Relevant bibliographies by topics / FZG test rig

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  1. Journal articles
  2. Dissertations / Theses
  3. Book chapters
  4. Conference papers

Academic literature on the topic 'FZG test rig'

Author: Grafiati
Published: 4 June 2021
Last updated: 10 February 2022

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Journal articles on the topic "FZG test rig"

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Durand de Gevigney, J., C. Changenet, F. Ville, and P. Velex. "Thermal modelling of a back-to-back gearbox test machine: Application to the FZG test rig." Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology 226, no. 6 (January 16, 2012): 501–15. http://dx.doi.org/10.1177/1350650111433243.

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A thermal model of a back-to-back gear test rig relying on a network approach is presented in which the predictions of temperatures and power losses are coupled. The numerical findings are in good agreement with the measurements for transient regimes on a FZG test rig and it is demonstrated that the proposed simulation is reliable. A number of results are presented which illustrate the influence of the pinion and gear immersion depths. It is found that, in certain conditions, the classic isothermal method for estimating integral temperatures is questionable because the actual bulk temperature can substantially deviate from that of the oil sump. The practical consequences in terms of scuffing capacity are emphasised.
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Navet, P., C. Changenet, F. Ville, D. Ghribi, and J. Cavoret. "Thermal Modeling of the FZG Test Rig: Application to Starved Lubrication Conditions." Tribology Transactions 63, no. 6 (August 24, 2020): 1135–46. http://dx.doi.org/10.1080/10402004.2020.1800155.

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Höhn, B. R., P. Oster, and U. Schedl. "Pitting load capacity test on the FZG gear test rig with load-spectra and one-stage investigations." Tribotest 5, no. 4 (June 1999): 417–30. http://dx.doi.org/10.1002/tt.3020050407.

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Spiegelberg, C., and M. Christie. "Torque loss in spur gears with interference." Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology 217, no. 5 (May 1, 2003): 385–95. http://dx.doi.org/10.1243/135065003322445304.

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Gears with interference (zero backlash) are used in robots and other precision equipment. The reason for using interference gearing is to improve positioning and motion control. It is then also desirable to compensate for the friction losses and therefore it is important to model the friction losses accurately. In this paper, results from a model for simulating spur gears with interference are compared with results from a test rig for spur gears with interference. FZG gears are used both in the test rig and in the simulations. Brief descriptions of the test rig and the simulation model are given in the paper; more thorough descriptions can be found in studies by Hedström and Kårhammar and by Spiegelberg, Andersson and Sellgren respectively. There is also a description of the measurements and the procedure of making them. The aim of this paper is to compare the results from the test rig with the results from the simulation model and to analyse the results from the test rig. The results show that the simulated torque loss corresponds well with the measured torque loss within the range of the test rig. The results from both the test rig and the simulation model show that there are large variations in the frictional torque during one mesh of a gear tooth. The loss increases with the number of contact points and the lowest loss is found when a driving gear flank passes the pitch point. The overall efficiency decreases when the mesh force increases and the lowest efficiency readings are found when a combination of high mesh force and low load is applied.
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Höhn, B. R., K. Michaelis, C. Eberspächer, and L. Schlenk. "A scuffing load capacity test with the FZG gear test rig for gear lubricants with high EP performance." Tribotest 5, no. 4 (June 1999): 383–90. http://dx.doi.org/10.1002/tt.3020050405.

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Bergstedt, Edwin, Jiachun Lin, and Ulf Olofsson. "Influence of gear surface roughness on the pitting and micropitting life." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 234, no. 24 (June 9, 2020): 4953–61. http://dx.doi.org/10.1177/0954406220931541.

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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: see text] 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.
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Neurouth, Adrien, Christophe Changenet, Fabrice Ville, and Michel Octrue. "Influence of Rolling Element Bearing Modeling on the Predicted Thermal Behavior of the FZG Test Rig." Tribology Transactions 60, no. 4 (July 15, 2016): 753–61. http://dx.doi.org/10.1080/10402004.2016.1208856.

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Fürstenzeller, Adam, František Tóth, Milan Kadnár, Juraj Rusnák, and Miroslav Bošanský. "Comparison of PVD Coatings Nacro4 and TIALN + DLC Deposited on High Contact Ratio Gearing Interacting With Conventional and Ecological Lubricants." Acta Technologica Agriculturae 22, no. 2 (June 1, 2019): 48–55. http://dx.doi.org/10.2478/ata-2019-0009.

