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An improved algorithm for McDowell’s analytical model of residual stress

null

《机械工程前沿（英文）》 2014年第9卷第2期页码 150-155 doi: 10.1007/s11465-014-0295-9

摘要：

The analytical model for two-dimensional elastoplastic rolling/sliding contact proposed by McDowell is an important tool for predicting residual stress in rolling/sliding processes. In application of the model, a problem of low predicting precision near the surface layer of the component is found. According to the volume-constancy of plastic deformation, an improved algorithm for McDowell’s model is proposed in order to improve its predicting accuracy of the surface residual stress. In the algorithm, a relationship between three normal stresses perpendicular to each other at any point within the component is derived, and the relationship is applied to McDowell’s model. Meanwhile, an unnecessary hypothesis proposed by McDowell can be eliminated to make the model more reasonable. The simulation results show that the surface residual stress predicted by modified method is much closer to the FEM results than the results predicted by McDowell’s model under the same simulation conditions.

关键词： residual stress McDowell’s model volume-constancy of plastic deformation FEM elastoplastic rolling/sliding contact

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3D mode discrete element method with the elastoplastic model

Wei HU, Feng JIN, Chong ZHANG, Jinting WANG

《结构与土木工程前沿（英文）》 2012年第6卷第1期页码 57-68 doi: 10.1007/s11709-012-0139-9

摘要： The three-dimensional mode-deformable discrete element method (3MDEM) is an extended distinct element approach under the assumptions of small strain, finite displacement, and finite rotation of blocks. The deformation of blocks is expressed by the combination of the deformation modes in 3MDEM. In this paper, the elastoplastic constitutive relationship of blocks is implemented on the 3MDEM platform to simulate the integrated process from elasticity to plasticity and finally to fracture. To overcome the shortcomings of the conventional criterion for contact fracturing, a new criterion based on plastic strain is introduced. This approach is verified by two numerical examples. Finally, a cantilever beam is simulated as a comprehensive case study, which went through elastic, elastoplastic, and discontinuous fracture stages.

关键词： mode discrete element method elastoplastic numerical method discontinuum contact

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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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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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Elastoplastic frictional contact problem study on interference fits of compressor

ZHANG Hongwu, WU Changhua, LIAO Aihua

《能源前沿（英文）》 2008年第2卷第3期页码 313-319 doi: 10.1007/s11708-008-0026-1

摘要： The FE parametric quadratic programming (PQP) method developed from the parametric variational principle (PVP) was used for the analysis of the stress distribution of the 3D elastoplastic frictional contact of an impeller-shaft sleeve-shaft. A locomotive-type turbocharger compressor with 24 blades under combined centrifugal and interference-fit loading was considered in the numerical analysis. The solution of elastoplastic frictional contact problems belongs to unspecified boundary problems where the interaction between two kinds of nonlinearities should occur. To save time in the numerical computation, a multi-substructure technique was adopted in the structural modeling. The effect of fit tolerance, wall thickness of the shaft sleeve, and rotational speed on the contact stress was discussed in detail in the numerical computation. To decrease the difficulty of the assembly process and ensure the safety of the working state, the amount of interference between the shaft sleeve and shaft by press-fitting should be controlled strictly to avoid the rapid increase of contact stress. The numerical results show that the algorithm has high accuracy and good convergence. The study can be referred to in deciding the proper fit tolerance and improving the design and manufacturing technology of compressor impellers.

关键词： computation thickness interference-fit interference unspecified

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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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Ribbed strip rolling by three-dimensional finite element method combining extremely thin array of elements

Zhengyi JIANG,

《机械工程前沿（英文）》 2010年第5卷第1期页码 52-60 doi: 10.1007/s11465-009-0087-9

摘要： In this paper, a three-dimensional finite element modelling of the ribbed strip rolling is carried out, coupling the use of an extremely thin array of elements that is equivalent to the calculation of the additional shear deformation work rate occurred by the velocity discontinuity in the roll bite. The formulation of the finite element modelling by adding a rib inclined contact surface boundary condition is derived, and the performance of the proposed method is conducted. The simulated rib height, forward slip, and the pulling down of rib height have been compared with the measured values and are in good agreement. The equivalent strain rate of the rib was obtained in the simulation. The effect of the rib inclined angle on pulling down of rib height has also been discussed, which is helpful in optimizing the design of the rib inclined angle.

