Bearing Housing Research Articles

A Comprehensive Model to Compute Roll Gap Profile for a Rolling Mill Including Bearing and Mill Housing Deflections

Abstract Obtaining the desired strip profile is of paramount importance in cold rolling. The final strip profile depends on several parameters of the plants including crown and taper profiles and segmented backup roll positions. This paper aims to present a newly developed combined finite element–analytical model of the rolling mill able to model not only the roll cluster but also the mill housing and backup bearings deformations. This makes the proposed model especially suitable to simulate cluster-type rolling mills. The model exploits a modified elastic foundation formulation for a precise computation of the contact forces between rolls, taking into account rolls’ crown and taper. A reduced stiffness matrix approach is implemented for accurate mill housing modeling. A full 3D finite element model of the rolling mill and experimental data are used for the validation of the presented model. By exploiting the validated model, the paper shows that the deformation of supporting bearings and mill housing plays a crucial role in the strip profile calculation and should be included in any cluster-type roll mill model.

Processing of a Part Such as a Composite Bearing Housing on a Milling Machine With a Digital Control Program

In the era of the industrial revolution of ndustry 4.0, the Republic of Kazakhstan is rapidly introducing automated robots and digital control programs in many of its production facilities. In this context, special attention is paid to modern technologies, and AKIRA SEIKI milling machines with FANUC control software stand out as advanced technologies in this process. They are becoming the most popular in the CIS countries due to the economic efficiency and intellectual support of the Taiwanese manufacturer. Practical aspects of constructing CNC milling machines and their practical use are presented in this article. Particular attention is paid to the functionality of milling machines using the example of processing such a part as a composite bearing housing. In addition, the process of writing processing operation codes in the CIMKO computer program is described. The code is provided with brief descriptions to help you understand the compiled workpiece processing operations. With the growing need for efficiency and precision in production, many companies and industrial plants in the Republic of Kazakhstan are considering AKIRA SEIKI milling machines with FANUC control software as a major investment. These machines not only provide high productivity, but also help automate complex technological processes. CIMKO, among other things, allows the development and optimization of machining code, which complements the efficiency and accuracy of the machines.

Finite Element Analysis of Sleeve Bearing Housing Based on Abaqus

Finite Element Analysis of Sleeve Bearing Housing Based on Abaqus

PROSES PEMBUATAN HOUSING BEARING GEARBOX 3Z2M21 DENGAN MATERIAL FCD 400

Fundamental, detailed and in-depth understanding of technology is carried out through the use of concrete pumps used to move fluid from one place to a higher place, high pressure and circulation. One of the important components of the pumping system in the industry is the Gearbox Bearing Housing which functions as a bearing housing so that the bearing can move and continue the shaft work system on the pump. The material used to make the Gearbox Bearing Housing is based on FCD 400. The manufacturing process for the Gearbox Bearing Housing is a lathe where in this process the workpiece is fed by rotating the workpiece and then touching it to a chisel which is moved in translation parallel to the axis of rotation. of the workpiece. The outer diameter is 700 mm, while the inner diameter is 340 mm and D2 is 440 mm. Drilling Machine Process, the machining process is the process of expanding or enlarging a hole that can be done with a drill bar. For the size of the holes, namely the diameter of 22 mm as many as 16 holes, the diameter of 20 mm as many as 16 holes and for the diameter of 12 mm there are 4 holes. Grinding Machine Process is a finishing process that is used to remove parts of the workpiece that are uneven. In the manufacture of Gearbox Bearing Housing, checks are carried out on the workpiece to determine whether or not an item is produced. If the workpiece is said to be feasible, it will be packaged to be marketed, if not, the workpiece will be destroyed.

Determination of Cutting Transition Parameters in the APQP Pre-production Process of the Engine Camshaft Bearing Housing

An example of the application of the experimental planning method in the APQP pre-production process to find the values of the cutting process parameters that provide a given margin of accuracy is considered on the example of roughing and finishing boring of the inner hole of the camshaft bearing housing. From the total set of geometric parameters, special characteristics are highlighted - the size of the inner hole, which ensures the fit tolerance of the steel-fiber sleeve and the height parameter of roughness Ra, as well as radial runout. The objectives and results of the application of engineering methods (calculation of allowances, dimensional analysis, evaluation of technological accuracy of machine systems, planning experiments) as well as special methods of APQP process (quality management tools - FMEA analysis, SPS, MSA) are considered. Attention is drawn to the insufficient information content of the methods, which does not allow for the selection of process indicators to ensure the necessary margin of accuracy of special characteristics. In order to achieve a given margin of accuracy, technological components of the internal diametrical size are identified - the deviation of the tuning size, the deviation of the cross-section profile and the height roughness parameter Ra, the values of which are found as a result of production experiments. The planning of a full-factor experiment is carried out according to the parameters of the cutting process - cutting speed, feed and cutting depth. To implement the plan, special samples of products with a stepped allowance were designed and manufactured. The shape of the product samples makes it possible to reduce the number of samples for a full-factor experiment from eight to four, providing a check of the linearity of regression models. The calculation and regression models are given, which allow predicting the values of the components of the internal diametrical size at the design stage of the manufacturing operations of parts. The solution of the regression model system that satisfies the specified limitations for a given margin of accuracy allows you to find the optimal range of values of the parameters of the cutting process, to provide rare settings of special characteristics in the serial manufacturing process of camshaft bearing housings. Systematic application of the methodology, along with statistical methods of quality management, allows monitoring the technical condition of equipment and maintaining it in the condition required for the production of quality products. Systematic application of the methodology, along with statistical methods of quality management, allows monitoring the technical condition of equipment and maintaining it in the condition required for the production of quality products.