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Abstract Proposed paper deals with experimental tests performed on the Nieman M01 FZG test rig. Experiments were carried out in accordance with STN 65 6280 standard for FZG scuffing tests, from which load values for each load level were obtained. HCR gears made of 16MnCr5 material were utilized during experimental tests. Gear surface was deposited by PVD coatings of nACRo4 and TiAlN + DLC. Conventional lubricant MADIT PP 90H and biological lubricant OMW Biogear S150 were selected for lubrication environments. Aim of the experimental tests lied in application and comparison of PVD coatings deposited on HCR gears. Values of the maximum height of the assessed profile Rz for tip and reference diameters were measured after each load level. Results of experimental tests were statistically processed and relations between the maximum height of assessed profile Rz and load levels for both utilized coatings in both environments were established on the basis of these results.
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Magalhães, Luís, Ramiro Martins, Ivo Oliveira, and Jorge Seabra. "Comparison of tooth profiles and oil formulation focusing lower power losses." Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology 226, no. 6 (March 7, 2012): 529–40. http://dx.doi.org/10.1177/1350650112439260.

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Environmental awareness, lower consumption of raw materials and longer life of equipment are main concerns nowadays and are leading to the research and development of lubricants and equipment to access those requirements. In this study, the power loss performance of three different tooth profile geometries, developed with the purpose of decreasing power losses while keeping the predicted life, were tested and evaluated in a FZG test rig. The path to reduce power losses was based on the decrease of the module, the increase of the helix angle and increase of the addendum modification coefficients in order to reduce the path of contact, i.e. the sliding velocity. The power loss behaviour of two different lubricants was also evaluated for each tooth profile geometry considered. The influence of the oil level in the gearbox was also evaluated. One of the lubricants has an ester base while the other has a polyalphaolefin base and both are fully formulated. An energetic model was developed for the FZG test gearbox and applied to these tests to improve the knowledge about the influence of tooth geometries as well as lubricant formulation in the power losses and coefficient of friction between gear teeth. The developed geometries showed that the path followed for the reduction of power losses produced the expected results and can be implemented with success on gear design.
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Michalczewski, Remigiusz, Witold Piekoszewski, Marian Szczerek, Waldemar Tuszynski, and Maksim Antonov. "The Rolling Contact Fatigue of PVD Coated Spur Gears." Key Engineering Materials 527 (November 2012): 77–82. http://dx.doi.org/10.4028/www.scientific.net/kem.527.77.

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The aim of the study was to investigate the resistance to rolling contact fatigue of a C:H:W and MoS2/Ti coated gears. The investigation of rolling contact fatigue was realised by means of a gear test rig using FZG PT C/10/90 pitting test. Four material combinations of gears were tested: wheel and pinion uncoated, wheel and pinion coated, wheel coated and pinion uncoated as well as wheel uncoated and pinion coated. The tests were performed using for lubrication mineral gear oil of API GL-5 performance level and 80W/90 viscosity grade. The results indicate that for the coated/coated pair (pinion and wheel coated) and coated pinion/steel wheel pair a significant decrease in the fatigue life compared to the uncoated gears was obtained. The best results were obtained in the case of the uncoated pinion / a-C:H:W coated wheel – even fourfold increase in the fatigue life was observed. This shows a very high potential of application of PVD coatings for gears.
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Dissertations / Theses on the topic "FZG test rig"

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Prakash, del Valle Carlos. "Thermal modelling of an FZG test gearbox." Thesis, KTH, Maskinkonstruktion (Inst.), 2014. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-157256.

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Gearboxes are always subject of study in order to increase their efficiency. Energy losses in gear contacts are transformed into heat which is distributed among the gearbox components increasing their temperature. A thermal model of the gearbox brings the opportunity of a deeper understanding of the heat dissipated related to the power losses in the gear contact. A MATLAB program based on ordinary differential equations was developed in order to make a thermal model of an FZG test gearbox. The model is based on a thermal network where each node represents a machine element. The thermal network is composed by thermal resistances due to deformation in the gear contact, conduction, convection and radiation. With thermal resistances, power losses and thermal inertia of each element, the temperature evolution was obtained by applying the First Principle of Thermodynamics. Due to the temperature evolution, heat transfer between different elements was estimated. Additionally, experimental results from an FZG test rig were implemented in the model and also used to verify its accuracy. Furthermore, additional features to the model such as a cooling system and spray lubrication were also studied. Results show a wide capability and handling of the program in terms of thermal analysis: heat flux direction and magnitude, visual tools such as thermal network of the test gearbox, as well as the analysis of different operating conditions. With these tools, an approach to the minimum amount of lubricant necessary and other ways to quench overheating could then be reached. Keywords: Thermal network, FZG gear test rig, heat flow, temperature, MATLAB, ODE.
Växellådor är ständigt ett forskningsområde för att förbättra deras verkningsgrad. Energiförluster i kuggkontakter omvandlas till värme som sprids i växellådan som sedan värmer upp komponenterna. En termisk modell av växellådan gör det möjligt för djupare förståelse hur värmen sprids i förhållande till energiförlusterna i kuggkontakten. Ett MATLAB-program baserat på ordinära differential-ekvationer utvecklades för att göra en termisk modell av en växellåda i en kuggrigg från FZG. Modellen är baserad på ett termiskt nätverk där varje nod representerar en maskinkomponent. Det termiska nätverket består av resistanser som uppstår på grund av deformation i kuggkontakten, ledning, konvektion och strålning. Med termiska resistanser, energiförluster, termisk tröghet från komponenterna och genom att applicera termodynamikens första grundsats kunde temperatur-genereringen bestämmas. Från temperatur-genereringen kunde värme-ledningen mellan komponenter uppskattas. Testresultat från en FZG-kuggrigg användes för att verifiera modellens noggrannhet. Andra egenskaper till modellen, som ett annat kylsystem och spraysmörjning studerades för att undersöka möjligheteten att adderas till modellen. Resultat visar på en bred användning av modellen i avseende på termisk analys: värmeflödets storlek och riktning, ett visuellt redskap för växellådans temperatur och hur växellådans temperatur varierar under olika driftförhållanden. Med de här redskapen kan den minsta oljemängden som behövs för att smörja kuggkontakten undersökas och hur kylning av kugghjulen kan förbättras. Nyckelord: Termiskt nätverk, FZG kugghjuls-rigg, värmeflöde, temperatur, MATLAB, ODE
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Spaccesi, José Agustín. "Analysis of design requirements for early failure detection in a gear test rig." Thesis, KTH, Skolan för industriell teknik och management (ITM), 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-280573.

