Fatigue and wear, degradation of materials in complex work environments
- A unique benchmark for quality testing of various (non)commercial fatigue solvers in the area of high-cycle multiaxial analysis (MKP, DummyModel)
- Experimental testing of the contact fatigue in blade and rotor alloys and as a result of this application, the construction of model (test) contact pairs (Doosan Škoda Power s.r.o.).
- Applications for an increase in the usable life of water turbines (Mavel, a.s.).
- Predictions of the fatigue strength of large-diameter shafts of extra large mining machines (Noen a.s.).
- Prediction of fatigue strength and durability of railway wheelsets (Bonatrans a.s.).
- Fatigue strength of weld points (Bobcat CZ a.s.), durability of mixer drives (Unipetrol Litvínov a.s.).
- Applications for an increase in the useful life of aeroplane motors (GE Aviation).
- Development of new types of tree and T-hinge turbine blades to minimise the concentration of stress and resulting fretting (Doosan Škoda Power s.r.o).
- Evaluation of the microstructure of samples after fatigue tests and an evaluation of deformation and possible recrystallisation surrounding the openings of fatigue cracks using the EBSD method (VZÚ Plzeň s.r.o.).
- Analysis of microstructures using the EBSD method for samples of repaired welds TN JR VVER 1000 (VZÚ Plzeň s.r.o.).
- Evaluation of local module elasticity of porous materials created by 3D printing using nanoindentation (ProSpon spol. s r.o.).
- Assessment of the state of Kaplan turbine blades at the Štětí hydroelectric power plant (Energia o.p.s.).
- Assessment of the causes of crack initiation in FRAME RST755 welds (UNEX Slévárna, s.r.o.).
- Tests of new types of railway wheels (Vossloh, VYKSA STEEL WORKS).
- Experimental testing and evaluation of axle steels (Ametso Limited).
- Fatigue tests and analysis of damage to railway axles (Lobellix, s.r.o., a Czech company manufacturing axles at a volume of approx. 2000 pieces / month and exported to a number of EU states as well as outside the EU).
- Evaluation of fatigue strength of various model types of axle-to-wheel connections (Technische Universität Chemnitz).
Prediction of material properties in critical applications
- Research and development of technologies for precise radial wheel casting for next-generation turbochargers and new types of gas turbine blades (the project won the Technology Agency of the Czech Republic awards, in collaboration with the company První brněnská strojírna Velká Bíteš, a.s.).
- Research and development of advanced technologies for precise casting of new types of casts of exposed parts of turbochargers from nickel-based superalloys (Czech Ministry of Industry and Trade, business project 2020).
- Interactions from the determination of material characteristics of railway applications, especially in the area of material fatigue, through collaboration in the optimisation of materials used, to the highly complex production processes in axle manufacture, or expert support of the company in negotiations with international customers and certified authorities (state-of-the-art axle for high-speed trains BONAXLE®, Bonatrans Group, a. s. producer of railway wheelsets, the results for example utilised by Deutsche Bahn).
- Tests of low-cycle fatigue of materials used for the construction of steam turbines under regular and increased temperatures (EKOL, a.s).
- Characterisation of delivered materials and long-term creep testing. Development of original methodology for the measurement of acoustical emissions during creep ruptures. Development of special inserts for acoustic emissions during creep tests (ÚJP Praha a.s.).
- Further uses: Aircraft Industries, a.s. (fatigue tests of structural elements), Hanon System Autopal s.r.o. (cyclical tests under increased temperatures), Institute of Applied Mechanics Brno, Ltd. (mechanical tests of energy device welds), Parma TP Engineering Italy (new metal materials for additive technologies), Bosch Rexroth AG Germany (fatigue tests), Voestalpine Giesserei Traisen GmbH (comprehensive creep tests and testing methodology).
Tribology
- Application of developed methods of colorimetric interferometry in the design of unique tribometers. For example, the one-of-a-kind tribometer with its control software Achilles, subsequently added infrared camera, capable of measuring the thickness of films, as well as the temperature of friction surfaces and the lubricant itself (K.K.IRISU / Japanese automotive manufacturer).
- Applications focused on the development of new polymer films for sliding bearings, reducing friction and wear of the sliding bearing in critical phases of operation, for example in the crankshafts of combustion engines. Unique / certified tribometer with optical module for the development of sliding bearings under transient operating conditions (Daido Metal).
- Optimisation of bearing design, lubrication of rolling bearings, lubrication type and object geometries for the verification of predictive lubrication models (INA Schaeffler).
- The field of gear load-capacity, tested by an internally developed tribometer allowing for tempering of the internal chamber up to 150°C and a friction surface speed of up to 4 ms-1. University of Munich, Gear Research Centre (FZG).
- Applications for the development and use of lubricants and lubricant additives in mechanical engineering and medicine: the influence of lubricant aging on the efficiency and useful life of rolling bearings (INA Schaeffler, Koyo Bearings), rheological and lubricant properties of coolants (United Technologies), the influence of water contamination on the lubrication of transmission systems (Wikov), the verification of lubricant layer thickness predictions based on new rheological models (Georgia Tech), development of traction lubricants for friction variators (K.K.Irisu), influence of the molecular weight of hyaluronic acid on joint replacement implant lubrication (Contipro), analysis of lubricant properties (Lubricant), development of hydrogel as an alternative to joint cartilage (Kyushu University), development of the texture of joint replacement implants for an increased useful life (Kanefusa, Meijo University), lubrication of actuator components of satellites for space applications (Honeywell), development of lubricants for rail transport (Tribotec).
