Experimental and numerical analysis of dry contact in the pin on disc test

The reduction of friction and wear in systems presenting metal-to-metal contacts, as in several mechanical components, represents a traditional challenge in tribology. In this context, this work presents a computational study based on the linear Archard's wear law and finite element modeling (FEM), in order to analyze unlubricated sliding wear observed in typical pin on disc tests. Such modeling was developed using finite element software Abaqus® with 3-D deformable geometries and elastic–plastic material behavior for the contact surfaces. Archard's wear model was implemented into a FORTRAN user subroutine (UMESHMOTION) in order to describe sliding wear. Modeling of debris and oxide formation mechanisms was taken into account by the use of a global wear coefficient obtained from experimental measurements. Such implementation considers an incremental computation for surface wear based on the nodal displacements by means of adaptive mesh tools that rearrange local nodal positions. In this way, the worn track was obtained and new surface profile is integrated for mass loss assessments. This work also presents experimental pin on disc tests with AISI 4140 pins on rotating AISI H13 discs with normal loads of 10, 35, 70 and 140 N, which represent, respectively, mild, transition and severe wear regimes, at sliding speed of 0.1 m/s. Numerical and experimental results were compared in terms of wear rate and friction coefficient. Furthermore, in the numerical simulation the stress field distribution and changes in the surface profile across the worn track of the disc were analyzed. The applied numerical formulation has shown to be more appropriate to predict mild wear regime than severe regime, especially due to the shorter running-in period observed in lower loads that characterizes this kind of regime.

Novel simulation methods for Coulomb and hydrodynamic interactions

This thesis presents new methods to simulate systems with hydrodynamic and electrostatic interactions. Part 1 is devoted to computer simulations of Brownian particles with hydrodynamic interactions. The main influence of the solvent on the dynamics of Brownian particles is that it mediates hydrodynamic interactions. In the method, this is simulated by numerical solution of the Navier--Stokes equation on a lattice. To this end, the Lattice--Boltzmann method is used, namely its D3Q19 version. This model is capable to simulate compressible flow. It gives us the advantage to treat dense systems, in particular away from thermal equilibrium. The Lattice--Boltzmann equation is coupled to the particles via a friction force. In addition to this force, acting on {it point} particles, we construct another coupling force, which comes from the pressure tensor. The coupling is purely local, i.~e. the algorithm scales linearly with the total number of particles. In order to be able to map the physical properties of the Lattice--Boltzmann fluid onto a Molecular Dynamics (MD) fluid, the case of an almost incompressible flow is considered. The Fluctuation--Dissipation theorem for the hybrid coupling is analyzed, and a geometric interpretation of the friction coefficient in terms of a Stokes radius is given. Part 2 is devoted to the simulation of charged particles. We present a novel method for obtaining Coulomb interactions as the potential of mean force between charges which are dynamically coupled to a local electromagnetic field. This algorithm scales linearly, too. We focus on the Molecular Dynamics version of the method and show that it is intimately related to the Car--Parrinello approach, while being equivalent to solving Maxwell's equations with freely adjustable speed of light. The Lagrangian formulation of the coupled particles--fields system is derived. The quasi--Hamiltonian dynamics of the system is studied in great detail. For implementation on the computer, the equations of motion are discretized with respect to both space and time. The discretization of the electromagnetic fields on a lattice, as well as the interpolation of the particle charges on the lattice is given. The algorithm is as local as possible: Only nearest neighbors sites of the lattice are interacting with a charged particle. Unphysical self--energies arise as a result of the lattice interpolation of charges, and are corrected by a subtraction scheme based on the exact lattice Green's function. The method allows easy parallelization using standard domain decomposition. Some benchmarking results of the algorithm are presented and discussed.

Model Predictive Control for Vehicle Stabilization at the Limits of Handling

Recent developments in vehicle steering systems offer new opportunities to measure the steering torque and reliably estimate the vehicle sideslip and the tire-road friction coefficient. This paper presents an approach to vehicle stabilization that leverages these estimates to define state boundaries that exclude unstable vehicle dynamics and utilizes a model predictive envelope controller to bound the vehicle motion within this stable region of the state space. This approach provides a large operating region accessible by the driver and smooth interventions at the stability boundaries. Experimental results obtained with a steer-by-wire vehicle and a proof of envelope invariance demonstrate the efficacy of the envelope controller in controlling the vehicle at the limits of handling.