关键词： rib inclined contact boundary condition ribbed strip extremely thin elements pulling down of rib height finite element modelling

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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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Robust SVM-direct torque control of induction motor based on sliding mode controller and sliding mode

Abdelkarim AMMAR,Amor BOUREK,Abdelhamid BENAKCHA

《能源前沿（英文）》 2020年第14卷第4期页码 836-849 doi: 10.1007/s11708-017-0444-z

摘要： This paper proposes a design of control and estimation strategy for induction motor based on the variable structure approach. It describes a coupling of sliding mode direct torque control (DTC) with sliding mode flux and speed observer. This algorithm uses direct torque control basics and the sliding mode approach. A robust electromagnetic torque and flux controllers are designed to overcome the conventional SVM-DTC drawbacks and to ensure fast response and full reference tracking with desired dynamic behavior and low ripple level. The sliding mode controller is used to generate reference voltages in stationary frame and give them to the controlled motor after modulation by a space vector modulation (SVM) inverter. The second aim of this paper is to design a sliding mode speed/flux observer which can improve the control performances by using a sensorless algorithm to get an accurate estimation, and consequently, increase the reliability of the system and decrease the cost of using sensors. The effectiveness of the whole composed control algorithm is investigated in different robustness tests with simulation using Matlab/Simulink and verified by real time experimental implementation based on dS pace 1104 board.

关键词： induction motor direct torque control (DTC) space vector modulation (SVM) sliding mode control (SMC) sliding mode observer (SMO) dS1104

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A rolling 6U parallel mechanism

Zhihuai MIAO, Yanan YAO

《机械工程前沿（英文）》 2011年第6卷第1期页码 96-98 doi: 10.1007/s11465-011-0214-2

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Novel probabilistic rolling regular tetrahedron mechanism

Yonghan GUAN, Yan’an YAO, Chao LIU, Ruiming LI

《机械工程前沿（英文）》 2021年第16卷第2期页码 363-378 doi: 10.1007/s11465-020-0628-9

摘要： With recent relevant publications on stochastic motion robots in , , and other journals, research on such robots has gained increasing attention. However, theoretical and applied research on stochastic motion in the field of robotics and mechanisms face many challenges due to the uncertainty of stochastic motion. Currently, a large gap remains in the research of stochastic motion mechanism. In this study, a novel mechanism that can conduct probabilistic rolling is proposed to reach a designated position and achieve overlying movement over a particular area. The mechanism consists of a regular tetrahedron frame, a central node, and four connecting linear actuators. According to mobility and kinematic analyses, the mechanism can implement probabilistic rolling. Each rolling gait has three probable rolling directions, and the mechanism rolls in one of the three directions in probability. A kinematic simulation is conducted, and a control method is proposed on the basis of the moving path analysis. Furthermore, the mathematical principle of probabilistic rolling is revealed in terms of probability theory and statistics. Lastly, a prototype is fabricated. To achieve the rolling function, the design of the linear actuators is improved, and the extension ratio is increased from 0.58 to 1.13. Then, tests are conducted. In a 4 m test site, the mechanism makes 11 moves to reach the target position and covers 29.25% of the site.

关键词： mobile mechanism probabilistic motion rolling mechanism stochastic motion

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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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A rolling 3-UPU parallel mechanism

Zhihuai MIAO, Yan’an YAO, Xianwen KONG

《机械工程前沿（英文）》 2013年第8卷第4期页码 340-349 doi: 10.1007/s11465-013-0282-6

摘要：

A novel rolling mechanism is proposed based on a 3-UPU parallel mechanism in this paper. The rolling mechanism is composed of two platforms connected by three UPU (universal-prismatic-universal) serial-chain type limbs. The degree-of-freedom of the mechanism is analyzed using screw theory. Gait analysis and stability analysis are presented in detail. Four rolling modes of the mechanism are discussed and simulated. The feasibility of the rolling mechanism is verified by means of a physical prototype. Finally, its terrain adaptability is enhanced through planning the rolling gaits.

关键词： parallel mechanism rolling mechanism screw theory

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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