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Gears are the heart of many machines, being its function transform and transmit torque. This work is a study of adequate design requirements, in particular, the best methodology to early detect gear fatigue failure using a gear test rig, an FZG test machine. The study used the widely proved QFD analysis technique that introduces the client in the design process by using a matrix system. All available relevant literature on the subject and interviews with relevant people in the field were sources of information for the development of this technique. In that way, a mapping is presented, showing the most common fatigue failure modes and available detection methods.  As a result of the investigation, the most suitable technique for the early gear failure detection in the FZG rig to be a combination of vibration analysis and acoustic emissions analysis, these techniques present the best practice at the moment and also possible to implement. However, other technologies are also presented in the report.
Kuggväxlar uppfyller en viktig funktion i många system. I det här arbetet studerades de viktigaste konstruktionskraven hos en tetstrigg för kugg, en FZG-rigg, för att kunna detektera tidiga tecken på kuggskador. Litteraturstudier tillsammans med intervjuer av personer från industrin lade grunden till en jämförelse av produktegenskaper som uppfyller kundkraven med hjälp av en så kallad Quality Function Deployment matrix (QFD-matris). I en QFD omvandlas kundkrav till funktion- och konstruktionskrav, i och med den kunde också de vanligaste kuggskadorna och detekteringsmetoderna kartläggas.  De mest relevanta teknikerna för att detektera tidiga tecken på skador i en FZG-rigg idag visade sig vara en kombination av vibrationsmätningar och akustiska emissionsmätningar. Lösningen är möjlig att implementera. Även andra teknologier finns presenterade i rapporten.
Los engranajes son el corazón de muchas máquinas, siendo su función transformar y transmitir par. En este trabajo se realizó un estudio de los requisitos de diseño más adecuados, en particular, la mejor metodología para detección anticipada de fallo a fatiga de engranajes testeados en un banco de pruebas de engranajes FZG. Durante el estudio se utilizó la técnica de análisis QFD que introduce al cliente en el proceso de diseño mediante el uso de un sistema matricial. Toda la literatura relevante disponible sobre el tema, así como entrevistas a personas relevantes en el campo fueron utilizadas como fuente de información para el desarrollo de dicha técnica. También se realizó un mapeo de los diferentes modos y mecanismos de fallo por fatiga más comunes, así como los métodos de detección disponibles.  Como resultado de la investigación se concretó como metodología más adecuada para la detección anticipada de fallo de engranajes en los bancos de prueba FZG, una combinación de análisis de vibraciones y análisis de emisiones acústicas, estas técnicas presentan las mejores características en función de la dificultad de implementación. Sin embargo, en el informe también se presentan otras tecnologías.
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Xinmin, Li. "Efficiency and wear properties of spur gears made of powder metallurgy materials." Doctoral thesis, KTH, Maskinkonstruktion (Inst.), 2016. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-187446.

