to develop an innovative, new technology for the destruction and immobilization of nitrate-based radioactive liquid waste, the United State Department of Energy (DOE) initiated the research project which resulted in the technology known as the Nitrate to Ammonia and Ceramic (NAC) process. However, inasmuch as the nitrate anion is highly mobile and difficult to immobilize, especially in relatively porous cement-based grout which has been used to date as a method for the immobilization of liquid waste, it presents a major obstacle to environmental clean-up initiatives. Thus, in an effort to contribute to the existing body of knowledge and enhance the efficacy of the NAC process, this research involved the experimental measurement of the rheological and heat transfer behaviors of the NAC product slurry and the determination of the optimal operating parameters for the continuous NAC chemical reaction process. Test results indicate that the NAC product slurry exhibits a typical non-Newtonian flow behavior. Correlation equations for the slurry's rheological properties and heat transfer rate in a pipe flow have been developed; these should prove valuable in the design of a full-scale NAC processing plant. The 20-percent slurry exhibited a typical dilatant (shear thickening) behavior and was in the turbulent flow regime due to its lower viscosity. The 40-percent slurry exhibited a typical pseudoplastic (shear thinning) behavior and remained in the laminar flow regime throughout its experimental range. The reactions were found to be more efficient in the lower temperature range investigated. With respect to leachability, the experimental final NAC ceramic waste form is comparable to the final product of vitrification, the technology chosen by DOE to treat these wastes. As the NAC process has the potential of reducing the volume of nitrate-based radioactive liquid waste by as much as 70 percent, it not only promises to enhance environmental remediation efforts but also effect substantial cost savings. ^

Shape and chemically anisotropic colloidal particles: A theoretical study of their structure, phase behavior, and slow dynamics

A detailed non-equilibrium state diagram of shape-anisotropic particle fluids is constructed. The effects of particle shape are explored using Naive Mode Coupling Theory (NMCT), and a single particle Non-linear Langevin Equation (NLE) theory. The dynamical behavior of non-ergodic fluids are discussed. We employ a rotationally frozen approach to NMCT in order to determine a transition to center of mass (translational) localization. Both ideal and kinetic glass transitions are found to be highly shape dependent, and uniformly increase with particle dimensionality. The glass transition volume fraction of quasi 1- and 2- dimensional particles fall monotonically with the number of sites (aspect ratio), while 3-dimensional particles display a non-monotonic dependence of glassy vitrification on the number of sites. Introducing interparticle attractions results in a far more complex state diagram. The ideal non-ergodic boundary shows a glass-fluid-gel re-entrance previously predicted for spherical particle fluids. The non-ergodic region of the state diagram presents qualitatively different dynamics in different regimes. They are qualified by the different behaviors of the NLE dynamic free energy. The caging dominated, repulsive glass regime is characterized by long localization lengths and barrier locations, dictated by repulsive hard core interactions, while the bonding dominated gel region has short localization lengths (commensurate with the attraction range), and barrier locations. There exists a small region of the state diagram which is qualified by both glassy and gel localization lengths in the dynamic free energy. A much larger (high volume fraction, and high attraction strength) region of phase space is characterized by short gel-like localization lengths, and long barrier locations. The region is called the attractive glass and represents a 2-step relaxation process whereby a particle first breaks attractive physical bonds, and then escapes its topological cage. The dynamic fragility of fluids are highly particle shape dependent. It increases with particle dimensionality and falls with aspect ratio for quasi 1- and 2- dimentional particles. An ultralocal limit analysis of the NLE theory predicts universalities in the behavior of relaxation times, and elastic moduli. The equlibrium phase diagram of chemically anisotropic Janus spheres and Janus rods are calculated employing a mean field Random Phase Approximation. The calculations for Janus rods are corroborated by the full liquid state Reference Interaction Site Model theory. The Janus particles consist of attractive and repulsive regions. Both rods and spheres display rich phase behavior. The phase diagrams of these systems display fluid, macrophase separated, attraction driven microphase separated, repulsion driven microphase separated and crystalline regimes. Macrophase separation is predicted in highly attractive low volume fraction systems. Attraction driven microphase separation is charaterized by long length scale divergences, where the ordering length scale determines the microphase ordered structures. The ordering length scale of repulsion driven microphase separation is determined by the repulsive range. At the high volume fractions, particles forgo the enthalpic considerations of attractions and repulsions to satisfy hard core constraints and maximize vibrational entropy. This results in site length scale ordering in rods, and the sphere length scale ordering in Janus spheres, i.e., crystallization. A change in the Janus balance of both rods and spheres results in quantitative changes in spinodal temperatures and the position of phase boundaries. However, a change in the block sequence of Janus rods causes qualitative changes in the type of microphase ordered state, and induces prominent features (such as the Lifshitz point) in the phase diagrams of these systems. A detailed study of the number of nearest neighbors in Janus rod systems reflect a deep connection between this local measure of structure, and the structure factor which represents the most global measure of order.

