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Contact fatigue life prediction of a bevel gear under spectrum loading

Pan JIA, Huaiju LIU, Caichao ZHU, Wei WU, Guocheng LU

《机械工程前沿（英文）》 2020年 第15卷 第1期   页码 123-132 doi: 10.1007/s11465-019-0556-8

摘要： Rolling contact fatigue (RCF) issues, such as pitting, might occur on bevel gears because load fluctuation induces considerable subsurface stress amplitudes. Such issues can dramatically affect the service life of associated machines. An accurate geometry model of a hypoid gear utilized in the main reducer of a heavy-duty vehicle is developed in this study with the commercial gear design software MASTA. Multiaxial stress–strain states are simulated with the finite element method, and the RCF life is predicted using the Brown–Miller–Morrow fatigue criterion. The patterns of fatigue life on the tooth surface are simulated under various loading levels, and the RCF curve is numerically generated. Moreover, a typical torque–time history on the driven axle is described, followed by the construction of program load spectrum with the rain flow method and the Goodman mean stress equation. The effects of various fatigue damage accumulation rules on fatigue life are compared and discussed in detail. Predicted results reveal that the Miner linear rule provides the most optimistic result among the three selected rules, and the Manson bilinear rule produces the most conservative result.

关键词： bevel gear     rolling contact fatigue (RCF)     multiaxial fatigue criterion     load spectrum     damage accumulation rule    

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非连续接触下滚圈的接触压力及疲劳寿命预测

时彧,肖友刚,雷先明

《中国工程科学》 2006年 第8卷 第7期   页码 54-57

摘要：

建立了非连续接触下筒体-滚圈接触压力的计算模型，得出了滚圈弯矩及弯曲应力计算公式。应用名义应力法和局部应力应变法，建立了滚圈疲劳寿命预测模型。通过实例分析，得出了如下结论：通过调窑，将滚圈的最大支承载荷控制在2500kN以内，能显著提高滚圈的疲劳寿命；在传统设计中，将滚圈支承角定为30°不合理；存在一个最佳滚圈支承角，此时滚圈疲劳寿命最大。

关键词： 滚圈     接触压力     支承角     疲劳寿命    

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Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique

Jia XU,Zhen-yu ZHOU,Zhong-yu PIAO

《机械工程前沿（英文）》 2016年 第11卷 第3期   页码 227-232 doi: 10.1007/s11465-016-0395-9

摘要：

The accumulated damage process of rolling contact fatigue (RCF) of plasma-sprayed coatings was investigated. The influences of surface roughness, loading condition, and stress cycle frequency on the accumulated damage status of the coatings were discussed. A ball-on-disc machine was employed to conduct RCF experiments. Acoustic emission (AE) technique was introduced to monitor the RCF process of the coatings. AE signal characteristics were investigated to reveal the accumulated damage process. Result showed that the polished coating would resist the asperity contact and remit accumulated damage. The RCF lifetime would then extend. Heavy load would aggravate the accumulated damage status and induce surface fracture. Wear became the main failure mode that reduced the RCF lifetime. Frequent stress cycle would aggravate the accumulated damage status and induce interface fracture. Fatigue then became the main failure mode that also reduced the RCF lifetime.

关键词： accumulated damage     spray coating     rolling contact fatigue     acoustic emission    

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Review of the damage mechanism in wind turbine gearbox bearings under rolling contact fatigue

Yun-Shuai SU, Shu-Rong YU, Shu-Xin LI, Yan-Ni HE

《机械工程前沿（英文）》 2019年 第14卷 第4期   页码 434-441 doi: 10.1007/s11465-018-0474-1

摘要： Wind turbine gearbox bearings fail with the service life is much shorter than the designed life. Gearbox bearings are subjected to rolling contact fatigue (RCF) and they are observed to fail due to axial cracking, surface flaking, and the formation of white etching areas (WEAs). The current study reviewed these three typical failure modes. The underlying dominant mechanisms were discussed with emphasis on the formation mechanism of WEAs. Although numerous studies have been carried out, the formation of WEAs remains unclear. The prevailing mechanism of the rubbing of crack faces that generates WEAs was questioned by the authors. WEAs were compared with adiabatic shear bands (ASBs) generated in the high strain rate deformation in terms of microstructural compositions, grain refinement, and formation mechanism. Results indicate that a number of similarities exist between them. However, substantial evidence is required to verify whether or not WEAs and ASBs are the same matters.