InUse – Intelligente Unterlegscheibe zur Messung der Kräfte in Schraubverbindungen

Die lösbare Verbindung von mechanischen Komponenten innerhalb von Maschinen und Anlagen wird zumeist über Schraubverbindungen realisiert. Um eine ausreichende Verbindung zu erzielen werden derzeit die Klemmkräfte durch ein definiertes Anzugsmoment aufgebracht. Bei der Berechnung des Momentes entsprechend der benötigten Kraft finden Reibbeiwerte innerhalb der Schraubverbindung Berücksichtigung, welche nur bedingt ermittelt werden können. In kritischen Maschinenkomponenten wird daher eine Überdimensionierung der Schrauben zur Erhöhung der Sicherheit akzeptiert. Die direkte Kraftmessung mittels einer intelligenten Unterlegscheibe und eine transpondergestützte Datenübertragung ermöglicht es, die Kräfte genau einzustellen und somit die Sicherheit zu erhöhen.

RNA-Activated Protein Kinase, PKR

The double-stranded RNA (dsRNA) activated protein kinase, PKR, is one of the several enzymes induced by interferons and a key molecule mediating the antiviral effects of interferons. PKR contain an N-terminal, double-stranded RNA binding domain (dsRBD), which has two tandem copies of the motifs (dsRBM I and dsRBM II). Upon binding to viral dsRNA, PKR is activated via autophosphorylation. Activated PKR has several substrates; one of the examples is eukaryotic translation initiation factor 2 (eIF2a). The phosphorylation of eIF2a leads to the termination of cell growth by inhibiting protein synthesis in response to viral infection. The objective of this project was to characterize the dsRBM I and define the dsRNA binding using biophysical methods. First, the dsRBM I gene was cloned from a pET-28b to a pET-11a expression plasmid. N-terminal poly-histidine tags on pET-28b are for affinity purification; however, these tags can alter the structure and function of proteins, thus the gene of dsRBM I was transferred into the plasmid without tags (pET-11a) and expressed as a native protein. The dsRBM I was transformed into and expressed by Rosetta DE3plyS expression cells. Purification was done by FPLC using a Sepharose IEX ion exchange followed by Heparin affinity column; yielding pure protein was assayed by PAGE. Analytical Ultracentrifugation, Sedimentation Velocity, was used to characterize free solution association state and hydrodynamic properties of the protein. The slight decrease in S-value with concentration is due to the hydrodynamic non-ideality. No self association was observed. The obtained molecule weight was 10,079 Da. The calculated sedimentation constant at zero concentration at 20°C in water was 1.23 and its friction coefficient was 3.575 ´ 10-8. The frictional ratio of sphere and dsRBM I became 1.30. Therefore, dsRBM I must be non-globular and more asymmetric shape. Isolated dsRBM I exhibits the same tertiary fold as compared to context in the full domain but it exhibited weaker binding affinity than full domain to a 20 bp dsRNA. However, when the conditions allowed for its saturation, dsRBM I to 20 bp dsRNA has similar stoichiometry as full dsRBD.

Laboratory shearing experiments at low sliding velocities of IODP Hole 343-C0019E

The 2011 Tohoku-Oki earthquake demonstrated that the shallowest reaches of plate boundary subduction megathrusts can host substantial coseismic slip that generates large and destructive tsunamis, contrary to the common assumption that the frictional properties of unconsolidated clay-rich sediments at depths less than View the MathML source should inhibit rupture. We report on laboratory shearing experiments at low sliding velocities (View the MathML source) using borehole samples recovered during IODP Expedition 343 (JFAST), spanning the plate-boundary décollement within the region of large coseismic slip during the Tohoku earthquake. We show that at sub-seismic slip rates the fault is weak (sliding friction µs=0.2-0.26), in contrast to the much stronger wall rocks (µs>~0.5). The fault is weak due to elevated smectite clay content and is frictionally similar to a pelagic clay layer of similar composition. The higher cohesion of intact wall rock samples coupled with their higher amorphous silica content suggests that the wall rock is stronger due to diagenetic cementation and low clay content. Our measurements also show that the strongly developed in-situ fabric in the fault zone does not contribute to its frictional weakness, but does lead to a near-cohesionless fault zone, which may facilitate rupture propagation by reducing shear strength and surface energy at the tip of the rupture front. We suggest that the shallow rupture and large coseismic slip during the 2011 Tohoku earthquake was facilitated by a weak and cohesionless fault combined with strong wall rocks that drive localized deformation within a narrow zone.