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Powder metallurgy (PM) is usually used in manufacturing parts with complex geometries, such as gears and structural parts. The main attractions of PM are the high rate of material utilization, environmental friendliness of production, economic advantages (especially for complex geometries), and possibility of obtaining lighter components. To find a wide range of applications and compete with regular steel gears, PM gear transmissions should have good transmission efficiency and wear properties. Furthermore, they should have low contact noise and adequate surface fatigue properties. Because of the porosity structure of PM gears both on gear flanks and in the body, the friction and wear properties of PM gear flank contacts differ somewhat from those of regular steel gears.    This doctoral thesis examines the efficiency and wear properties of PM gears. Paper A compares the wear, friction, and damage mechanism properties of two sintered gear materials with those of a standard gear material. Paper B deals with the gear mesh torque loss mechanism of PM and regular steel gears by combining both pin-on-disc frictional and FZG efficiency tests. Paper C comparatively examines the efficiency of PM and regular steel gears by conducting FZG gear efficiency tests. Paper D focuses on the wear and friction properties of PM and regular steel gear materials treated using the triboconditioning process. Paper E studies the friction and wear properties attributable to different pore sizes in PM gear materials.    The results indicate that regular steel meshed with PM gear material and PM meshed with PM gear material are good candidate combinations for gear transmissions. This is because the porosities of PM material can lower the friction coefficient while the wear rate can be the same as or even better than that of regular steel contacts. The triboconditioning process enhances the wear resistance and reduces the friction coefficient of the PM gear material. The friction and wear coefficients of PM meshed with PM gear material display increasing trends with increasing pore size. The friction and wear coefficients of regular steel meshed with PM gear material display decreasing trends with increasing pore size.

QC 20160523

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Book chapters on the topic "FZG test rig"

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Kobayashi, Shiro, Soo-Ik Oh, and Taylan Altan. "Axisymmetric Isothermal Forging." In Metal Forming and the Finite-Element Method. Oxford University Press, 1989. http://dx.doi.org/10.1093/oso/9780195044027.003.0012.

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According to Spies, the majority of forgings can be classified into three main groups. The first group consists of compact shapes that have approximately the same dimensions in all three directions. The second group consists of disk shapes that have two of the three dimensions (length and width) approximately equal and larger than the height. The third group consists of the long shapes that have one main dimension significantly larger than the two others. All axially symmetric forgings belong to the second group, which includes approximately 30% of all commonly used forgings. A basic axisymmetric forging process is compression of cylinders. It is a relatively simple operation and thus it is often used as a property test and as a preforming operation in hot and cold forging. The apparent simplicity, however, turns into a complex deformation when friction is present at the die–workpiece interface. With the finite-element method, this complex deformation mode can be examined in detail. In this chapter, compression of cylinders and related forming operations are discussed. Since friction at the tool–workpiece interface is an important factor in the analysis of metal-forming processes, this aspect is also given particular consideration. Further, applications of the FEM method for complex-shaped dies are shown in the examples of forging and cabbaging. Finite-element discretization with a quadrilateral element is similar to that given in Chap. 8. The cylindrical coordinate system (r, ϑ, z) is used instead of the rectangular coordinate system. The element is a ring element with a quadrilateral cross-section, as shown in Fig. 9.1. The ξ and η of the natural coordinate system vary from −1 to 1 within each element.
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Keefer, Robert F. "Micronutrients." In Handbook of Soils for Landscape Architects. Oxford University Press, 1999. http://dx.doi.org/10.1093/oso/9780195121025.003.0016.