关键词： rolling contact fatigue (RCF)     white etching area (WEA)     white etching crack (WEC)     adiabatic shear band (ASB)    

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Durability of plasma-sprayed Cr3C2-NiCr coatings under rolling contact conditions

Xiancheng ZHANG, Fuzhen XUAN, Shantung TU, Binshi XU, Yixiong WU

《机械工程前沿（英文）》 2011年 第6卷 第1期   页码 118-135 doi: 10.1007/s11465-011-0127-0

摘要：

The aim of this paper was to address the rolling contact fatigue (RCF) failure mechanisms of plasma-sprayed Cr3C2-NiCr coatings under different tribological conditions of contact stress. Weibull distribution plots of fatigue lives of the coated specimens at different contact stresses were obtained. The failure modes of coatings were identified on the basis of wore surface observations of the failed coatings. Results showed that the RCF failure modes can be classified into four main categories, i.e., surface abrasion, spalling, cohesive delamination, and interfacial delamination. The probabilities of the surface abrasion and spalling type failures were relatively high at low contact stress. When the coatings were subjected to abrasion and spalling type failures, the failure of the coating was depended on the microstrcture of the coating. The stress concentration near the micro-defects in the coating may be the may reason for the formation of spall. The coatings were prone to fail in delamination under higher contact stresses. However, the delamination of coating may be related to distribution of shear stress amplitude within coating. The location of maximum shear stress amplitude can be used as a key parameter to predict the initiation of subsurface cracks within coating in rolling contact.

关键词： rolling contact fatigue     coating     Weibull distribution     failure mode     mechanism    

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Application of Cu nanoparticles as N32 base oil additives

Qiang HE, Jun YE, Hongzhao LIU, Jinling LI,

《机械工程前沿（英文）》 2010年 第5卷 第1期   页码 93-97 doi: 10.1007/s11465-009-0083-0

摘要： Cu nanoparticles as N32 base oil additives are studied in the paper and their structure is characterized by transmission electron microscopy (TEM) and X-ray powder diffraction spectroscopy (XRD). The widely used steel-steel friction system is chosen to test the feasibility and practicality of Cu nanoparticles as bearing lubricant additives. The results show that N32 base oil with 0.5% Cu nanoparticle can improve the test sample contact fatigue life than pure N32 base oil.

关键词： Cu nanoparticle     tribological property     contact fatigue     weibull distribution    

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Thin-liquid-film evaporation at contact line

Hao WANG, Zhenai PAN, Zhao CHEN

《能源前沿（英文）》 2009年 第3卷 第2期   页码 141-151 doi: 10.1007/s11708-009-0020-2

摘要： When a liquid wets a solid wall, the extended meniscus near the contact line may be divided into three regions: a nonevaporating region, where the liquid is adsorbed on the wall; a transition region or thin-film region, where effects of long-range molecular forces (disjoining pressure) are felt; and an intrinsic meniscus region, where capillary forces dominate. The thin liquid film, with thickness from nanometers up to micrometers, covering the transition region and part of intrinsic meniscus, is gaining interest due to its high heat transfer rates. In this paper, a review was made of the researches on thin-liquid-film evaporation. The major characteristics of thin film, thin-film modeling based on continuum theory, simulations based on molecular dynamics, and thin-film profile and temperature measurements were summarized.

关键词： meniscus     thin film     contact line     disjoining pressure     evaporation    

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Modelling of dynamic contact length in rail grinding process

null

《机械工程前沿（英文）》 2014年 第9卷 第3期   页码 242-248 doi: 10.1007/s11465-014-0305-y

摘要：

Rails endure frequent dynamic loads from the passing trains for supporting trains and guiding wheels. The accumulated stress concentrations will cause the plastic deformation of rail towards generating corrugations, contact fatigue cracks and also other defects, resulting in more dangerous status even the derailment risks. So the rail grinding technology has been invented with rotating grinding stones pressed on the rail with defects removal. Such rail grinding works are directed by experiences rather than scientifically guidance, lacking of flexible and scientific operating methods. With grinding control unit holding the grinding stones, the rail grinding process has the characteristics not only the surface grinding but also the running railway vehicles. First of all, it’s important to analyze the contact length between the grinding stone and the rail, because the contact length is a critical parameter to measure the grinding capabilities of stones. Moreover, it’s needed to build up models of railway vehicle unit bonded with the grinding stone to represent the rail grinding car. Therefore the theoretical model for contact length is developed based on the geometrical analysis. And the calculating models are improved considering the grinding car’s dynamic behaviors during the grinding process. Eventually, results are obtained based on the models by taking both the operation parameters and the structure parameters into the calculation, which are suitable for revealing the process of rail grinding by combining the grinding mechanism and the railway vehicle systems.

