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R&D collaboration among Academy and automotive industry - The TriboFlex
consortium example
Presentation · November 2013
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University of São Paulo
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 R&D collaboration among Academy and
automotive industry
The TriboFlex consortium example

DESAFIOS
TRIBOLÓGICOS EM
MOTORES FLEX FUEL

Seminário “Direcionadores Estratégicos e Boas Práticas de Gestão de

Tecnologia e Inovação no Brasil”, Campinas, 6/Nov/2013

Dr. Eduardo Tomanik

MAHLE Metal Leve SA 1
 Índice
1- Introduction

2- Challenges of a R&D automotive consortium

3- The “Tribo-Flex” consortium

4- Final Recomendations

UNICAMP – Seminario 10 anos GEIT Ind /Univ/ - Tomanik Dec/2013 2

 Index
1- Introduction

2- Challenges of a R&D automotive consortium

3- The “Tribo-Flex” consortium

4- Final Recomendations

UNICAMP – Seminario 10 anos GEIT Ind /Univ/ - Tomanik Dec/2013 3

 Do we should do R&D?
1) On internal combustion engines? (they are not dissapearing ?)
2) .. with bio-etanol fuel? (it is competitive?)
3) ... through univeristy-company consortia?
4) .... here in Brazil ?!
if yes, how to do?

4
 1) Should we do R&D on ICE?
2030 Worldwide Vehicle Fleet - Forecast
MPI still
significant
In 2030, 90% of the car will
Gasoline DI with still have ICE.
Market share %

new systems,
e.g. CAI

D I with new
systems, e.g. HCCI

E-cars, Fuel cell CNG/LPG* HCCI: Homogeneous Charge

Diesel (DI & hybrid) Diesel – New Systems Compression Ignition,
Gasoline – New systems Gasoline DI (&hybrid) CAI: Controlled Auto Ignition
Gasoline MPI
Source: Continental estimation based on EUCAR 2002, SV, VDA, OEM-Feedback, CVA, CSM 11/2010. 5
 2) Should we do R&D on bio-fueled engines?
Considering well to wheel, use of bio-fuels bring more CO2 reduction
than pure electric cars.

Adapted from “Mobility 2030: Meeting the challenges to sustainability” World Business Council for Sustainable Development
6
 2) Should we do R&D on bio-fueled engines? (cont.)
a) Ethanol has also potential to reduce CO2 by optimized combustion.

b) Ethanol production is growing.

Otto

Diesel * 109
(2011)

MTZ Feb 2012

 3, 4) Should we do R&D through consortia of companies and
universities in Brazil?

The automotive industry is the major R&DI player in both $ and

Head Count in Brazil.

Spending on R&D (S.Queiroz, Estratégias de Inovação ....)

8
Well, and how to do collaborative automotive R&D in Brazil?

9
 Index
1- Introduction

2- Challenges of a R&D automotive consortium

3- The “Tribo-Flex” consortium

4- Final Recomendations

UNICAMP – Seminario 10 anos GEIT Ind /Univ/ - Tomanik Dec/2013 10

Reasons, expectations and background differ among the partners

Industry University

“know-how” “know-why”

11
Tomanik, Challenges and Best-Practices on Automotive Industry/University R&D Consortia
 Importance for consortium success perception

There is large difference on the

expectations from industries and
universities

Tomanik, Challenges and Best-Practices on Automotive Industry/University R&D Consortia

12
Main expected outputs from the consortium.

Tomanik, Challenges and Best-Practices on Automotive Industry/University R&D Consortia

13
 Items affecting consortium satisfaction

1. Clear and challenging objectives

2. Participant commitment

3. Research subject importance to the organization.

4. Mutual benefits

5. Good industry-university relationship

14
 Index
1- Introduction

2- Challenges of a R&D automotive consortium

3- The “Tribo-Flex” consortium

4- Final Recomendations

UNICAMP – Seminario 10 anos GEIT Ind /Univ/ - Tomanik Dec/2013 15

 DESAFIOS
The Tribo-Flex consortium TRIBOLÓGICOS EM
MOTORES FLEX FUEL

Discussion about the consortium started in 2009 motivated by the tribological challenges (wear, fuel
dilution, corrosion etc.) on Brazilian flex-fuel engines. Such challenges are peculiar and important both to
industry and academy.

Project scope was defined trough a series of workshop. The consortium started in 2012 Q3 with 50%
government funding (PITE2 da FAPESP) and 50% from the company particpants.

The project is pre-competitive and has strong focus on development on developing Human Resources on
R&DI and ICE tribology in a way that such HR should be able to support future R&D on flex-fuel engines
both in industry and academy.

