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This research project experimentally and numerically investigates the growth and coalescence of pre-existing voids for a wide range of stress states in a ductile matrix with a special focus on shear dominated loading conditions and presents quantitative kinetics data for these processes. The results obtained contribute to further development of current fracture models by generating reliable experimental data for void growth and coalescence, which can be used to evaluate the existing fracture models. A lead-containing copper alloy has been selected as model material, in which lead inclusions act as pre-existing voids – as demonstrated by unit cell numerical simulations for a wide range of stress states. A second copper alloy of similar composition, but without lead allows us to obtain mechanical properties of the matrix. By comparing the behavior of the two alloys it is possible to evaluate the effect of the voids on the macroscopic mechanical behavior. The model materials are deformed and fractured in combined torsion / tension tests and notched tensile tests to subject them to the desired wide range of stress triaxialities. Quantitative fractography and metallography provide the desired kinetics data on void shape, size and orientation, that can be correlated with numerical simulations, as well as existing void growth and coalescence models. The influence of stress-state and micro-structural characteristics on void growth and void coalescence – particularly for zero nominal stress triaxiality conditions – is illustrated at the hand of the results of the investigation. Contrary to the predictions of current micromechanical models, significant growth of small voids resulting in moderate increases in the total void volume is observed in torsion specimens. This growth may be triggered by the developing texture of the matrix material and particularly by twinning. By means of FEM computations with 3D single cell simulations comprising initially ellipsoidal voids, the effect of the initial texture and texture evolution is emphasized. The numerical results showed that the experimentally observed texture of the material accelerates void growth under relatively high stress triaxialities, and possibly allows growth of small voids under low and zero stress triaxialities. The initial shape of the lead inclusions and possibly their growth, was found to be dependent on their initial size. These results emphasize the need for a complete and rather detailed modeling of microstructural and deformation features in order to model damage process correctly. The presented work contributes to a better understanding of void growth and coalescence fracture processes, particularly under shear dominated loading conditions.

Therapies using so called extracorporeal shock waves (Extracorporeal Shock Wave Therapy ESWT) have become current medical practice in orthopedy and traumatology. In order to understand and to optimize the effect of shock waves in clinical applications, medical results must be correlated with well characterized mechanical stimuli. This thesis has an industrial scope. It contributes to the comprehension of the generation and propagation of pressure waves in human tissues with the aim of improving existing ESWT therapies and of providing the industrial partner with tools for the design of a new generation of extracorporeal shock waves devices. The adopted general approach is based on a combination of experimental characterization and analytical and numerical modeling of wave generation and propagation phenomena in a medical treatment device and in biological tissues. Firstly, the characterization of a wave generator is based, on the one hand, on measurements of the dynamic behavior of the moving parts coupled with rigid body simulation, and on the other hand on measurements of wave propagation by means of a Hopkinson bar coupled with finite elements simulations. This characterization has shown that the generator produces very reproducible stress pulses. The simulation technique allows designing a new wave generator with a higher energy range and with well controlled operating parameters. The new design is covered by a patent. Secondly, a measurement technique for generation and propagation of pressure waves in soft animal tissues has been developed that is based on PVDF gages. The applicability of these gages has been qualitatively validated by comparative measurements with a Hopkinson bar. The perturbation effect of the gage, acting as an inclusion in the medium to be characterized, has been evaluated by means of simulations of wave propagation in water. Comparison with measurements in soft tissues suggests that it is negligible for pressure measurement in this type of materials. An independent calibration of the gage could however not be performed. Finally, measurements of wave propagation in pig skin and fat using PVDF gauges showed good reproducibility for a given sample. They highlighted the influence of the supply pressure of the wave generator on the amplitude and on the attenuation of the wave in tissues. Moreover, the dependence between the amplitude of the wave and its propagation velocity suggests a non-linear viscoelastic behavior of soft tissues as well as the need of a constitutive model for high strain rates. Simulations of wave propagation using a known hyperelastic constitutive model highlighted the difficulty of modeling such soft tissues. A viscoelastic non-linear constitutive model based on power laws was considered and is an interesting candidate for future simulations. The simulation technique for wave generation and propagation in a solid (aluminum) and a liquid (water) has been validated by comparing its results with measurements performed in these materials (strain gages and PVDF hydrophone respectively). Simulations of pressure wave propagation validated for solids and liquids showed that they can be applied to biological tissues modeled using a known constitutive model; they are a tool for any other simulation using more complex constitutive models. This work contributes to a broader study aimed at establishing and validating constitutive models for biological materials suitable for use in simulations of wave propagation.