Formulation and stability of topical water in oil emulsion containing corn silk extract

Purpose: To formulate the water in oil (W/O) emulsion of corn silk (CS) extract and to evaluate its stability at various storage conditions. Methods: Ethanol CS extract was prepared using maceration (cold) technique. A 4 % CS emulsion was prepared using varying concentrations of liquid paraffin, ABIL EM90 and water. The formulations were kept at 40 oC for 28 days and to screen out the less stable formulations. The remaining formulations were further stressed at 50 oC to choose the most stable formulation. The optimized formulation was evaluated for physical characteristics including phase separation, rheology and mean droplet size. The physical stability of the formulation was evaluated by monitoring these parameters over a period of 12 weeks at 8, 25, 40 and 40 oC, and 75 % RH. Results: The chosen formulation showed good resistance to phase separation on centrifugation under all storage conditions. Rheological behavior followed non-Newtonian pseudoplastic pattern at various storage conditions. Mean droplet size of freshly prepared formulation was 2.98 ± 1.32 µm and did not show significant (p < 0.05) changes at normal storage conditions (8 and 25 oC). Conclusion: The findings indicate that the developed CS extract W/O emulsion is stable and therefore may be suitable for topical use on skin as an antioxidant preparation.

The textural properties and microstructure of konjac glucomannan - tungsten gels induced by DC electric fields

Konjac glucomannan - tungsten (KGM-T) gels were successfully prepared under DC electric fields, in the presence of sodium tungstate. The textural properties and microstructure of the gels were investigated by Texture Analyzer, Rheometer and SEM. Based on the response surface methodology (RSM) results, the optimum conditions for KGM-T gel springiness is 0.32% sodium tungstate concentration, 0.54% KGM concentration, 24.66V voltage and 12.37min treatment time. Under these conditions, the maximum springiness value of KGM-T gel is 1.21mm. Steady flow measurement indicated that KGM-T gel showed characteristic non-Newtonian pseudoplastic behaviour, with low flow behaviour indexes in the shear thinning region. SEM demonstrated the porosity of the freeze-dried samples. These findings may pave the way to use DC electric fields for the design and development of KGM gels and to apply KGM gels for practical applications.

Thermo-magnetic convection of paramagnetic fluids with non-instantaneous heating

The unsteady boundary-layer development for thermomagnetic convection of paramagnetic fluids inside a square cavity has been considered in this study. The cavity is placed in a microgravity condition (no gravitation acceleration) and under a uniform magnetic field which acts vertically. A ramp temperature boundary condition is applied on left vertical side wall of the cavity where the temperature initially increases with time up to some specific time and maintain constant thereafter. A distinct magnetic convection boundary layer is developed adjacent to the left vertical wall due to the effect of the magnetic body force generated on the paramagnetic fluid. An improved scaling analysis has been performed using triple-layer integral method and verified by numerical simulations. The Prandtl number has been chosen greater than unity varied over 5-100. Moreover, the effect of various values of the magnetic parameter and magnetic Rayleigh number on the fluid flow and heat transfer has been shown.

Multiphase models for simulating hot and slightly miscible DNAPL (dense non-aqueous phase fluids) in a saturated rock fracture under deformation

In the present study a two dimensional model is first developed to show the behaviour of dense non-aqueous phase liquids (DNAPL) within a rough fracture. To consider the rough fracture, the fracture is imposed with variable apertures along its plane. It is found that DNAPL follows preferential pathways. In next part of the study the above model is further extended for non-isothermal DNAPL flow and DNAPL-water interphase mass transfer phenomenon. These two models are then coupled with joint deformation due to normal stresses. The primary focus of these models is specifically to elucidate the influence of joint alteration due to external stress and fluid pressures on flow driven energy transport and interphase mass transfer. For this, it is assumed that the critical value for joint alteration is associated with external stress and average of water and DNAPL pressures in multiphase system and the temporal and spatial evolution of joint alteration are determined for its further influence on energy transport and miscible phase transfer. The developed model has been studied to show the influence of deformation on DNAPL flow. Further this preliminary study demonstrates the influence of joint deformation on heat transport and phase miscibility via multiphase flow velocities. It is seen that the temperature profile changes and shows higher diffusivity due to deformation and although the interphase miscibility value decreases but the lateral dispersion increases to a considerably higher extent.

Time-dependent flows of rotating and stratified fluids in geometries with non-uniform cross-sections

Unsteady rotating and stratified flows in geometries with non-uniform cross-sections are investigated under Oseen approximation using Laplace transform technique. The solutions are obtained in closed form and they reveal that the flow remains oscillatory even after infinitely large time. The existence of inertial waves propagating in both positive and negative directions of the flow is observed. When the Rossby or Froude number is close to a certain infinite set of critical values the blocking and back flow occur and the flow pattern becomes more and more complicated with increasing number of stagnant zones when each critical value is crossed. The analogy that is observed in the solutions for rotating and stratified flows is also discussed.