Ago 2009 – Workshop at MAHLE Ago 2010 – Workshop at VW

 Brief excursion: what means “Tribology”
Tribology is the science that studies friction, wear and lubrication.
For ICE the aim is generally to reduce wear and friction.

Lubricant film: 0.5 to 4 μm

(Ø human hair: 50 μm)

m
System: performance, efficiency, wear, durability
mm Component: torque, forces, vibrations, clearances etc.
Contact: Contact pressures, EHD, pitting, scuffing, scoring
µm Asperities: fracture, elastic and plastic deformation, “debris” e coatings

17
Adapted from Kenneth Holmberg, TriboBR-2010
 Project Overview DESAFIOS
TRIBOLÓGICOS EM
MOTORES FLEX FUEL

• 3 (+2) years, consortium university – automotive industries, 50% government funded (by FAPESP).
• 6 company participants (Dez/2013). New members with same funding values done by the others.
• Leadership by the Surface Phenomena Lab (LFS) from EPUSP.
• Project “Steering committee” composed by one responsible per company.

18
© MAHLE
 Tribo-Flex consortium DESAFIOS
TRIBOLÓGICOS EM
Main projects: MOTORES FLEX FUEL

• Tribological Characterization of flex-fuel ICE components

• Piston Ring / lubricant / cylinder tribology
• Valve / valve Seat tribology
• Development of computer models for material and components loading
• Development of specialized human resources

Expected project contributions in case of success:

a) Structured knowledge in tribology with focus on:

- coatings (films and oxides)
- Surface texturing / topography on automotive components
- Lubricant additives and ICE material interactions

b) Structured knowledge in modeling and experiment analysis of tribological systems:

piston ring / lubricant / cylinder; valve / interface media / valve seat

allowing that companies and universities deal, with its own resources, future tribological challenges in
flex-fuel engines.
19
© MAHLE
 Tribo-Flex consortium management

Main expectation and main project challenge is to transfer and make perennial the
project knowledge to the industry and inside the academy.

20
 P&D consortia - main difficulties or challenges
How to manage the consortium members was the most cited challenge.
How to reach common perspectives and objectives or how to divide them among the
consortium partners.
Missing or weak leadership, unclear time schedules and fuzzy objectives.

Actions to mitigate the difficulties:

a) Actions based on previous experiences

from the partners and “stake-holders” on
other R&D consortia:
- RECOPE
- MIT Lube consortium
- etc.
b) Studies and proposals of management on
collaborative projects

21
 e.g.: Model of the consortium as a process
Gestão de um consórcio de P&D automotivo envolvendo diferentes
universidades e empresas concorrentes (Jun/2013)

Universidade

Industria

A. Cruz, B. Domingues, F. Kahn, R. Gastim

22
 Project Overview - Tech Meetings
Several meetings/workshops before project official launching.
After project official start:
- Bi-monthly technical meetings to present project progress and invited presentations from experts.
- Steering committee meeting each 4 months
- Dedicated courses

23
© MAHLE
 Copy of some presentations done on consortium meetings

Copy of the most of the presentations done in the workshops can be found on http://www.lfs.usp.br/Portal_Triboflex*
* Till project begin, the site was public open. Later, only for the Project members.
Presentations done during consortium meetings

Prof. Deniol Tanaka – LFS/Poli

Patent applied
 Steering Committee

• Meeting each 4 months

• One representative of each company
• Mgmt. overview of project progress
• Definition of focus for the coming 4 months.

26
© MAHLE
 Some post-graduations by industry professionals

Eficiência Energética (medida) Characterization and performance of

aC:H silicium doped, on ICE cylinder
Samad liners
MSc: Edney Deschauer Rejowski
Rajput Mentor: Dra. Marina Fuser Pillis - IPEN
Patent applied

Identification of operation regimes with

large potential to increase energy
efficiency on SI engines
Márcia Fernandez – TCC de Esp.Eng. Automotiva
Resp: Prof. Marcelo Massarani, USP