This work deals principally with two important issues and their interrelation: the evolution of damage in coated cemented carbide tools used for cold forming, and the assessment of mechanical behavior of cemented carbides under compressive contact loads. Damage evolution in ironing tools is qualitatively investigated by planar and cross-sectional microscopical observations. Several mechanisms of damage are identified by taking into account the circumferential distribution along the surface of the ironing tools: coating wear and/ fracture, plastic deformation and fracture of the substrate. In the context of damage location in the substrate, the emphasis is put on the study of damage following all processing steps in substrate and coating preparation. This analysis aims at determining whether the substrate is weakened or not by the mechanical and chemical pre-treatment prior to coating. Spherical indentation testing is used as an experimental procedure to reproduce the compression stress state during cold forming. Large indenter tips (300 microns) are employed for testing cemented carbides in an effort to minimize the effects of material structural inhomogeneities. The behavior of cemented carbides under compressive loads is governed by the reversibility of deformation induced by indentation. A unique feature revealed by analysis of experimental load-displacement indentation curves is the positive energy balance, in that a gain of energy is evidenced after a loading-unloading cycle. Two hypotheses are developed for interpreting such a behavior: the strain induced martensitic transformation of the cobalt ductile phase and the thermal residual stresses in the composite. Substrate weakening subsequent to mechanical and chemical pretreatment prior to coating is expected to have a particular role on the indentation behavior of cemented carbides. The impact of substrate damage on the indentation parameters is identified by a parametric study using finite element simulations in which the damage is considered uniform. In reality, the damage distribution over the surface is rather irregular. In this context, a statistical approach is used for assessment of the material indentation parameters. The failure of coating/substrate systems under compressive contact loads is investigated by finite element simulations. The first failure events are identified by considering that system failure occurs either by substrate plastic deformation or coating fracture. The response of coated systems to spherical indentation is synthesized in damage diagrams which can predict whether the coating or the substrate fails first. The possibility for using such diagrams for assessing the evolution of damage in coated cemented carbide tools is highlighted.

The scribe and break technique (or dicing) is a widely employed method in the industry of semiconductors to separate infrared laser diodes made from gallium arsenide (GaAs). The scribing step allows to create a precursor crack which is then propagated during the breaking step, along preferential {110} cleavage planes of GaAs. The main drawback of the scribing process is that it generates a lot of undesirable cracks and particles that degrade the performances of devices. In this dissertation, we have investigated the indentation process as a possible way to replace the scribing operation. For that purpose, we have investigated the morphology of the crack field and the cracking sequence as a function of the indenter geometry (shape, apex angle) and experimental conditions (maximal load, loading rate). Such investigations have been made with the help of a new tool: the in-situ SEM instrumented indentation which allows us to establish the cracking sequence and to correlate direct observations with the load-displacement histories. A new experimental technique has also been developed: cleavage cross-sectioning techniques allow us to determine the morphology of the crack field beneath the surface. The second research axis was focused on the interaction between deformation mechanisms and crack initiation. These investigations have been conducted with the help of Transmission Electron Microscopy (TEM) and cathodoluminescence. In the first part of the dissertation, we have shown that acute wedge indenters with an included angle of 60° promote the formation of a well defined half-penny crack, the nucleation of which is affected by load rate and indenter radius. The relation between the final half-penny crack size and the maximum indentation load was made with the help of a fracture mechanics model. The crack field has been compared for several indenter shape including conical (60° and 120° apex angles), cube corner and Vickers indenters. In the second part of this dissertation we have determined that the indenter apex angle influences the slip systems that are activated and the nature of dislocations that are found under the indenter. In particular, we have shown that below 60° wedge indenters, mainly diverging slip systems are activated whereas under obtuse wedge indenters, mainly converging slip systems are activated. The converging pattern predominant under obtuse indenters is correlated with a delayed half-penny crack formation and is so interpreted as a plastic shielding phenomenon. Some experiments have been performed on commercial devices under production conditions. Although some adjustments are needed to reduce the chipping-out effect that occurs at the indenter extremities, the results are encouraging.

