Fatigue life analysis of scraper conveyor chain ring under different chain speeds and loads

Abstract

This study aims to explore how different chain speeds and loads impact the fatigue life of the scraper conveyor chain ring. To achieve this, the study validates the reliability of a coupled simulation involving multi-body dynamics and the discrete element method. It also acquires time-varying tension load spectra under various operational conditions. The research evaluates the effects of distinct chain speeds and loads on parameters such as chain tension, vibration acceleration in the Y and Z-directions of the chain ring. Furthermore, finite element simulation is employed to examine stress distribution changes and fatigue life trends within the three-chain ring structure. The findings demonstrate that Y and Z-direction vibration accelerations of the chain ring correlate positively with the load. Additionally, the vibration acceleration in the Y-direction correlates positively with the chain speed. Across different chain speeds and loads, the maximum equivalent stress in the chain ring exhibits dynamic variations mirroring the load spectrum. Within the elastic deformation range of the chain ring, the highest stress within the transition region correlates linearly with chain tension. Load has a greater effect on the fatigue life of chain rings than chain speed. The fatigue life within the transition region of the chain ring decreases exponentially with increasing load at a constant chain speed. Conversely, at a constant load, chain ring life correlates positively with chain speed. Specifically, the fatigue life of the chain ring in LS 22 amounts to 32.64 days. When both chain speed and load are adjusted by 25%, the chain ring's lifespan reduces by 51.66% during simultaneous increments and increases by 39.26% with concurrent reductions in speed and load.