Alaitz Zabala

Alaitz Zabala
Mondragon University | Mu · Department of Mechanical Engineering and Industrial Production

PhD

About

55
Publications
14,860
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547
Citations

Publications

Publications (55)
Article
Full-text available
Residual stresses and surface roughness have been recognized to play a critical role in the fatigue strength of metal components. Machining processes can induce different roughness and residual stress conditions depending on the parameters used in the process. Therefore, it is essential to develop knowledge that helps to predict the residual stress...
Article
Full-text available
The turning process remains one of the most widely used manufacturing methods in the industry due to its high flexibility and production rates. Despite being an extensively used technique, the impact of this machining process on the surface integrity of the components has not yet been resolved in the literature, although it is well known that it ca...
Article
Full-text available
The coefficient of friction (CoF) between the deflection pulley and rope in a lift strongly affects the life span of the rope. Although surface roughness is a key factor affecting the metallic pulley–rope CoF, its effect on polymeric pulleys is unknown. The present study analyses the effect of roughness and working conditions on cast polyamide 6 (P...
Article
Full-text available
Abrasive and adhesive wear is a major issue in sheet metal forming processes. Although different solutions exist to reduce its impact, there is still room for progress. Surface texturing presents a big potential for tribological behaviour improvement by introducing oil retention voids on the surface. However, the economic efficiency of the surface...
Preprint
Full-text available
Residual stress and surface roughness have been recognized to play a critical role in the fatigue strength of metal components. Machining processes can induce different roughness and residual stress conditions depending on the parameters used in the process. Therefore, it is essential to develop knowledge that helps to predict the residual stresses...
Article
Full-text available
Wear-driven tool failure is one of the main hurdles in the industry. This issue can be addressed through surface coating with ceramic-reinforced metal matrix composites. However, the maximum ceramic content is limited by cracking. In this work, the tribological behaviour of the functionally graded WC-ceramic-particle-reinforced Stellite 6 coatings...
Article
Full-text available
Since electrospinning can generate micro- to nanometre-scale fibres, it is widely used for fabricating wound dressings. Electrospun scaffolds with defined three-dimensional patterns at the mat surface can be efficiently fabricated using textured collectors that transfer the topography during the manufacturing process. However, the efficacy of surfa...
Conference Paper
Full-text available
Despite the untapped resource stored in ocean waves, none of the suggested wave energy converters (WECs) has yet demonstrated economical viability. This viability lies in two counter-productive aspects: enhancing energy absorption and generation, and reduction of the loads in the critical elements such as mooring lines and dynamic cables. Both obje...
Conference Paper
Full-text available
Antibiotic resistance is a growing global problem which poses a massive threat to human health. Although human activity contributes to the acceleration of the process, bacteria have a self-driven stabilisation mechanism to protect themselves from such and other external threats: biofilm formation. Nonetheless, it is the adhesion of a single bacteri...
Article
In this work, the theory of critical distances using point method and mesh control approach for fretting fatigue life prediction in complete and nearly complete contacts is analysed. The approach is applied to thirty experimental tests found in the literature, where almost nine hundred simulations are carried out. The work concludes that the theory...
Article
Full-text available
Bone tissue is usually damaged after big traumas, tumours and increasing aging‐related diseases such as osteoporosis and osteoarthritis. Current treatments are based on implanting grafts which are shown to have several inconveniences. In this regard, tissue engineering through the 3D bioprinting technique has arisen to manufacture structures that w...
Patent
Full-text available
Laser textured guide for elevators. Tribological improvement of guiding system by laser textured surface application. Lubricant residence time increases, as well as friction reduction demostrated by dimples configuration optimization.
Article
Full-text available
Cartilage is a connective tissue which a limited capacity for healing and repairing. In this context, osteoarthritis disease may be developed with high prevalence in which the use of scaffolds may be a promising treatment. In addition, three-dimensional (3D) bioprinting has become an emerging additive manufacturing technology because of its rapid p...
Article
Full-text available
Numerical simulation of sheet metal forming processes has become indispensable in the last decades. Although the complexity of the frictional behaviour is identified as a key factor for the prediction accuracy, the industry commonly considers a constant friction coefficient for the whole tool. Furthermore, the influence of roughness distribution of...
Article
3D-bioprinting is an emerging technology of high potential in tissue engineering (TE), since it shows effective control over scaffold fabrication and cell distribution. Biopolymers such as alginate (Alg), nanofibrillated cellulose (NC) and hyaluronic acid (HA) offer excellent characteristics for use as bioinks due to their excellent biocompatibilit...
Article
Full-text available
The increasing demands for lightweight design in the transport industry have led to an extensive use of lightweight materials such as aluminium alloys. The forming of aluminium sheets however presents significant challenges due to the low formability and the increased susceptibility to galling. The use of tailored workpieces and controlled die roug...
