| 1. |
- Ali, Nashit, et al.
(författare)
-
Friction, wear, and airborne particle emissions from rail-wheel contact with laser cladded overlays-A pin-disc tribometer simulation
- 2023
-
Ingår i: Wear. - Amsterdam : Elsevier BV. - 0043-1648 .- 1873-2577. ; 518
-
Tidskriftsartikel (refereegranskat)abstract
- The present study uses a pin-on-disc tribometer to evaluate friction, wear, and airborne particle emissions for a rail-wheel contact. Test pins from UIC60 900A rail carbon steels were in contact with three types of test discs surfaces: R7 wheel carbon steel, laser cladding overlayed martensitic stainless steel, and laser cladding overlayed Ni-based-8% MnS self-lubricating alloy. Test results show about halving of the coefficient of friction, 0.42 to 0.22, and one ten-power lower specific pin and disc wear of discs with self-lubricating overlay compared to standard railway carbon steel contacts. Using stainless-steel overlayed discs also resulted in one ten-power lower specific disc wear, but pin wear is unchanged. Particle emission for the tests with discs with self-lubricating overlay is constant at almost 200 particles/cm3 while running in the distance is needed for the other tests. Almost all generated airborne wear particles were in the sub-100 nm range. The use of laser-cladded (LC) overlay reduced the number of airborne wear particles in the sub-100 nm range by more than a factor of 10.
|
|
| 2. |
- Andersson, Martin, et al.
(författare)
-
Efficiency and temperature of spray lubricated superfinished spur gears
- 2022
-
Ingår i: Proceedings of the Institution of mechanical engineers. Part J, journal of engineering tribology. - : SAGE Publications. - 1350-6501 .- 2041-305X. ; 236:11, s. 2283-2291
-
Tidskriftsartikel (refereegranskat)abstract
- Gearboxes are one of the most power dense systems used today, and in certain instances their limiting factor is the ability to evacuate heat from the gear contact. This work analyses the efficiency (i.e. heat generation) and tooth temperature in the three lubricating conditions dip, into mesh spray and out of mesh spray for superfinished gears which are then compared to ground gears. A back-to-back gear test rig is employed to test maximum contact pressures at the pitch of 0.59 to 0.96 GPa and pitch velocities from 0.5 to 20 m/s at a controlled lubricant temperature of 90 °C. The results show superfinished gears have higher mesh efficiency and lower gear tooth and bulk temperatures, hence lower heat flux compared to ground gears in all lubricating conditions.
|
|
| 3. |
- Athanassiou, N., et al.
(författare)
-
Simulation of thermal and mechanical performance of laser cladded disc brake rotors
- 2022
-
Ingår i: Proceedings of the Institution of mechanical engineers. Part J, journal of engineering tribology. - London : SAGE Publications Ltd. - 1350-6501 .- 2041-305X. ; 236:1, s. 3-14
-
Tidskriftsartikel (refereegranskat)abstract
- Disc brakes wear during braking events and release airborne particulates. These particle emissions are currently one of the highest contributors to non-exhaust particle emissions and introduce health hazards as well as environmental contamination. To reduce this problem, wear and corrosion-resistant disc coatings have been implemented on grey cast iron brake disc rotors by using various deposition techniques such as thermal spraying and overlay welding. High thermal gradients during braking introduce risks of flaking off and cracking of thermally sprayed coatings with adhesive bonding to the substrate. Overlay welding by laser cladding offers metallurgical bonding of the coating to the substrate and other benefits that motivate laser cladding as a candidate for the coating of the grey cast iron brake discs. This study aims to investigate the effect of laser cladding on the thermal and thermo-structural performance of the coated grey cast iron brake discs. Therefore, thermal and thermo-stress analysis with COMSOL Multiphysics 5.6 software is performed on braking events of grey cast iron brake discs as non-coated – reference and laser cladding coated with stainless steel welding consumables. The Results demonstrated that surface temperatures were more localised, overall higher in the laser cladded coating with over three times the stresses attained of reference grey cast iron discs. The output of the simulations has been compared by tests found in the literature. Laser cladding presented higher reliability and braking performance, nonetheless requiring the evaluation of its thermal impact on other system components.