关键词： rail grinding     contact length     dynamic model     Hamiltonian system     grinding stone     rail grinding car    

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Computation and investigation of mode characteristics in nonlinear system with tuned/mistuned contact

Houxin SHE, Chaofeng LI, Qiansheng TANG, Hui MA, Bangchun WEN

《机械工程前沿（英文）》 2020年 第15卷 第1期   页码 133-150 doi: 10.1007/s11465-019-0557-7

摘要： This study derived a novel computation algorithm for a mechanical system with multiple friction contact interfaces that is well-suited to the investigation of nonlinear mode characteristic of a coupling system. The procedure uses the incremental harmonic balance method to obtain the nonlinear parameters of the contact interface. Thereafter, the computed nonlinear parameters are applied to rebuild the matrices of the coupling system, which can be easily solved to calculate the nonlinear mode characteristics by standard iterative solvers. Lastly, the derived method is applied to a cycle symmetry system, which represents a shaft–disk–blade system subjected to dry friction. Moreover, this study analyzed the effects of the tuned and mistuned contact features on the nonlinear mode characteristics. Numerical results prove that the proposed method is particularly suitable for the study of nonlinear characteristics in such nonlinear systems.

关键词： coupling vibration     nonlinear mode     original algorithm     contact interface    

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Transient analysis of thermoelastic contact problem of disk brakes

Ali BELHOCINE, Mostefa BOUCHETARA

《机械工程前沿（英文）》 2013年 第8卷 第2期   页码 150-159 doi: 10.1007/s11465-013-0266-6

摘要：

The main purpose of this study is to analyze the thermomechanical behavior of the dry contact between the brake disk and pads during the braking phase. The simulation strategy is based on computer code ANSYS11. The modeling of transient temperature in the disk is actually used to identify the factor of geometric design of the disk to install the ventilation system in vehicles. The thermal-structural analysis is then used with coupling to determine the deformation established and the Von Mises stresses in the disk, the contact pressure distribution in pads. The results are satisfactory compared to those found in the literature.

关键词： brake disks     heat flux     heat-transfer coefficient     Von Mises stress     contact pressure    

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Experimental study and numerical simulation on compressive buckling behavior of thin steel skins in unilateral contact

Nicholas KEAGE, Christopher MAIOLO, Rebecca PIEROTTI, Xing MA

《结构与土木工程前沿（英文）》 2011年 第5卷 第3期   页码 335-343 doi: 10.1007/s11709-011-0121-y

摘要： In this paper, a practical test and finite element analysis has been undertaken to further investigate the effects of contact buckling. A test rig was designed and constructed to record vertical and transverse deflections of compressively loaded steel skin plates. The boundary conditions were modeled as fully fixed. A finite element analysis was also undertaken using the software package Strand7. Results from both analyses have been examined and compared to data established from previous studies on contact buckling. Both the finite element analysis and practical results correlate well with this data. The result of the investigation has confirmed contact buckling theories and has foreshadowed the onset of the newly observed phenomenon of secondary contact buckling.

关键词： compressive     buckling     thin steel skins     unilateral contact     rigid constraints    

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A dimensional analysis on asphalt binder fracture and fatigue cracking

Qian ZHAO, Zhoujing YE

《结构与土木工程前沿（英文）》 2018年 第12卷 第2期   页码 201-206 doi: 10.1007/s11709-017-0402-1

摘要： Fracture and fatigue cracking in asphalt binder are two of most serious problems for pavement engineers. In this paper, we present a new comprehensive approach, which consists both of dimensional analysis using Buckingham Theorem and -integral analysis based on classic fracture mechanics, to evaluate the fracture and fatigue on asphalt binder. It is discovered that the dimensional analysis could provide a new perspective to analyze the asphalt fracture and fatigue cracking mechanism.

关键词： Dimensional analysis     asphalt     fracture     fatigue cracking    

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Performance of a hybrid anaerobic-contact oxidation biofilm baffled reactor for the treatment of decentralized

Minmin LIU,Ying ZHAO,Beidou XI,Li’an HOU,Xunfeng XIA

《环境科学与工程前沿（英文）》 2014年 第8卷 第4期   页码 598-606 doi: 10.1007/s11783-013-0576-2

摘要： A novel hybrid anaerobic-contact oxidation biofilm baffled reactor (HAOBR) was developed to simultaneously remove nitrogenous and carbonaceous organic pollutants from decentralized molasses wastewater in the study. The study was based on the inoculation of anaerobic granule sludge in anaerobic compartments and the installation of combination filler in aerobic compartments. The performance of reactor system was studied regarding the hydraulic retention time (HRT), microbial characteristics and the gas water ratio (GWR). When the HRT was 24h and the GWR was 20:1, total ammonia and chemical oxygen demand (COD) of the effluent were reduced by 99% and 91.8%, respectively. The reactor performed stably for treating decentralized molasses wastewater. The good performance of the reactor can be attributed to the high resistance of COD and hydraulic shock loads. In addition, the high solid retention time of contact oxidation biofilm contributed to stable performance of the reactor.