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Micronutrients needed by plants are Cu, Fe, Mn, Zn, B, Mo, Cl, Ni, Co, V, Si, and Na. The required amounts of each of these elements is very small but still essential for desirable plant growth and reproduction. These elements must be applied to soils cautiously for the range between deficient and toxic is very small. It is unwise to use a fertilizer containing all of these micronutrients. Any one of them may already be high enough in soils to cause toxicity from that particular element. If a micronutrient is suspected of being deficient, it would be wise to get soil tests and plant tissue tests to corroborate your suspicions. If a micronutrient is deficient, one should apply only the amount recommended but no more. Sometimes a toxicity of an element is more difficult to correct than a deficiency. Copper, iron, manganese, cobalt, and zinc can be present in soils as (a) several types of precipitates, (b) adsorbed onto the surface of soil particles, (c) present in primary minerals (rocks) and secondary minerals (clays), and (d) present as complex ring compounds. These forms may or may not be available to plants. Precipitates of Cu, Fe, Mn, or Zn often form in soils at high pH (after liming Fig. 14.1). This may occur in soils near buildings from the lime used in the mortar. Soil acids dissolve the lime into Ca++ or Mg++ that migrate into the soil raising the pH and cause these micronutrients to precipitate. Often an Fe deficiency is evident, particularly on acid-loving plants, such as azaleas, rhododendrons, or hollies. If this is extensive, the soil near the buildings may need to be replaced. With limited areas, the soil can be acidified by adding elemental S near the plants affected. The elements Cu, Fe, Mn, and Zn can exist as soluble forms or precipitates, depending on the pH of the soil. The soluble forms as cations are present when soils have poor internal drainage (poorly drained soils), whereas the oxides of these elements are present where the soil is well aerated.
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"2. Adhesion of the plasma-polymerized fluorocarbon films to silicon substrates The adhesion properties of the plasma-polymerized FC coatings were determined by using a test, already employed by Yasuda and Sharma [13] (see Fig. 1 and Table 1) in which the silicon substrates coated with plasma FC-films were boiled in a0.9% sodium chloride solution. The FC thin films produced in the processes 1 and 2 were lifted after a very short time (15 minutes). Coatings generated in process 3 were lifted after the second cycle of boiling. The films produced in processes 4 and 5 withstood the complete test procedure. The results are shown in Fig. 3. The poor adhesion of the polymerized films in the first two processes is due to the fact that these processes do not involve a plasma pre-treatment process. The difference between processes 1 and 3 is only in the plasma pre-treatment (process 1 does not contain the pre-treatment step of the silicon surface). The fluorocarbon films deposited by processes 4 and 5 have shown the best adhesion. These test results indicate that the plasma pre-treatment is very important and necessary for a good adhesion of the FC coatings to the silicon surfaces. 2.3. Patterning of FC films 2.3.1. Patterning through resist mask. The patterning of the FC films through a photoresist mask (conventional All resist AR-P351) was examined after deposition for process No. 5. Different coating parameters were investigated to improve the adhesion of the resist to the FC surface. The best adhesion results were obtained using the process parameters, shown in Table 3. Differences in the thickness uniformity of so-deposited resists were in a range below 5%. The samples were etched in a pure oxygen plasma in an RIE-system after the lithography steps (pre-bake, exposure, development, post-bake). A resolution of 2 /xm was obtained. A significant increase in the surface energy was not observed after resist stripping. The sessile contact angle of water was 103°. 2.3.2. Lift-off process for patterning thin plasma polymerized FC films. A lift-off process was also examined to pattern the thin FC films. The lithography steps were used before the plasma polymerization process was carried out (Fig. 2). A standard resist AR-P351 was coated directly onto the Si substrates. After all lithography." In Adhesion Aspects of Thin Films, Volume 1, 275–78. CRC Press, 2014. http://dx.doi.org/10.1201/b11971-44.

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Conference papers on the topic "FZG test rig"

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Michalczewski, Remigiusz, Marian Szczerek, Waldemar Tuszynski, and Jan Wulczynski. "The Scuffing Resistance of the Coated Tribosystems Lubricated With Ecological Oils." In World Tribology Congress III. ASMEDC, 2005. http://dx.doi.org/10.1115/wtc2005-63432.

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The objective of the paper is to show that thin, hard coatings deposited on heavy-loaded machine components working in a non-conformal contact (e.g. gears) and lubricated with ecological oils, make it possible to increase the service-life of these components. The scuffing resistance was assessed by employing a high-resolution four-ball test method realized in a tester with continuously increasing load. Also another test method — FZG scuffing test — was realized using a back-to-back gear test rig. The test balls and gears were coated with thin, hard TiN and WC/C coatings deposited using arc-vacuum and reactive sputtering techniques respectively. The performed tests indicate that the presence of thin coatings on machine components gives a possibility of eliminating or reducing the content of toxic AW/EP additives in lubricating oils, as well as using ecological oils made of renewable resources, without any risk of a scuffing failure.
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O’Connor, B. M. "The Influence of Additive Chemistry on Gear Micropitting." In ASME 2003 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. ASMEDC, 2003. http://dx.doi.org/10.1115/detc2003/ptg-48125.

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Gear micropitting has been a highly visible issue in selected applications in recent years, most notably in large wind turbine transmissions. Various industry groups have addressed the problem from their own area of expertise. This has included evaluation of the gear design characteristics, surface finishing, the use of special coatings, and lubrication. A common approach to improve the lubrication has been first to increase the viscosity and create thicker films, which, in turn, reduce the amount of surface asperity interaction. Another approach from the lubricant side has been to alter the additive chemistry to effect a change in the wear properties of the system. This paper discusses the potential effects observed for different antiwear and EP chemistry on the micropitting of cylindrical gears. Tests were conducted in an FZG test rig which has been used by the industry as a guide to general gear performance. Fluids were examined in a series of experimental designs which served as the iterative process leading toward an optimized additive system. The results show that the EP, or antiscuff agent, was the most effective component at reducing the level of micropitting.
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Choi, Alexander, Tyler Luneski, Zbigniew M. Bzymek, Vito Moreno, and Geri Gonxhe. "A Search for Optimal Friction Resistant Material to Cover Contact Surfaces: A Case Study in the Senior Mechanical Engineering Design Student Project." In ASME 2016 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2016. http://dx.doi.org/10.1115/imece2016-65481.

