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Fokussiert auf
Reibung, Verschleiß
& Schmierstoff
Kompetenzzentrum
für TribologieAC2T research GmbH
© Copyright AC2T research GmbH 2017. All rights reserved. Reproduction of any material, whether by photocopying, photographing or storing in any medium by electronic or other means is prohibited without prior written consent of AC2T research GmbH.
U. Cihak-Bayr
AC2T research GmbH
EMMC WORKSHOP
TRANSLATOR USE CASE
IN TRIBOLOGY
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research service provider
in Tribology
one of the largest private
(independent) tribology centres
founded 2002
turnover: ~12 M€/year
~120 employees
COMET K2 Excellence Centre of Tribology – Xtribology
Overall research project, funded by FFG
AUSTRIAN CENTER OF COMPETENCE FOR TRIBOLOGY
AC2T RESEARCH GMBH
2012
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MOTIVATION
Industrial Motivation → Materials up-scalingReduction of time to market & reduction of costs
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I-TRIBOMAT
WORKFLOW
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I-TRIBOMAT
B2B RELATIONS
Excellence Centre of Tribology, www.ac2t.at
TRANSLATOR
CASE
CONTEXT
SIMULATION OF
WEAR - UPSCALING
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Lifetime limited by wear of circular harrow
High costs as all tooth have to be exchanged simultaneously
Maintenance not plannable due to wide range of soil conditions
TILLAGE MACHINE
BOTTLE NECK
www.hanki-ker.hu
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Understanding of the business case
Understanding of the industrial case
Analysis of the experimental data available within the client
Translation to modelling workflows
Strategy for model validation
Translation of modelling results to information understandable and
usable by the client
Economical Balance
TRANSLATION STEPS
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Industrial Needs
Increased life-time
Decreased harvest time
Stoppage during harvesting season = catastrophic
Increased reliability
Complete season without stoppage
BUSINESS CASE – INDUSTRIAL CASE
AC2T research was the consortium leader of a group of SMEs and large
companies representing the production chain:
Busatis , Fronius, Voestalpine Böhler Welding
Josephinum Research, FH Wels
www.amazone.at
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Business case
New material and design concept for teeth of tillage machine
Material wear resistant, predictable life-time
Enforcement of selected locations on tooth
Aim was a shorter development environment for material design and selection
in agricultural machinery components
Production of prototypes
Combined experimental and simulation chain
BUSINESS CASE – INDUSTRIAL CASE
Challenges of wear/life-time simulations:
Contact conditions and environment is typical not a one-to-one match of
the real system
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Tillage production and machinery – former approach
Classical design process for mechanical strength
No modelling of wear or lifetime
Prototyp production of one material type
Verification: Field test
duration:1 week; only possible
inhomogeneous conditions (weather, season)
ANALYSIS OF THE (EXPERIMENTAL) DATA
AVAILABLE WITHIN THE CLIENT
www.hanki-ker.hu
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Former apporach
TIMELINE
CAD Field test
1 week
VerificationDesign Production
forming, machining
Total development time:
years
No modelling of wear or life-time
only mechanical material properties were taken into consideration
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MODELLING WORKFLOW
Field test duration: > several days
Lab test duration: < 1 hour
Simulation duration: ~ 5 hours
Josephinum Research
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Former apporach
New approach
NEW TIMELINE
CAD Field test
1 week
VerificationDesign Production
forming, machining
CAD
Wear
Simulation
5 h
Forming Field test
1 week
Laser-
Cladding
5 min
Material pre-
selection
2 h
Labtest
1 day
Total development time:
years
3 months
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MODELLING WORK FLOW
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Validation G65
MODELLING – FIRST VALIDATION STEP
WEAR RATE FOR EACH MATERIAL
Quick model test (ASTM G65): 15 min5 h on PC
ASTM G65
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MODELLING
MODEL OF REAL SYSTEM
1.5 cm
33
cm
translation tractor motion;
typical speed: 2.2 m/s
Rotation motion;
typical speed: 5.9 m/s
translation & rotation
Simulation approach:
counter clockwise rotation
leading surface
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MODELLING
CFD-FEM
Velocity profile takes
rotation and driving
motion into account
Wear rate calculated
per rotation of tooth
Geometry update of the
FEM mesh
soil density: 1250 kg/m³ (38% clay, 32% silt, 30% sand)*
*Abrol V, Sharma P. (2012) Resource
Management for Sustainable Agriculture
soil: assumed as incompressible, isotropic, homogeneous
viscoplastic material with a single-phase laminar flow
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WEAR ACCUMULATION &
GEOMETRY UPDATE
(calculated positions: each 45°; geometry update: once every 360°)
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MODELLING
VALIDATION
newly developed experimental
laboratory test
Position specific wear rates on tillage
Josephinum Research
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Benefit
Stoppage during harvesting season
Indirect benefit
Lower load on field – less damage
Less wear – lower consumption of metal parts
More sustainable agricultural production!!!!!
(SOCIO-)ECONOMIC BALANCE
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CONCLUSIONS &
DISCUSSION
We established a framework for abrasive wear prediction
on machinery components
Our results show good qualitative and quantitative agreement
with experimental measurements
This framework constitutes an engineering tool for enhancement and
optimization of wear protection via identification of critical wear zones
The establishment of a relation between laboratory and field test
facilitates the evaluation and selection of machinery materials
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XTribology:
The topics presented are based on research projects carried out at the “Excellence Centre of Tribology”
(AC2T research GmbH, Wiener Neustadt, Austria) with the support by the Austrian program
(Project XTribology, no. 849109) and by the concerned program management institutions, viz the Austrian Research
Promotion Agency (Österreichische Forschungsförderungs-Gesellschaft mbH), on behalf of the Federal Government,
as well as by the Government of Niederösterreich, Wien, and Vorarlberg. We are as well grateful to the involved
company partners and scientific partners for their financial support and for the fruitful cooperation.
i-TRIBOMAT:
This project has received funding from the European Union’s Horizon 2020 research and innovation programme
(innovation action) under grant agreement No. 814494 (Call: H2020-NMBP-TO-IND-2018)
XTRIBOLOGY & i-TRIBOMAT ACKNOWLEDGEMENT
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to existing third party intellectual property rights, especially patent rights including copyrights, trademarks and designs. In particular, we cannot give any warranty, whether express or implied, or
guarantee product properties in the legal sense. We reserve the right to make any changes according to technological progress or further developments. The performance of products described
herein should be verified by each user with experiments (designed for the respective application) which are to be carried out by qualified experts. Suggestions for uses or applications are only
opinions. Reference to trade names used by other companies is neither a recommendation, nor does it imply that similar products cannot be used.
DISCLAIMER
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