Shear experiments from IODP Expedition 322 and 333 samples

The mechanical behavior of the plate boundary fault zone is of paramount importance in subduction zones, because it controls megathrust earthquake nucleation and propagation as well as the structural style of the forearc. In the Nankai area along the NanTroSEIZE (Kumano) drilling transect offshore SW Japan, a heterogeneous sedimentary sequence overlying the oceanic crust enters the subduction zone. In order to predict how variations in lithology, and thus mechanical properties, affect the formation and evolution of the plate boundary fault, we conducted laboratory tests measuring the shear strengths of sediments approaching the trench covering each major lithological sedimentary unit. We observe that shear strength increases nonlinearly with depth, such that the (apparent) coefficient of friction decreases. In combination with a critical taper analysis, the results imply that the plate boundary position is located on the main frontal thrust. Further landward, the plate boundary is expected to step down into progressively lower stratigraphic units, assisted by moderately elevated pore pressures. As seismogenic depths are approached, the décollement may further step down to lower volcaniclastic or pelagic strata but this requires specific overpressure conditions. High-taper angle and elevated strengths in the toe region may be local features restricted to the Kumano transect.

Grain-size distribution and frictional behaviour of sediment cores from the Nice Slope

The upper shelf of the landslide-prone Ligurian Margin (Western Mediterranean Sea) off Nice well-known for the 1979 Airport Landslide is a natural laboratory to study preconditioning factors and trigger mechanisms for submarine landslides. For this study low-stress ring shear experiments have been carried out on a variety of sediments from >50 gravity cores to characterise the velocity-dependent frictional behaviour. Mean values of the peak coefficient of friction vary from 0.46 for clay-dominated samples (53 % clay, 46 % silt, 1 %) sand up to 0.76 for coarse-grained sediments (26 % clay, 57 % silt, 17 % sand). The majority of the sediments tested show velocity strengthening regardless of the grain size distribution. For clayey sediments the peak and residual cohesive strength increases with increasing normal stress, with values from 1.3 to 10.6 kPa and up to 25 % of all strength supported by cohesive forces in the shallowmost samples. A pseudo-static slope stability analysis reveals that the different lithologies (even clay-rich material with clay content >=50 %) tested are stable up to slope angles <26° under quasi-drained conditions.

Determinación del coeficiente de rozamiento grano-pared en silos de pared corrugada mediante el método de los elementos discretos

El comportamiento de los materiales granulares almacenados en silos se ve afectado por varios parámetros, tanto aquellos característicos del material como de la geometría del silo. La determinación del coeficiente de rozamiento pared-partícula es uno de los parámetros de mayor importancia, siendo habituales en su determinación el uso de ensayos de corte directo. En el presente trabajo se estudia dicho coeficiente para el supuesto de una pared corrugada, el cual, teóricamente, debe representar a un valor efectivo que depende tanto del coeficiente de rozamiento grano-pared (para el caso de una pared lisa) y el ángulo de rozamiento interno del material. La determinación del rozamiento efectivo se ha realizado a través de la simulación por elementos discretos de un ensayo de corte sobre una pared corrugada. Los valores obtenidos han sido comparados con las prescripciones expuestas en la normativa vigente. La potencialidad del método de los elementos discretos permite el estudio de diversas configuraciones geométricas de la pared corrugada de los silos sin necesidad de realizar ensayos de laboratorio. Esto permitirá, en trabajos sucesivos, investigar la influencia de muy diversos factores en el valor del rozamiento efectivo grano-pared en este tipo de paredes. The mechanical behaviour of granular materials stored in silos is affected by numerous parameters, some of them being related to the characteristic of the stored materials and others to the geometry of the silo. The determination of the particle-wall friction coefficient (or wall friction) is of great importance and direct shear tests are usually conducted in order to obtain its value. In this work this variable is analysed for the case of a corrugated wall. This value is expected to be an effective value between the particle-wall friction coefficient (obtained for a flat wall) and the internal friction coefficient of the material under study. The effective wall friction determination has been carried out by using a discrete element model to simulate a direct shear test on a corrugated wall. The values obtained have been compared with prescriptions given in the current standards. The potential of the discrete element method allows different geometries of the silo corrugated wall to be considered without the necessity of developing laboratory tests. In future works it will allow the influence of numerous parameters on the effective wall friction in corrugated walls to be studied.