关键词： combination filler     contact oxidation biofilm     food wastewater     anaerobic baffled reactor    

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Hierarchical approach for fatigue cracking performance evaluation in asphalt pavements

Ibrahim ONIFADE, Yared DINEGDAE, Björn BIRGISSON

《结构与土木工程前沿（英文）》 2017年 第11卷 第3期   页码 257-269 doi: 10.1007/s11709-017-0410-1

摘要： In this paper, a hierarchical approach is proposed for the evaluation of fatigue cracking in asphalt concrete pavements considering three different levels of complexities in the representation of the material behaviour, design parameters characterization and the determination of the pavement response as well as damage computation. Based on the developed hierarchical approach, three damage computation levels are identified and proposed. The levels of fatigue damage analysis provides pavement engineers a variety of tools that can be used for pavement analysis depending on the availability of data, required level of prediction accuracy and computational power at their disposal. The hierarchical approach also provides a systematic approach for the understanding of the fundamental mechanisms of pavement deterioration, the elimination of the empiricism associated with pavement design today and the transition towards the use of sound principles of mechanics in pavement analysis and design.

关键词： fatigue cracking     energy based     crack initiation     mechanistic approach     pavement analysis    

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Assessment of fatigue life of remanufactured impeller based on FEA

Lei XU,Huajun CAO,Hailong LIU,Yubo ZHANG

《机械工程前沿（英文）》 2016年 第11卷 第3期   页码 219-226 doi: 10.1007/s11465-016-0394-x

摘要：

Predicting the fatigue life of remanufactured centrifugal compressor impellers is a critical problem. In this paper, the S-N curve data were obtained by combining experimentation and theory deduction. The load spectrum was compiled by the rain-flow counting method based on the comprehensive consideration of the centrifugal force, residual stress, and aerodynamic loads in the repair region. A fatigue life simulation model was built, and fatigue life was analyzed based on the fatigue cumulative damage rule. Although incapable of providing a high-precision prediction, the simulation results were useful for the analysis of fatigue life impact factors and fatigue fracture areas. Results showed that the load amplitude greatly affected fatigue life, the impeller was protected from running at over-speed, and the predicted fatigue life was satisfied within the next service cycle safely at the rated speed.

关键词： remanufactured impeller     fatigue life     impeller failures     finite element analysis (FEA)    

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标题 作者 时间 类型 操作

Contact fatigue life prediction of a bevel gear under spectrum loading

Pan JIA, Huaiju LIU, Caichao ZHU, Wei WU, Guocheng LU

期刊论文

非连续接触下滚圈的接触压力及疲劳寿命预测

时彧,肖友刚,雷先明

期刊论文

Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique

Jia XU,Zhen-yu ZHOU,Zhong-yu PIAO

期刊论文

Review of the damage mechanism in wind turbine gearbox bearings under rolling contact fatigue

Yun-Shuai SU, Shu-Rong YU, Shu-Xin LI, Yan-Ni HE

期刊论文

Durability of plasma-sprayed Cr3C2-NiCr coatings under rolling contact conditions

Xiancheng ZHANG, Fuzhen XUAN, Shantung TU, Binshi XU, Yixiong WU

期刊论文

Application of Cu nanoparticles as N32 base oil additives

Qiang HE, Jun YE, Hongzhao LIU, Jinling LI,

期刊论文

Thin-liquid-film evaporation at contact line

Hao WANG, Zhenai PAN, Zhao CHEN

期刊论文

Modelling of dynamic contact length in rail grinding process

null

期刊论文

Computation and investigation of mode characteristics in nonlinear system with tuned/mistuned contact

Houxin SHE, Chaofeng LI, Qiansheng TANG, Hui MA, Bangchun WEN

期刊论文

Transient analysis of thermoelastic contact problem of disk brakes

Ali BELHOCINE, Mostefa BOUCHETARA

期刊论文

Experimental study and numerical simulation on compressive buckling behavior of thin steel skins in unilateral contact

Nicholas KEAGE, Christopher MAIOLO, Rebecca PIEROTTI, Xing MA

期刊论文

A dimensional analysis on asphalt binder fracture and fatigue cracking

Qian ZHAO, Zhoujing YE

期刊论文

Performance of a hybrid anaerobic-contact oxidation biofilm baffled reactor for the treatment of decentralized

Minmin LIU,Ying ZHAO,Beidou XI,Li’an HOU,Xunfeng XIA

期刊论文

Hierarchical approach for fatigue cracking performance evaluation in asphalt pavements

Ibrahim ONIFADE, Yared DINEGDAE, Björn BIRGISSON

期刊论文

Assessment of fatigue life of remanufactured impeller based on FEA

Lei XU,Huajun CAO,Hailong LIU,Yubo ZHANG

期刊论文