|
|
| 4. |
- Bergstedt, Edwin, 1986-
(författare)
-
A Comparative Investigation of Gear Performance BetweenWrought and Sintered Powder Metallurgical Steel : Utilizing In-situ Surface Profile Measurements to Investigate theInitiation and Evolution of Micropitting and Pitting Damage
- 2021
-
Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Vehicle electrification is a strong trend that introduces new challenges, such as increased input speed of the transmission and increased power density. Alsothe noise emittance of the gearbox is of increasing importance, as the sound of the gearbox is no longer masked by the internal combustion engine. Pressed and sintered powder metallurgical steel could be an interesting alternative towrought steel; the internal porosity has a dampening effect on the noise, and gears can be made in a fast and efficient process. However, current manufacturing of powder metallurgical steel has significant performance limitations. The Nanotechnology Enhanced Sintered Steel Processing project aims to reduce the gap in performance between conventional steel and powder metallurgical steel. One of the potential benefits is that with the inclusion of nano-powder the density can be increased. To validate the new material, its performance needs to be compared to the performance of current generation powder metallurgical materials and also to wrought steel. It is therefor crucial to be able to test and evaluate different materials and gears. This thesis has developed methods for testing, comparing, and evaluating the performance of gears. Powder metallurgical steel has been tested and compared to wrought steel; the efficiency as well as pitting life have been investigated in an FZG test rig. Also the effects of different surface finishing operations have been evaluated. The gear flanks were measured in-situ in the gearbox using a stylus instrument; an optimisation routine was created to fit the measurements to the theoretical involute profile. This enabled an in-depth analysis of surface wear and presented an opportunity to investigate micropitting initiation. It was found that the damage mechanisms of wrought steel and powder metallurgical steel are similar and related to the surface finishing method. However, the powder metallurgical steel was also susceptible to sub-surface cracks. Superfinished gears can be negatively influenced by the lack of tip relief as cracks initiate in the surface layer of the root, rapidly destroying the tooth.
|
|
| 5. |
- Bergstedt, Edwin, et al.
(författare)
-
Gear micropitting initiation of ground and superfinished gears : Wrought versus pressed and sintered steel
- 2021
-
Ingår i: Tribology International. - : Elsevier BV. - 0301-679X .- 1879-2464. ; 160
-
Tidskriftsartikel (refereegranskat)abstract
- This paper investigates the resistance of micropitting on two materials, using an FZG back-to-back test rig with CPT gears. The materials are wrought steel (16MnCr5) and a commercial powder metallurgical material (AstaloyTM Mo). Two finishing methods were studied: grinding and superfinishing. Experimental results show that the superfinishing prevented micropitting, but led to premature failure due to cracks in the root caused by tip-to-root interference. Micropitting was initiated at a higher load stage for the powder metallurgical steel compared to the ground wrought steel. The failure mechanisms were similar between materials with the same surface finish. The powder metallurgical steel showed subsurface initiated fatigue compared to the wrought ground steel having surface-initiated fatigue. Testing new finishing methods and materials, one has to be aware of the influence of the gear micro geometry.
|
|
| 6. |
- Bergstedt, Edwin, et al.
(författare)
-
Influence of gear surface roughness on the pitting and micropitting life
- 2020
-
Ingår i: Proceedings of the Institution of mechanical engineers. Part C, journal of mechanical engineering science. - : SAGE Publications Ltd. - 0954-4062 .- 2041-2983. ; 234:24, s. 4953-4961
-
Tidskriftsartikel (refereegranskat)abstract
- Pitting and micropitting are the two main gear rolling contact fatigue modes. It is widely accepted that micropitting will lead to pitting; however, the relationship between pitting and micropitting life needs further investigation. In this work, micropitting and pitting tests were performed on an FZG back-to-back test rig using standard FZG PT-C and GF-C gears. The gear tooth profile change due to micropitting and pitting damage was measured in situ in the gearbox using a profilometer after each test. The gear surface roughness parameters were calculated from the measured tooth profile. A Gaussian low pass filter with cut off length (Formula presented.) mm was applied to the measured tooth profile to obtain the waviness. The calculated roughness parameters and the obtained tooth profile with waviness for each test were imported into the KISSsoft software to calculate the contact stress and specific film thickness at the corresponding load stage. Experimental results show that smooth gear surface can reduce or even avoid micropitting damage, but could lead to a reduction in pitting life.
|
|
| 7. |
- Bergstedt, Edwin, et al.