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The University of Connecticut Department of Mechanical Engineering has developed an industry recognized Senior Design Capstone course that provides students the opportunity for a major design experience. This paper will discuss the issues and challenges associated with project demonstrated on the base of the Search for Optimal Friction Resistant Material to Cover Contact Surfaces in an Electric Manual Switch. In order to determine the viability of potential substitute materials, the team produced custom testing rigs to evaluate material wear and corrosion performance. The construction of these rigs, the fabrication of the testing coupons, testing results and the final choice of the covering material were the primary deliverables of this project. The wear rig allowed the team to determine mechanical performance on the basis of mass loss. In the evaluation of mechanical performance, the coated test coupons were revolved on a testing plate while a flat coated column contacted the surface to wear the plating. After a certain number of cycles, the coupons were subjected to environmental testing. The corrosion rig was designed to provide aggressive corrosion on the worn coupons, and was modeled after the industry standard salt fog test. The worn test coupons were immersed in a humid salt fog test chamber and held at temperature until corroded. A series of calibration checks were completed to evaluate the UConn test severity to ASTM (American Society of Testing Materials) standard testing. The surfaces before and after the corrosion process were analyzed in a number of ways. Optical microscopy, profilometry, and surface metrology techniques were employed to determine which platings were likely to meet the consumer standards necessary for replacement. The large set of data on volume loss, mass loss, and surface degradation provided good metrics for the evaluation of material suitability. The project described in this paper is based on the contribution of the students’ team as well as is the result of consulting effort of the faculty who were directly involved in the course and also the other department’s faculty who were consulting the detail processes. General Electric (GE) especially its Industrial Solution Division that sponsored the project, is a company that provides a wide variety of services in electrical appliances, power, and home and business solutions. It has tasked the team with identifying a suitable replacement for Hexavalent Chromium Chromate passivation. This material is plated on many components in GE electrical appliances due to its resistance to abrasion and corrosion. However, because of changing regulations and the health risks that come from dealing with HCC, the sponsor has determined that it is necessary to remove the plating from production by 2019. In order to determine the viability of potential substitute materials, the team produced custom testing rigs to evaluate material wear and corrosion performance. The construction of these rigs and the fabrication of the 400+ testing coupons, the environmental and mechanical tests results and the final conclusions were the primary deliverables of this project. The team examined three different plating materials (JS 600, trivalent chrome, and zinc phosphate) and compared their performance to that of the original HCC plating. The resulting comparative analysis drove the final recommendation of the best candidate material for the sponsor on the basis of mechanical and environmental performance.
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4

Kano, Makoto, Yoshiteru Yasuda, Jiping Ye, Shozaburo Konishi, Jean Michel Martin, Isabel De Barros, and Thierry Le Mogne. "Super Low Friction Property of DLC Lubricated With Ester-Containing Oil: Part 1 — Friction Properties Evaluated in Rig Tests." In World Tribology Congress III. ASMEDC, 2005. http://dx.doi.org/10.1115/wtc2005-63920.

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This paper presents a material combination that reduces the friction coefficient markedly to a super low friction regime (below 0.01) under boundary lubrication. Friction tests were conducted with a test rig consisting of three pins pressed against a rotating disc, as shown in Fig. 1. The pins were made of bearing steel AISI52100 and the disc was made of carburized steel SCM415, which was coated with a diamond-like-carbon (DLC) film. The test conditions were as follows. Pins: Fixed, not rotating; DLC: CVD a-C:H, PVD ta-C; Lubricant: 5W-30 API SG Engine oil; Ester-containing oil (PAOES1): Poly alpha-Olefin containing 1 mass% of glycerol mono-oleate; Pressure: 0.7 Gpa; Sliding speed: 0.03–1m/s; Oil temperature: 353K (80 deg. Celsius).
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5

Hou, J., J. Dubke, K. Barlow, S. Slater, L. Harris, S. Calcuttawala, and W. Beres. "3D Crack Growth Analysis and Its Correlation With Experiments for Critical Turbine Components Under an International Collaborative Program." In ASME Turbo Expo 2008: Power for Land, Sea, and Air. ASMEDC, 2008. http://dx.doi.org/10.1115/gt2008-50548.

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Following a reanalysis of the original material data plus supplementary Low Cycle Fatigue (LCF) specimen testing, an Original Equipment Manufacturer (OEM) reduced the low cycle fatigue life limits for a number of turbine components. To ascertain the validity of the new life limits, an international collaborative spin rig test program was initiated to provide more accurate low cycle fatigue life limits. The program covered a broad range of activities including, Finite Element (FE) stress analyses, cyclic spin rig testing, fractographic assessment and fatigue crack growth (FCG) analyses. This paper describes the 2D and 3D crack growth analyses of critical turbine components in a turboprop gas turbine engine, comparison of predicted results obtained using different software and also correlations with spin test results from the program. First, FE stress analyses of selected turbine components were carried out under both engine operating conditions and spin-rig test configurations in order to determine the maximum and minimum operating speeds required to match the stress ranges at the critical location specified by the OEM under engine operating conditions. Second, 2D and 3D crack growth analyses were performed independently by three organisations for a disk bolthole using the state-of-the-art software. Third, the predictions from different software were compared, and the relative technical merits of each software were evaluated. Finally, the predicted results were correlated against the striation counts determined by the OEM from the results of spin rig tests.
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Rautenberg, M., M. Malobabic, A. Mobarak, and M. Abdel Kader. "Design and Testing of a 10KW Steam Turbine for Steam Turbochargers." In ASME 1985 Beijing International Gas Turbine Symposium and Exposition. American Society of Mechanical Engineers, 1985. http://dx.doi.org/10.1115/85-igt-113.