Article
Full-text available
In the last few years many efforts have been carried out in order to better understand what the real contact between material and tools is. Based on the better understanding new friction models have been developed which have allowed process designers to improve numerical results in terms of component viability and geometrical accuracy. The new mode...
Article
This work presents a critical assessment of wear volume determination methods for ball-on-flat linear reciprocating sliding tribological tests. It revealed that the ASTM D7755-11 standard leads to the highest relative errors (up to 106%) and deviations (up to 27%) depending on the regularity of the wear track shape. The present study suggests impro...
Article
Full-text available
Progress made by materials scientists in recent years has greatly helped the field of ultra-precision manufacturing. Ranging from healthcare to electronics components, phenomena such as twinning, dislocation nucleation and high-pressure phase transformation have helped to exploit plasticity across a wide range of metallic and semiconductor material...
Conference Paper
Full-text available
We have studied a new approach for maximizing the absorption capabilities of a wound dressing by using textured collectors in the electrospinning process. Thus, we aim to increase the surface to volume ratio of the mesh, obtaining a larger area to interact with the environment and to improve the healing process of a wound by a larger absorption rat...
Article
Full-text available
This work presents a coupled 3D wear and fatigue numerical procedure for fretting problems in ultra-high strength steel wires that combines Archard's wear equation with the Smith-Watson-Topper parameter to predict crack nucleation. For total life prediction, a mode I crack propagation based on the weight function method was used. To assess fretting...
Article
Full-text available
Automotive die spotting is one of the most complex and least standardized processes in the tool making process. A spotting expert identifies local contact areas through a blue-paste pattern and the die/sheet contact is optimized by manual grinding. Research performed on the impact of tribology conditions and surface irregularities on die behaviour...
Article
Full-text available
In this work, the role of the contact stiffness in the measurement of principal variables in fretting wear tests is assessed. Several fretting wear tribometers found in the literature, including one developed by the authors, are analysed and modelled using numerical methods. The results show the importance of the tribosystem stiffness and tangentia...
Conference Paper
This work presents a critical analysis of the suitability of surrogate models for finite lement method application. A case study of a finite element method (FEM) structural problem was selected in order to test the performance of surrogate algorithms. A simple design of experiments (DoE) approach, based on 1D kernel density estimations, is employed...
Conference Paper
Full-text available
Additive Manufacturing (AM) presents significant industry-specific advantages allowing the creation of complex geometries and internal features that cannot be produced using conventional manufacturing processes. However, a current limitation of AM is the degraded dimensional control and surface integrity of specific surfaces. The parts are construc...
Article
Full-text available
The integrity of dental implant surfaces might be compromised during surgical insertion. Wear and topographical modifications can occur during implant insertion, which can potentially have clinical implications. Accordingly, the analysis and prediction of the wear behaviour of dental implant surfaces is fundamental. Surface mean curvature is a key...
Article
Full-text available
In the last few years many efforts have been carried out in order to understand better what the real contact between material and tools is. Based on the better understanding new friction models have been developed which have allowed process designers to improve numerical results in terms of component viability and geometrical accuracy. Aluminum for...
Article
Full-text available
Titanium dental implants are subjected to frictional stresses during insertion, which may lead to surface wear and modification of original surface topography. The main goal of this study was to comprehensively quantify the wear and topographical modification of dental implants suffered during insertion procedure. Two commercially available dental...
Article
Full-text available
This work presents a critical analysis of coefficient of friction derivation methods for fretting under gross slip regime. A mass review of tribology journals revealed that 41% of papers did not specify the derivation method used and 37% employed the least effective methods. Following an analytical and experimental study, the use of the geometric i...
Article
Full-text available
This work analyses the viability of the theory of critical distances (TCD) using mesh control for fretting fatigue lifetime assessment. More than seven hundred sets of simulations were performed by taking seventy different experimental tests reported previously in the literature. The outcome of the present study suggests that the TCD mesh control m...
Article
Full-text available
Laser-induced periodic surface structures (LIPSS, ripples) with ~500–700 nm period were produced on titanium alloy (Ti6Al4V) surfaces upon scan processing in air by a Ti:sapphire femtosecond laser. The tribological performance of the surfaces were qualified in linear reciprocating sliding tribological tests against balls made of different materials...
Article
A proper prediction of crack paths is required when assessing accurately the fatigue crack propagation life. Recently, some authors have pointed out that the criterion of minimum shear stress range leads to inconsistent results when predicting fretting crack paths under incomplete contacts. In this paper, different fretting experiments with cylinde...