Modelización de contactos termoelastohidrodinámicos

La mejora en la eficiencia energética y la reducción de la tasa de fallos en los contactos lubricados son aspectos que resultan de gran interés en numerosos sectores de la industria, y plantean en estos momentos nuevas dificultades operativas y retos para un futuro próximo. Los avances tecnológicos han incrementado las exigencias técnicas que se requieren a los aceites para cumplir su función al extender sus variables operativas a un mayor espectro de aplicaciones, tanto de condiciones de funcionamiento como a la gran variedad de nuevos materiales constitutivos de los engranajes en los que se tiene que utilizar. Por ello, actualmente se está incentivado el desarrollo de nuevos procedimientos que permitan comprender el comportamiento de este tipo de contactos lubricados, con el fin de lograr mejoras técnicas en su diseño y la correcta selección del aceite. En esta Tesis Doctoral se presenta una metodología de cálculo numérico que permite simular el comportamiento de contactos elastohidrodinámicos (EHD) puntuales, como puede ser el caso de un rodamiento. La resolución de este problema presenta diversas complejidades matemáticas y exige el desarrollo de un elaborado procedimiento de cálculo basado en técnicas multinivel. Para hacer del procedimiento una herramienta válida en un gran número de condiciones de funcionamiento y tipos de lubricantes, se ha tenido en cuenta en el cálculo la posible aparición de comportamientos no-Newtonianos del lubricante y fenómenos de generación y disipación de calor, provocados por el movimiento relativo del fluido y las superficies en contacto. Para la validación del procedimiento, se han contrastado los resultados numéricos obtenidos con nuestro método, con los resultados numéricos y experimentales publicados por otros autores y con valores experimentales propios medidos en un equipo de ensayo de contacto puntual tipo MTM. El desarrollo de este programa ha dotado a la División de Ingeniería de Máquinas de una herramienta que ha permitido, y sobre todo va permitir, evaluar la importancia de cada uno de los parámetros reológicos en los diferentes problemas que va a tener que abordar, evaluación que hasta el momento se realizaba con métodos aproximados que describen la fenomenología con mucha menos precisión. A la hora de emplear nuestro procedimiento numérico para simular situaciones reales, nos hemos encontrado con el obstáculo de que es muy complicado encontrar, en la bibliografía y bases de datos, los parámetros que caracterizan el comportamiento reológico del lubricante en las condiciones de presión, temperatura y grado de cizallamiento habituales en las que se trabaja en este tipo de contactos, y las pocas medidas que existen para estas condiciones de funcionamiento son poco fiables. Por ello como complemento al objetivo principal de esta Tesis hemos desarrollado una metodología para caracterizar los lubricantes en estas condiciones extremas. Dicha metodología está basada en la buena descripción que hace nuestro programa del coeficiente de fricción, lo que nos ha permitido obtener los parámetros reológicos del III lubricante a partir de las medidas experimentales del coeficiente de fricción generado en un equipo MTM lubricado con el lubricante que se desea caracterizar. Madrid, Octubre de 2012 IV Improving energy efficiency and reducing the failure rate in lubricated contacts are issues that are of great interest in many sectors of industry, and right now posed operational difficulties and new challenges for the near future. Technological advances have increased the technical demands required to oils to fulfil its role by extending its operational variables to a wider range of applications, both operating conditions and to the wide variety of new materials which constitute the gear in which must be used. For this reason, has being encouraged currently to develop new procedures to understand the behaviour of this type of lubricated contacts, in order to achieve improvements in design techniques and the correct oil selection. In this Thesis we present a numerical methodology to simulate the puntual elastohydrodynamic contact behaviour (EHD), such as a roller bearing. The resolution of this problem presents various mathematical complexities and requires the development of an elaborate calculation procedure based on multilevel techniques. To make the procedure a valid tool in a wide range of operating conditions and types of lubricants, has been taken into account in calculating the possible occurrence of non-Newtonian behaviour of the lubricant and phenomena of generation and dissipation of heat, caused by the fluid relative motion and contacting surfaces. For the validation of the method, we have compared the numerical results obtained with our method with numerical and experimental results published by other authors also with own experimental values measured on point-contact test equipment MTM. The development of this program has provided the Machines Engineering Division of a tool that has allowed, and especially will allow to evaluate the importance of each of the rheological parameters on the various problems that will have to be addressed, evaluation performed hitherto described methods that phenomenology approximated with much less accuracy. When using our numerical procedure to simulate real situations we have encountered the obstacle that is very difficult to find, in the literature and database, parameters characterizing the rheological behaviour of the lubricant in the usual conditions of pressure, temperature and shear rate in which you work in this type of contact, and the few measures that exist for these operating conditions are unreliable. Thus in addition to the main objective of this thesis, we have developed a methodology to characterize the lubricants in these extreme conditions. This methodology is based on the good description, which makes our program, of the coefficient of friction, that allowed us to obtain the lubricant rheological parameters from experimental measurements of the friction coefficient generated on lubricated MTM equipment with the lubricant to be characterized.

Influence of the rheological behaviour of the lubricant on the appearance of pitting in elastohydrodynamic eegime

This paper analyses the influence of lubricant behaviour on the appearance of pitting. It attempts to study the effect of viscosity?pressure relation, compressibility, film thickness?roughness relation and friction coefficient on pitting failure of the contacting elements.To explain these effects, we first deal with the influence of the oil on the lubrication of the contact using elastohydrodynamic theory and secondly two multiaxial fatigue criteria are used, Crossland criterion and Dang Van criterion, to evaluate the influence of the rheology on the appearance of pitting. Finally, different applications are presented together with a discussion on the results obtained.