Rotor-bearing systems take an important place in engineering applications and are used in many industrial systems: gas turbines, compressors, jet engines, machine-tool spindles, etc. The spindle is an essential component of manufacturing systems involving metal removal processes. Its performance largely influences the quality of machined parts. This importance has increased with the advent of High Speed Machining, High Productivity Machining and Hard Machining with low lubrication. In machining, manufacturers aim at higher cutting speeds and feed rates in order to increase productivity. These trends imply higher rotational speeds for spindles but also higher cutting forces. At the same time, manufacturers wish to improve surface roughness and tolerances of the machined parts. To meet those goals, it is essential to master the dynamic behavior of spindles. Stiffness is a fundamental parameter controlling the static and dynamic performances of the spindle. Modeling and controlling the dynamic behavior of spindles is a complex problem, because of the non-linear nature of the bearing stiffness, of its speed dependence and because of thermo mechanical effects associated with the heat dissipation in the bearings. In this dissertation, a mixed experimental-numerical method is presented for evaluating bearing stiffness of very high speed rotor-bearing systems. This method focuses on determining the stiffness properties of angular contact ball bearings used in the design of high-speed spindles for machine-tool applications. The goal of this method is to provide accurate and reliable stiffness data to improve dynamic predictive models of spindles. These models will then serve to improve and facilitate the design of high-speed spindles. A special attention is paid to the speed dependence of the bearing stiffness. The mixed identification method is based on the comparison of an experimental modal model with a numerical modal model of spindles. An optimization procedure based on a non-linear least square fit algorithm is used to estimate the bearing stiffness. The optimization criterion combines error functions based on natural frequencies and mode shapes. Based on the measurement of frequency response functions, the experimental modal parameters (natural frequencies and mode shapes) are extracted. In order to match numerical modal parameters with the experimental ones, the iterative optimization procedure updates the numerical parametric model. The model parameters are the bearing stiffness parameters to estimate. The procedure terminates once the error between the experimental and numerical parameter falls below a predefined threshold value. At this point, the bearing stiffness estimation is completed. The numerical model was developed to be easily implemented in a commercial finite element software. Moreover, the 3D finite element model allows to take into account all the surrounding structural elements which can influence the dynamic behavior of the spindle. The ball bearing is modeled as a stiffness matrix including radial, axial, tilting and coupling terms. On the other hand, a test rig using contact-free capacitive sensors to measure frequency response functions of motor-spindles was developed. Measurements can be performed either under non-rotating conditions or under rotation. Experimental modal parameters are extracted using a traditional curve fitting method. Several numerical applications were used to assess the performances of the identification method and validate it. As an example, the proposed identification procedure is applied to a mid-size (7kW) motor-spindle running at up to 70'000 rpm. Two test cases are presented: test spindle equipped with angular contact ball bearings with a contact angle of 15° and then 25°, commonly used in industrial high-speed spindles. For these two configurations, the goal is to estimate bearing stiffness and validate the method with experimental data. Several identifications were conducted at various rotational speeds. The rotational speed range was chosen to highlight the decrease in the bearing stiffness with rotational speed. In both test cases, we observed significant decrease in axial bearing stiffness with speed. With a contact angle of 15°, at 66'000 rpm, the axial stiffness can drop to 40% of its value at zero speed. With a contact angle of 25°, at 54'000 rpm, the axial stiffness can drop to 30% of its value at zero speed. The behavior of the radial stiffness is different in the two test cases. With a contact angle of 15°, the radial stiffness remains almost constant over the whole range of rotational speed. Conversely, with a contact angle of 25°, the behavior of the radial stiffness is similar to the behavior of the axial stiffness. At 54'000 rpm, its value can decrease to less than 40% of its value at zero speed. The obtained results are in good agreement with the literature and with numerically predicted stiffness values.

Today's vehicle must be efficient in terms of gas (CO2, NOx) emissions and fuel consumption. Due to improvements in material and oil, the continuous variable transmission (CVT) is now making a breakthrough in the automotive market. The CVT decouples the engine from the wheel speed. CVT enables significant fuel gains by shifting the engine operating point for specific power demands. This optimization of the operating point enables a reduction of this fuel consumption. A CVT is constituted of two pulley sheaves, one fixed and the other one movable in its axial direction when subjected to an external axial force, in general hydraulic. The transition from the minimum to the maximum speed ratio is continuous and an infinite numbers of ratio is available between these two limits. An intermediate element (a metallic belt or chain) transmits the power from the input (the primary) to the exit (the secondary) of the CVT or variator. Further improvements of the fuel consumption and gas emission are still required for example by improving the variator efficiency. Increasing hydraulic performance or decreasing mechanical losses by reducing the axial forces are some solutions. The latter method is not without risks. The diminution of the clamping forces increases the slip between pulley sheaves and the intermediate element. If the axial forces decrease too much, high slip values can be reached and cause damage to the pulleys and the intermediate element. Control of the slip is an attractive solution to decrease the clamping forces in order to safely improve the variator efficiency. The objective of this thesis is to understand and model the slip of each pulley and establish analytic tools dedicate to the variator control. The slip study and the theoretical approach of the CVT variator is applied to the slip control of the variator with a chain. The contribution of this work is threefold. Firstly, the slip and the traction coefficient are analyzed for each pulley. The slip analysis of each pulley is then used to define a new slip synthesis as the summation of the slip of each pulley. It is demonstrated that the slip and the traction coefficient are different for each pulley and depend on the speed ratio of the variator. In low ratios, both the secondary pulley and the primary pulley slip, but only the primary reaches macro slip. For middle or higher ratios, only the secondary pulley slips and reaches high values of slip. Experiments show that the pulley with the smallest clamping force limits the system. Secondly, based on kinematics, force equilibrium, elastic deformations of the pulleys and the intermediate element, a detail model of the variator is proposed. The principal results are the estimation of the clamping forces, of the traction curve for each pulley and of the chain efficiency. These results are implemented in a simpler model that describes the variator dynamics. This last model considers the two pulleys and the intermediate element as free bodies. The hydraulic circuit and the actuators, which are important to take into account for control, are also modeled. Thirdly, the new slip synthesis and the results of the dynamic models are applied to the slip control of the variator in order to improve the efficiency. A pole placement law is applied to the actuators to control the flow that enters or exits the pulleys. With this law, the actuators are decoupled and the bandwidth is increased sufficiently for actuators dynamics to be neglected. The primary and the secondary pressures are decoupled and linearized by an input-output feedback linearization. The resulting system is linear and linear control theory can be applied to control the two pressures. The speed ratio is controlled by the primary clamping force. The secondary pressure is chosen as a function of the control mode of the variator: standard mode or slip mode. In standard mode, the intermediate element is overclamped by 30%, whereas in slip mode, the secondary clamping force is set as a function of the desired slip. By controlling the slip at 2%, the mechanical efficiency was increased by more than 2% and the clamping forces reduced by more than 30%. For the slip control, a proportional-integrator law and a model reference adaptive control (MRAC) are presented and the performances compared. The MRAC gives slightly better results.