(författare)
-
Influence of the DIN 3962 Quality Class on the Efficiency in Honed Powder Metal and Wrought Steel Gears
- 2020
-
Ingår i: Tribology Transactions. - : Taylor and Francis Inc.. - 1040-2004 .- 1547-397X. ; 63:6, s. 1076-1084
-
Tidskriftsartikel (refereegranskat)abstract
- To increase the efficiency of a gearbox, research on gear mesh loss is of importance. Britton et al. concluded that the surface finishing method affects the gear mesh efficiency. The efficiency benefits of superfinishing a surface and reducing the surface roughness have been reported by Kahraman. A novel method for calculating the bearing loss torque was proposed by Tu et al. Andersson et al. found that the efficiency can vary between 2 and 5% during repeated efficiency tests due to variations in the assembly process. This work investigates how the honing surface finishing process and DIN 3962 quality class affect the gear mesh efficiency by performing tests in an FZG back-to-back test rig. Two materials, a powder metal and a wrought steel, were tested. All gears were finished using a honing process and sorted according the measured quality class. Powder metal gears of class 6, 7, 8, and ≥9 and wrought steel gears of class 6, 7, and ≥9 were tested. The efficiency were calculated from measuring the torque required to maintain a constant velocity of the FZG test rig. The results from the efficiency tests showed no significant difference in efficiency between the wrought steel and powder metal steel gears. In addition, no obvious correlation between the DIN 3962 quality class and the gear mesh efficiency could be found. When examining the wrought steel material it was found that the reproducibility of the efficiency was comparable to the assembly error of the test rig, despite the variation in quality class.
|
|
| 8. |
- Dizdar, Senad, et al.
(författare)
-
Grey Cast Iron Brake Discs Laser Cladded with Nickel-Tungsten Carbide-Friction, Wear and Airborne Wear Particle Emission
- 2020
-
Ingår i: Atmosphere. - Basel : MDPI. - 2073-4433. ; 11:6
-
Tidskriftsartikel (refereegranskat)abstract
- Airborne wear particle emission has been investigated in a pin-on-disc tribometer equipped with particle analysis equipment. The pins are cut out from commercial powder metallurgy automotive brake pads as with and without copper content. The discs are cut out from a commercial grey cast iron automotive brake disc as cut out and as in addition to a laser cladded with a powder mix of Ni-self fluxing alloy + 60% spheroidized fused tungsten carbide and then fine-ground. Dry sliding wear testing runs under a contact pressure of 0.6 MPa, sliding velocity of 2 m/s and a total sliding distance of 14,400 m. The test results show both wear and particle emission improvement by using laser cladded discs. The laser cladded discs in comparison to the reference grey cast iron discs do not alter pin wear substantially but achieves halved mass loss and quartered specific wear. Comparing in the same way, the friction coefficient increases from 0.5 to 0.6, and the particle number concentration decreases from over 100 to some 70 (1/cm(3)) and the partition of particles below 7 mu m is approximately halved.
|
|
| 9. |
- Hjelm, Rikard, et al.
(författare)
-
Ultrafine particle emissions from dry clutches : number concentration, size distribution and chemical composition
- 2024
-
Ingår i: Environmental Science. - : Royal Society of Chemistry (RSC). - 2634-3606. ; 4:1, s. 35-42
-
Tidskriftsartikel (refereegranskat)abstract
- Non-exhaust sources, such as brakes, tyres, roads, and clutches, emit a large portion of airborne particles in road transportation, from ultrafine to coarse sizes. While airborne wear particle emissions from brakes and road-tyre contacts have been studied extensively, emissions from clutches have been overlooked. A preliminary study using a novel test rig has indicated that dry clutches also emit airborne wear particles. This paper presents a multi-method for the assessment of ultrafine particles from dry clutches regarding the number concentration, size distribution and chemical composition. The results show that ultrafine particles are emitted both during run-in and at the steady state, featuring a bi-modal size distribution. Elementary analysis shows that the particles consist of several elements, predominately iron, silicon, and sulfur. It can be concluded from this study that ultrafine particles are always generated when the clutch is operated. Clutches in automobiles are shown to produce ultrafine particles, consisting of several metallic elements, which become airborne.
|
|
| 10. |
|
|