- Applications for the development of targeted delivery of foreign particles into contact or the prevention of their negative effects: optimisation of sanding and lubrication processes for rail vehicles (Tribotec), development of nanoparticle-based lubricants (Nanotech Europe), assessment of the properties of nanoparticles for tribological applications (Poličské strojírny, a.s.).
- Applications for the development of coatings and layers reducing
friction and wear: development of coatings and layers replacing environmentally
harmful coatings and layers on cutting tools and aircraft landing gear shock
absorbers (SHM), optimisation of sliding layers to minimise friction (Ibond),
evaluation of the level of friction on the plastic casing and bellows covers of
machine tools (TOS Hulín, Hestego), tyre wear depending on composition
(Continental),
development of rotary shaft seals (Edwards). - Applications in the area of machine component design and joint replacement implants: influence of targeted topography on friction and wear of joint implants (Meijo University, Kyushu University), optimisation of the casting process for intermediate machine parts (Feramo), effects of silicon board production technological processes (ON Semiconductor), analysis of sintered materials lubrication (TU Munich).
Fluid mechanics and heat and mass transfer
- Use of equivalent temperature measurement method processes and the evaluation of thermal sensation in the optimisation of air distribution into vehicle passenger compartments (Škoda Karoq, Scala, Kamiq, VW Forschung, MAN BUS, EMPA).
- Equivalent temperature methods used for the development of new technologies for the radiant heating of passenger compartments in electric vehicles (Škoda, VW Forschung, MAN BUS, EMPA).
- Monitoring of aerosol microclimate in vehicle passenger compartments under regular operating conditions with the goal of improving the scrubbing of fine particles from the air delivered by the HVAC unit – biosensorics (Škoda, VW Innovations).
- Measurement of filtration material quality, materials with low pressure loss and high efficiency in virus, aerosol-sized particle capture (Nafigate, SPUR and others during COVID19).
- Development of fuel nozzles for turbine motors PBS TJ100, TJ150. Removal of injection pulsation and improvement of fuel injection characteristics, leading to lower mileage, vibration, and heat load of motors (První brněnská strojírna a.s. Velká Bíteš).
- Design and creation of combined three-media nozzles for waste fuels.
- Development of a nozzle for waste fuel combustion (Polymer suspension with solid particles up to 2 mm). Verified and used in actual operation (KOSA Offenbach), proven reduction in ash and NOx emissions. In collaboration with ERC GmbH Germany.
- Two-fuel effervescent nozzle, swirl nozzles for industrial burners provided to the INDAVER Belgie and BP Dormagen incinerators.
- Pressure nozzles for industrial burners. Design of changes to existing nozzles. Improvement of spray quality for reduced emissions in retrofitted nozzles (PBS a.s. Třebíč).
- Development of combustion system of a small turbine aeroplane motor for alternative fuels; optimisation and experimental testing of changes to the TJ100 turbine motor with the goal of optimum combustion, low CO and NOx emissions and reduction in smoke (PBS Velká Bíteš, a.s.).
- Industrial burners with an effervescent atomising system for reduced emissions (První brněnská strojírna Třebíč).
- Design of injection nodes for biogas plants (VÍTKOVICE POWER ENGINEERING a.s).
- Design of steam aftercooler solution (EKOL spol. s r.o).
- System for the control of the internal environment based on equivalent temperature and comfort preferences for individual body parts (processes applied to HVAC control systems of car platforms of VW, such as Octavia IV generation, Golf 8).
- Increased efficiency of a system for fine particle filtration in the passenger compartment (Škoda Auto a.s.).
- Development of special systems for personalised microclimate in aeroplane cabins for temperature, air inflow humidity and seat heating / cooling management (IBP Hozkirchen, Airbus, iSPACE project).
- Special breathing simulator – simulations of any healthy or pathological breathing, for individual lobes. Collaboration with the University of Cyprus in developing magnetic fibres for the targeted delivery of medicine (field of personalised medicine). The simulator was also chosen as respiratory tract model for benchmarking verified computer CFD simulations with 8 teams of the SimInhale project.
Dynamic machine / machine mechanism behaviours
Results and outputs of measurements and
experiments are only used to determine the initial boundary conditions for
mathematical models, and to verify theoretical calculations and designs with
real data. Experimental approaches and measurement methods have a broad
application in physics, mechanics, mechatronics, materials engineering and the
energy industry. Formulation of recommended measures for the construction and
utilised materials with the goal of a minimisation of noise and vibrations, as
a result of complex measurements. One example might be:
- The measurement and analysis of the primary mechanisms of industrial sewing machines, reduced operating vibrations (AMF Reece, Anita B, Minerva).
- Noise reduction in machines, assembly of a noiseless machine (Koenig&Bauer, Tajmac ZPS, Wikov).
- Control and initial run bench for headstocks and milling heads (TOS Varnsdorf).
- Cutting mechanism balancing (Preciosa Ornela).
- Noise and vibration measurement and analysis of unmanned helicopter, antivibration hinges, development of test benches (Modelárna LIAZ).
- Optical methods for the evaluation of rotary part geometry, thread detection (Continental, Knorr Bremse).
- Development of machines for the continuous measurement of the mechanical properties of yarns and fibres (Rieter, Glanzstoff-Bohemia).
- Verification of flow and temperature models (PZP, Kovárna a.s.).
- Measurement of torsional oscillation in drive shafts and systems (Škoda Auto, TEDOM).
- Measurement of the temperature expansion of long or combined samples (TOS Varnsdorf, SAB Aerospace).