Metallurgical and topographic changes on flex-fuel engine

block cylinders
MSc: Dinecio dos Santos Filho
Mentor: Prof. Dr. Hélio Goldenstein - USP
 Publications (by Oct/2013)
01. Tanaka, D. K. Caracterização tribológica de válvulas e sedes. Relatório técnico 24pp
02. Policarpo, E. Inspeção Visual de Válvulas de Motores 8 e 16 Válvulas Submetidos a Ensaios de Choque Térmico. Relatório técnico 22pp.
03. Trindade, E. D.; Zuleta-Durango, A.; Sinatora, A.; Friction and wear performance of MoDTC- and ester-containing lubricants over steel
surfaces under reciprocating conditions. World Tribology Congress 2013 . Torino, Italy, Sep. 8 – 13, 2013
04. RovanI, A. C. et al.. Influence of mass loss and friction coefficient for cleaning of debris sliding system. In: X Brazilian MRS Meeting, 2011
05. Seriacopi, V. et al. Finite element analysis of stresses field in the pin on disc test. In: X Brazilian MRS Meeting, 2011
06. Rovani, A. C. Mermoux, M., Sinatora, A. Influence of the lubricating additive in sliding wear system analyzed by Raman spectroscopy –
IBERTRIB (2013) Porto - Portugal.
08. Lima, Luiz G.D.B.S. et al. Numerical analysis of the influence of film thickness and properties on the stress state of thin film-coated piston
rings under contact loads. Surface& Coatings Technology, v. 215, p. 327-333, 2012.
09. Tomanik E., Profito, F., Zachariadis, D., Modelling the hydrodynamic support of cylinder bore and piston rings with laser textured surface.
Tribology International, Vol. 59, pp. 90-96, 2013.
10. Capitulo 18 Tribologia. Uehara, S. et al. in BRUNETTI, F. Motores de Combustão Interna, Ed. Blucher – MAUÁ. Vol 2., 2012.
11. Trindade, E.; Lastres, L.; Sinatora, A. The role of interfacial media composition and applied normal force on MoDTC friction reduction
effectiveness. 19th Int. Colloquium Tribology. Stuttgart/Ostfildern, 2014.

28
© MAHLE
 P&D em Etanol MCI – Some other initiatives in the field

FAPESP International Workshop Ethanol ICE

(Oct, 2012)

PSA/FAPESP
Edictal Nov.2012;
10 years agreement ;
US$800.000 a.a.
 Índice
1- Introduction

2- Challenges of a R&D automotive consortium

3- The “Tribo-Flex” consortium

4- Final Recomendations

UNICAMP – Seminario 10 anos GEIT Ind /Univ/ - Tomanik Dec/2013 30

 R&D consortia - Final recommendations

 Define clear and challenging objectives;

 Search long term collaborations.
 Produce and share fundamental and applied knoweledge.
Pay attention that they have different meaning for university
and industry.
 Define projects com intermediated goals and deliveries. Do
route corrections when necessary.
 Exercise project management with care and
professionalism. Do periodical and meetings and personal
contacts.
 Define clear responsibilities and what / when is expected at
each project phase/gate.
 Assure that correct understanding was reached by the
diverse partners and “stake-holders”.
 Find ways to survive the bureaucracy to obtain resources
(both financial and human ones)

31
 Simple (tentative) model for P&D consortia

Sound management, clear responsibilities

Start Progress Output

Work hard and early to define Effective communication. Balance fundamental and
clear and objective goals. applied knowledge.
Balance market needs from
Build long term, strategic educational roles. Assure that outputs were
partnerships. transferred and recognized by
the partners.

Built teamwork, mutual trust and commitment

 Long term strategic partnerships with built-in flexibility.  Meet and talk regularly. Get response.

 Built teamwork, mutual trust and commitment.
 Built a shared common vision and strategy from the start
 Make use of a steering committee.
 Clear and defined objectives but leave space for
adjustments and do not get trapped on technical details.
 Effective communication. Background and
perspectives may be different within partners.
 Built, share the consortium roadmap.
 Reach a good balance, eventually even de-couple,
market needs from the educational roles.
 Do not get trapped on IP or formal academics .

Challenges and Best-Practices on Automotive Industry/University - Tomanik Apr/2013 32

 Thanks for the attention.

Thanks also to the professors, industry professionals and funding agencies to make real this and
other R&D consortia.

And to the Universal Pictures for the pictures and for making our life happier.
Eduardo.tomanik@gmail.com 33
Brief updates from 2016-2017 other
presentations about the consortium

34
Brief update 2017-2017

35
 2 Main Outcomes (2009-15)

Valve / Valve Seat

- Effect of body and conter-body

hardness, load, work hardening on
wear of valve materials

- Effect of temperature,
speed and load on wear
of valve materials

- Characterization of oxide
formation and growth mechanism

- Novel methodology for

valve/valves seat bench tests
Piston-Ring Liner Contact (BAM interaction)

- Computational tools for

component (VTL) and
deterministic/roughness Engine Bearings
(SurfLUB) scales simulations