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A Clausius-Rankine-cycle has been proposed to recover waste heat from a piston engine. This waste heat is then used to supercharge the cylinders by means of a steam turbocharger. The advantage of using this steam turbocharger system is to avoid the losses due to the engine back pressure which accompany the use of the conventional exhaust gas turbocharger. The mass flow rate of turbines for steam turbochargers in the range from 1 to 10 kW is about 0.03 to 0.08 kg/s. This implies a special turbine design, characterised by partial admission and supersonic flow, which unfortunately leads to low turbine efficiencies. A small Pelton turbine for steam has been designed and produced. The turbine is connected to the radial compressor of a conventional exhaust gas turbocharger which works, in this case, as a brake to dissipate the generated turbine power. A special test rig has been built to carry out the experimental investigations on the proposed Pelton turbine. The test rig is supplied with superheated steam from the University’s power plant. Two different rotors for this Pelton turbine have been tested under the same operating conditions (rotor 2 see Fig. 1). Some experimental test results of a special Pelton turbine are presented and discussed in this report.
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D’Ercole, Michele, Giovanni Biffaroni, Francesco Grifoni, Francesco Zanobini, and Paolo Pecchi. "Results and Experience From GE Energy’s MS5002E Gas Turbine Testing and Evaluation." In ASME Turbo Expo 2005: Power for Land, Sea, and Air. ASMEDC, 2005. http://dx.doi.org/10.1115/gt2005-68053.

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GE Energy’s new gas turbine, the MS5002E, is a 30 MW-class industrial gas turbine for mechanical drive and power generation applications. The MS5002E (fig.1) is the latest in the Frame5 two-shaft family and, while it retains some features from previous versions, the machine has been specifically designed for low environmental impact and high reliability, in direct response to customer demand for high efficiency and availability [1] & [2]. Main features for the MS5002E are: • 32 MW base load power at ISO inlet conditions (no losses); • 36% thermal efficiency; • 11-stage axial compressor and 17:1 pressure ratio; • reverse flow, six cans, Dry Low NOx (DLN2 technology) combustion system; • two-stages reaction type HP turbine; • two-stages PT leveraged from the LM2500+ HSPT (High Speed Power Turbine); • HP speed operating range 90% (6709rpm) / 101% (7529rpm); • PT speed operating range 50% (2857rpm) / 105% (6000rpm); • exhaust gas temperature (EGT): ∼510°C; • two-baseplates configuration (gas turbine flange-to-flange unit and auxiliary system); • integrated enclosure and baseplate, providing maximum accessibility for maintenance. The design of the MS5002E has been validated through an extensive test program which has included some key-test rigs such as the Rotordynamic Test, the CTV Test (full-scale axial compressor test) and numerous component and full-scale combustion tests in laboratory, conducted in advance of the First Engine to Test (FETT). The MS5002E First Engine to Test was initially started in January 2003 and the validation program has been completed with a full gas turbine teardown, dirty layout (visual and dimensional inspections for each major gas turbine component in as-is conditions) and NDT inspection in June 2004. During engine teardown, disassembly/assembly procedures and tools have been tested and validated. Additional endurance and operability testing is ongoing and will be completed by the end of 2005. The First Engine to Test is a complete equivalent-to-production package including gas turbine, auxiliaries and control system. For the test, a dedicated plateau has been built in Massa, Italy [3]. The gas turbine has been equipped with over 1400 direct measurement points (for a total of more than 2400 direct and indirect measurements) covering the flange-to flange, the package and auxiliaries. All critical-to-quality parameters, such as turbine gas path components temperatures and stresses, combustor temperatures and dynamics, performances and emissions, have been carefully verified by means of redundant instrumentation. This paper presents how the test program has been built on the GE Energy NPI (New Product Introduction) Development Process and how results from tests are fed back to the gas turbine design process. The paper discusses test rig and facilities layout, gas turbine operation experience and lessons learned. Results from the tests and measurements are also discussed.
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Bühlmann, Stefan, Daniela Limacher, Thomas Manyoky, and Mauro Melas. "Laboratory Method to Evaluate Fog Rejection Effectiveness of Hydrophobic Coatings for Steam Turbine Applications." In ASME Turbo Expo 2018: Turbomachinery Technical Conference and Exposition. American Society of Mechanical Engineers, 2018. http://dx.doi.org/10.1115/gt2018-77296.