Ductile fracture in steels is essentially due to cavity nucleation, growth and coalescence. Once voids are initiated in the metallic matrix, and the deformation continues to increase, voids grow in size and finally coalescence to fracture. This dissertation investigates ductile fracture initiating in the bulk of material for relatively low stress triaxialities. Particularly zero stress triaxiality conditions, i.e. under shear dominated loading, provided for an isolated study of single mechanisms such as void nucleation, and shear localization. In this dissertation, we show that the idealized division of ductile fracture in a sequence of elementary processes is not appropriate for the selected quenched and tempered VAR steel. Ductile fracture is nucleation-controlled, i.e without meaningful void growth. Void nucleation occurs by debonding of tempering carbides from the surrounding metallic matrix. The carbide-matrix interface strength is estimated by a dislocation-based stress decohesion model. By means of FEM computations with a unit cell simulations comprising a single carbide, the role of the carbide-matrix interface strength is emphasized. The results of FE computations demonstrate that the carbide-matrix interface strength is the key parameter controlling damage initiation and its evolution to fracture.

The research presented in this thesis addresses the design of gear drives for micro engineering applications, and was performed in collaboration with a watch manufacturer. Gears have long been found in many fields of mechanical engineering. Their use in watches satisfy specific constraints: small dimensions, little or no lubrication and unusual performance specifications. A literature review allows us to establish a catalogue of existing gear profiles, and a synthesis of profile analysis and generation methods. On the basis of this assessment, we define knowledge gaps which we propose to bridge in the present work by reaching the following objectives: 1. Characterize the behavior of existing gear profiles used in the watchmaking industry (nominal profiles, but also profiles affected by shape errors and axes misalignment errors); determine their kinematic and static performances, and their transmission efficiency. Use these results to compare various profiles on an objective and rigorous basis. 2. Formulate the equations necessary to calculate the tooth profiles using conjugate conditions differing from the tradition-al kinematic conditions ( i.e. imposing the transmission ratio) 3. Work out a design methodology for gear profiles relying on the results obtained while working on the first two objectives To reach those objectives, we develop a computer code allowing us to evaluate the performances of the profiles. The diversity of existing profiles led us to formulate a generic geometrical representation applicable to all profiles, while allowing us to use the same analysis code. The developed tool is then validated by simulating profiles, the behavior of which is known analytically. To calculate conjugate tooth profiles respecting a static criterion, we use the classical theory again, adding a new equation to it, which we derive from a balance of power. We present this equation for the three dimensional case, and the planar case. The resolution method for this equation, valid for static conjugated cams (i.e. a unique pair of teeth), must satisfy a supplementary condition that ensures that the imposed torque ratio leads to an average kinematic ratio compatible with the desired number of teeth. A numerical method was developed for the planar gears case that establishes the range of torque ratios satisfying the imposed average transmission ratio. The lower and upper bounds of the range of solutions are defined in terms of geometric and efficiency considerations, respectively. The proposed approach is illustrated and validated by some profiles computations. In parallel to those theoretical developments, we designed and built a test bench to characterize experimentally the performances of gear profiles, (altered or not by various shape or misalignment errors) under operating conditions similar to those prevailing in a watch. The last part of the thesis provides a critical discussion of these developments places them in a broader context and comments how they could be generalized in future research works.

Gas Lubricated Herringbone Grooved Journal Bearings (HGJB) have long been used in equipment such as navigation systems, optical scanners for laser printers and high speed cameras and disk spindle for flyhead testers. All such applications are characterized by a relatively small size (journal diameter