Article
Full-text available
This work presents the design of a modular ad-hoc fretting fatigue and fretting wear tribotester for thin steel wires. The working principles of the different modules are described, such as the displacement and contact modules. Preliminary studies for understanding the effect of crossing angle between wires on tangential force measurement has been...
Article
Full-text available
Use of an alpha-beta (multiphase HCP-BCC) titanium alloy, Ti6Al4V, is ubiquitous in a wide range of engineering applications. The previous decade of finite element analysis research on various titanium alloys for numerous biomedical applications especially in the field of orthopedics has led to the development of more than half a dozen material con...
Article
Full-text available
In this work the suitability of the criterion of maximum effective amplitude of the normal stress (Δσn,eff)max and the criterion of minimum shear stress range (Δτ)min for 2D cylindrical plain fretting contact condition has been analysed. The numerical analysis has been performed by means of the extended finite element method, which takes into accou...
Article
Full-text available
This work presents a numerical procedure for combined fretting wear and fretting fatigue problems. It combines the Archard wear model and the Smith-Watson-Topper fatigue indicator parameter with the Miner damage rule for crack nucleation estimation. The eXtended Finite Element Method (XFEM) is then used in combination with the Archard wear model fo...
Article
Full-text available
In one of the previously published papers in Int. J. Mach. Tools Manuf. [1] an approach, namely the hybrid molecular dynamics-finite element analysis (MD-FEA) model was proposed. As a preliminary work in this area, the esteemed authors of the cited paper have attempted to gather the stress-strain data from the uniaxial tensile test simulation using...
Conference Paper
AM presents significant industry-specific advantages allowing the creation of complex geometries and internal features that cannot be produced using conventional manufacturing processes. However, a current limitation of AM is the degraded dimensional control and surface integrity of specific surfaces. The parts are constructed through layer-by-lay...
Conference Paper
Full-text available
Deep drawing process is based on the flow of material between the pair of surfaces that made up the tool. The nature and topography of both, the surface of the tools and the surface of the blank, determines the higher or lower easiness for the material to flow. In this regard, the deep drawing of materials such as aluminum alloys or stainless steel...
Chapter
Full-text available
This chapter presents a general background and the state of the art of numerical simulation and modelling of fretting phenomenon in terms of wear, fatigue and fracture. First of all, an introduction of fretting and its implications is exposed. Secondly, different methodologies for wear modelling and simulation are described and discussed. Afterward...
Conference Paper
Full-text available
Steel wire ropes experience fretting wear damage when the rope runs over a sheave promoting an oscillatory motion between the wires. Consequently, wear scars appear between the contacting wires leading to an increase of the stress field and the following rupture of the wires due to fatigue. That is why the understanding and prediction of the fretti...
Conference Paper
Full-text available
Although the effect of surface topography on fatigue life is widely accepted, the underlying role of surface roughness from first principles is still poorly understood. Currently used approaches to consider surface influence on fatigue life prediction can be broadly classified into surface corrector factors (Cf) and stress concentration factors (Kt...
Conference Paper
Full-text available
Although the effect of surface topography on fatigue life is widely accepted, the underlying role of surface roughness from first principles is still poorly understood. Currently approaches which consider the influence of surface roughness on fatigue life prediction can be broadly classified into surface corrector factors (Cs) and stress concentrat...
Conference Paper
Steel wire ropes experience fretting wear damage when the rope runs over a sheave promoting an oscillatory motion between the wires. Consequently, wear scars appear between the contacting wires leading to an increase of the stress field and the following rupture of the wires. That is why the understanding and prediction of the fretting wear phenome...
Conference Paper
Clinical success of dental implants is obtained when a stable and durable bond between the implant and the host bone is achieved. Albrektsson et al. stated that surface topography is one crucial parameter affecting ossoeointegration, and is considered to be one of the most important surface properties regarding the biological response. Therefore, a...
Conference Paper
La correcta integración del implante dental en el hueso es condición necesaria para lograr reponer la funcionalidad perdida. Dentro de las modificaciones superficiales tendentes a conseguir una mayor osteointegración, el aumento de la rugosidad es la más determinante. Además, se sabe que las modificaciones en los rangos micro y nanométricos modulan...
Conference Paper
Knee prosthesis can be either femoral or tibial and in each case the applied material might be different. Usually, a damaged femoral surface is replaced with a metallic prosthesis and polymeric piece of UHMWPE is fixed to the tibial counterpart. In respect of metallic prosthesis, CoCr alloys have been widely used in orthopaedic devices. However, el...
Article
Full-text available
La simulación del desgaste mediante el Método de Elementos Finitos (MEF) es una técnica que presenta grandes ventajas para la mejora del diseño de componentes ya que permite reducir el coste que conlleva la experimentación (tiempo de ensayo, materiales, medidas tribológicas). En el caso concreto de la optimización de sistemas multihilo sometidos a...

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