- Advanced surface roughness - Advanced modelling and

analysis (SURFAT), i.e. simulation framework for
folded metal quantification, bearings’ systems (LUBST)
roughness filters etc.
- Effect of different lubricant
- Studies on lubricant additives viscosity index improvers
and their behaviours in the (VIIs) on the conrod
presence of ethanol performance of HSEs.
 Softwares
Summits
2D & 3D surface analysis, input for commercial (and in-
house) simulations (Excite, Ricardo, GT-Suite etc.)
http://www.lfs.usp.br/Portal_Triboflex/mahle.html
LUBST – Lubrication Simulation Tools
Deterministic simulation for bearings and rings with
complex geometries and surfaces.
Fluid pressure
Deformation
 International Symposia and Courses
1st Int. Course Liner honing Int. workshop “Super-Lubricity in the
3 D evaluation, S. Paulo Oct 2013 Automotive Real World” S. Paulo, May 2015
Prof. Zlate Dimkowsky. Halmstad University http://www.lfs.usp.br/superlubricity2015 Abroad
15%
Academia Industry
53% 47% Industry
38%

Academia
62%
 Tribo-Tests
Valve/Valve Seat – Friction-Wear test Ring & Liner Scuffing test
Ball – Disk of SRV® Tribometer Based on the Daimler protocol

Time: 30 min to 15 h.
Temperature: room temperature to 500°C

Lopez, D. et all at “VDI Symposium Zylinderlaufbahn,

Collaboration under discussion with Kolben, Pleuel, 2016, Baden-Baden
 Publications
Modelling the hydrodynamic support
of cylinder bore and piston rings with
laser textured surfaces
Hydro Support (%)
Tomanik, E., Profito, F.J.,
Zachariadis, D.C.,
Tribology international 59,
90-96 2013
Folded Metal and Other Surface
Parameters on Combustion Engine
Cylinders
RB Obara, E Tomanik, RM Souza, SAE Tech Paper 2014
“Dois artigos técnico-científicos de professores do
Departamento de Engenharia Mecânica da Escola
Politécnica (Poli) da USP receberam menção honrosa
no 23º Congresso SAE Brasil, 2014”.
 Partnerships
Effect of Ethanol on Lubricant Fully Deterministic Model for
Tribofilms Rings/Liners
(FURG, Imperial College London) (ICMC, USP, Buscaglia’s Group)
Costa, H.L. Impact of ethanol on the formation of antiwear
tribofilms from engine lubricants, Trib. Int. 93, 364-376 2016.

Prof. Henara Costa (FURG-RS)

Member of the IEA for Advanced Materials for
Transportation

Checo, H.M. et al., Moving textures - Simulation of a ring

sliding on a textured liner, Trib. Int. 72, 131-142 2016
http://www.lfs.usp.br/superlubricity2015
Tech-Meetings & ICE related MSc and PhDs
Overview of the impact of biofuel Bore Wear and deposits of engine
ethanol on the frictional response of tests with E22 and E100
piston ring/cylinder liner contacts Dinécio Santos (GM)
under cold-start/warm-up/short-
journey driving cycles
Prashan R. De Silva, Univ. Leeds/UK
Tribological Characterization of Flex-Fuel
Engine Components

Thrust side – Top Dead Center Thrust side – Bottom Dead Center

450h E100 and E20 10h E20

Tribological Characterization of Flex-Fuel
Engine Components
1200
350º C Exhaust Valve
700
M -1
223 670 M -1
M -2
1000 M -3 600 404 M -2
289 M -3
M -4

670 M -5 500 289

Intensity (A.U.)

800

Intensity (A.U.)
400 223 1310
600 404 1310
300
400
200

200
100

0 0
200 400 600 800 1000 1200 1400 1600 200 400 600 800 1000 1200 1400 1600

Raman shift (cm-1) Raman shift (cm -1)

Identified oxides
Hematite (α-
( - Fe2O3)
Magnetite (Fe 3O4)
 FCA-LFS Project on Automotive
Transmissions Materials
Mechanical Losses • Sintering
Transmission Losses
Engine • Low friction coatings
Tire-road
system
contact
• Alloys
(35%)
(35%) • Self-lubricating materials
Brake Friction
contact in Gears
(15%) (55%)
Transmission
system (15%)
Target:
Surfaces Topography Lubricants
Efficiency improvement in the • Texturing • Low viscosity oils
transmission system Friction in
• Superfinishing • Additives
Team: Bearings
15 Researchers/ Students • Shot
(20%) peening (AW, EP, FM)
Drivers:
Market and Legislation Materials
requirements (‘Inovar-Auto’,
‘Lei do Bem’)
Friction in seals, Viscous losses in the oil tank,
Ensuring:
forks, etc (5%) gear contacts, synchronizers,
Performance reliability
and bearings (20%)
Market competitiveness Surfaces Lubricants
Holmberg, K. et al., Trib. Intern. 2012
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3 University-Industry Partnerships