During its 42 months, the following work has been performed:
Within WP1 “Friction Modelling”, advanced models for the prediction of the friction variation produced by a texture pattern (with respect to the untextured case) have been developed, as well as Reduced Order Models that are able to instantaneously predict the friction variation as a function of the parameters of influence. Experimental tests have been performed on a textured pneumatic U-cup rod seal in order to validate the simulation model and the ROM.
In WP2, a Holistic Design Software, called Mouldtex Optimizer, has been developed. It consists of a simple web platform with a real-time user-friendly visualization that allows users to analyse the effects of the micro-texture on a seal application, for different operational conditions, in terms of friction reduction and demoulding forces. It has an optimisation module which reveals the optimum texture which provides the highest friction reduction for a specific application and operational conditions in real-time. The tool has the capability of being expanded, easily adding different materials, geometries and/or applications.
Within WP3 “Laser Texturing”, we have improved the precision of mould texturing through pico-laser based techniques. The physical mechanisms underlying laser-matter interactions have been analysed, leading to the development of a multiscale computational code that is able to correlate the laser parameters with the surface pattern features. We have developed an adaptive optics configuration for the accurate and dynamic control of the pico-laser irradiation scheme and a prototype pico-laser system combining the modelling software and adaptive optics enabling reliable and accurate formation of the desired texture on the mould.
Within WP4 “Mould Tool”, a workflow has been defined in order to take into account the possible impact of both the moulding and demoulding processes after the best texture combination is defined with the holistic software. In addition, a highly effective sol-gel coating that enhances the demoulding process has been developed. Finally, a prototype of a 5-axis laser system with an innovative miniaturised head as well as other beyond-the-SOA features has been developed and optimised.
In WP 5, an innovative optical system for the in-line quality control of the seal texture has been developed. Mould etching and regeneration procedures have also been developed within this WP.
Finally, in WP6, three pilot lines have been set up for demo purposes: one for the production of surface textured moulds, another for the production of a V-ring rotational seal and a third one for the manufacturing of a U-ring translational seal.