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The application of hydrophobic coatings in steam turbines is expected to partially inhibit the formation of water films on blade surfaces, and consequently reduce the associated efficiency loss and mechanical damage. Since testing coatings in real steam turbines is impractical, a method is presented to assess, under laboratory conditions, the tendency of materials to reject rather than collect water droplets impinging on them. This behavior was demonstrated to poorly correlate with wetting angle measurements which proved the necessity to use a more complex approach. A test rig was therefore used which allows evaluating fog-rejection effectiveness, by placing coated specimens on a rotor and exposing them to a flow of saturated steam carrying micron size droplets. Steam condition, impact angle, droplet size and velocity are kept close to what is expected in low pressure steam turbines. While rotating, the formed water film is centrifuged and captured in tanks within the supports holding the coated specimens. The mass of their content is measured upon experiment completion. Having tanks in 4 different locations along a specimen’s edge gives an additional insight about variations in collection location and film flow direction. Repeatability and parameter variation tests have shown that the collection is reasonably insensitive to the changes in operation conditions, yet the scatter in the data remained high. Nevertheless, statistical analysis showed that the method is able to clearly detect differences in collection behavior, thus enabling the industrial partner to select coatings that provide enduring steam turbine efficiency increase.
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Coker, Joseph D., Darryll J. Pines, Paul D. Samuel, and Jason Kiddy. "Fiber Optic Strain Sensor Vibration Separation for Detection of Seeded Faults in Rotorcraft Transmissions." In ASME 2008 Conference on Smart Materials, Adaptive Structures and Intelligent Systems. ASMEDC, 2008. http://dx.doi.org/10.1115/smasis2008-432.

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This paper presents a refined methodology for performing helicopter transmission anomaly detection through the use of vibration separation techniques applied to the output of a fiber optic sensor array. Fiber Bragg grating (FBG) sensors—distributed about the exterior of a planetary gearbox annulus—record the local strain response of the annulus surface due to tooth-mesh interactions. These strain profiles are collected for a number of loading conditions both with and without seeded faults. The profiles are separated and synchronously averaged to illustrate the effect of damage to planetary gears on local strain variation. Results of experiments conducted on the University of Maryland Transmission Test Rig (UMTTR) are included. Additional processing and comparison to traditional vibration-based diagnostic methods indicate the potential for increased sensitivity to damage of such a system and the feasibility of fiber optic strain sensors for in situ health and usage monitoring.
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Hashemi, Saeed, and William K. Durfee. "Low Friction, Long-Stroke Rolling Diaphragm Cylinder for Passive Hydraulic Rehabilitation Robots." In 2017 Design of Medical Devices Conference. American Society of Mechanical Engineers, 2017. http://dx.doi.org/10.1115/dmd2017-3518.

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Hydraulic actuators are commonly used in mechanical systems, and actuator efficiency is one of the most important factors in these systems [1]. The energy loss to overcome friction force makes the actuator less efficient. Wearable rehabilitation robotics is one of the applications of hydraulic actuators. Hydraulic cylinders deliver the power extracted from the external resources and/or less stroke-affected limbs to the more stroke-affected limbs (Fig. 1). O-ring seal, rolling diaphragm, and gap seal cylinders are three common technologies that have been used in different hydraulic systems for years. O-ring seal actuators use an O-ring seal between the piston and cylinder. Rolling diaphragm actuators have a diaphragm between the cylinder and piston which rolls back and forth. In gap seal cylinders, there is a gap between the piston and cylinder. Since it is a tradeoff between leakage and friction, leakage between the two chambers in these cylinders is tolerated to reduce friction (Fig. 2). One study examined low friction cylinders in a low pressure hydraulic transmission [2]. In this study, rolling diaphragm cylinders were used in the transmission, but the restriction on stroke length of these cylinders is a problem that needs to be solved. Commercial rolling diaphragms are manufactured using compression molding of a sheet rubber and woven fabric [2], a manufacturing method that limits the stroke length to no more than the bore of the cylinder. Rolling diaphragm cylinders with the higher stroke-to-bore ratios could multiply the work per cycle of the system [2]. Furthermore, there are limitations of using short stroke length rolling diaphragm cylinders [3] [4]. A more thorough friction evaluation of various cylinder technologies is needed to determine which technology has the lowest friction and is most appropriate for low pressure hydraulic systems like rehabilitation robots. Developing a low friction, leakage-free cylinder without stroke limitations is needed for small hydraulics. Using an experimental test, we measured the resistance forces in three types of cylinders: O-ring, gap seal, and rolling diaphragm. The cylinders were tested at low-pressure and with mineral oil to determine the lowest friction cylinder technology. The same friction test was performed in a novel, long-stroke, rolling diaphragm cylinder (LSRD) to compare it in two different thicknesses with commercial actuators.
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