Vibration Transmission Characteristics and Measuring Points Analysis of Bearing Housing System

The vibration transmission characteristics of the bearing housing system are crucial for the system fault diagnosis based on vibration signals collected at various measuring points. To study its vibration transmission characteristics, a dynamic model of the rolling bearing housing system based on the elastic interface is established. The interference fit between the bearing outer ring and the bearing housing is modelled by contact pairs. The proposed model is verified by the experimental results, which demonstrate that the interference fit can be better simulated by contact pairs. Based on the comparisons between the vibration signals obtained from the defect point and the measuring points on the bearing surface, the transmission mechanism of the defect excitation and the generation mechanism of the bearing housing structural vibration are clarified. The change law of defect excitation through an interface and the effects of bearing operational conditions (load and speed) on the vibration signals of measuring points are summarized. The results show that the optimal measuring point on the bearing housing surface is the location that is closest to the defect when the bearing housing system is working under light loads or high speeds. However, when under low speeds, the preferred measuring points are the positions where the rigidity of the bearing housing structure is weak. The analysis results provide a theoretical basis for the sensor arrangement and improvement of fault diagnosis accuracy under different operating conditions.

A Case Study on Remote Instrumentation of Vibration and Temperature in Bearing Housings

Data collection is one of the most relevant topics of modern automation and industry. It is usually a costly and time-consuming task, especially in continuous processes. Our case study takes place in a sugar cane mill. The required continuous operation of a belt conveyor for bagasse transportation makes it a critical system in the overall production process. Therefore, a predictive maintenance tool is highly applicable here. We identified bearing housings as critical points for data collection intended for prognostics of the conveyor. However, given the number of points, the cost of a commercial solution becomes unfeasible by our company. This paper reports the development of low-cost devices for measurements and wireless transmission of vibration and temperature data from bearing housings. We assessed several sensor options and made decisions based on a cost-suitability commitment, which led to the design of the electronic devices. The devices were tested for correct operation, reliability (99%), and relative measurement errors under 1.2%. From the tests, we conclude that our proposal is appropriate for our case study’s industrial needs and budget restrictions.

Experimental and numerical optimization of process parameters for thin wall machining of bearing housings

Bearing Housing is the critical part in Air end assembly of Screw compressor, because it determines the Discharge end clearance (DEC) which in term determine the volumetric and adiabatic efficiency. For setting a DEC in air end assembly, it is important to maintain the shoulder thickness of bearing housing within close tolerance of 10 µm. If not maintained so, metallic shim to be added in assembly process to maintain the clearance. Metallic shim selection for each assembly involves iteration method which is time consuming process. However due to machining constraint the current tolerance which achieved is 100 µm but the requirement is 10microns. If the improvement is done to achieve the required tolerance, DEC setting time can be reduced by eliminating iteration shim setting process. The aim of this project is to achieve the linear & Geometric dimensions within deserved critical tolerance in milling thin wall areas of housings in CNC milling machine by optimizing the process parameters using Design of experiments (DOE) and Finite element analysis (FEA). DOE with cutting parameters using Response surface modeling (RSM) with face centered design is used to obtain the significance level of Cutting speed, feed and Depth of cut. Optimize the tool cutting parameters to minimize the tool and part deflection during machining. FEA is used to reach the optimum clamping area and force to minimize the part deflection & deformation.

Effects of gearbox housing flexibility on dynamic characteristics of gear transmission system

The lightweight design of the gear system is the current tendency. The gearbox housing is modeled as a rigid body and is neglected in the gear dynamic analysis. It is of great significance to introduce the gearbox housing flexibility into the dynamic analysis and analyze the influence of the gearbox housing flexibility on the dynamic behaviors of the gear transmission system, as this can provide important instructions for the lightweight structure design of the housing. The gear–rotor–bearing model and the gear–rotor–bearing–housing model are established by the finite element node method. A Timoshenko beam element is used to represent the shafts. To illustrate the housing effect, two kinds of housing model are established: one tends to be rigid and the other to be flexible and lighter. The housings are simplified as a super element obtained by the dynamic substructure method. Natural frequencies and dynamic responses are illustrated to indicate the effects of housing flexibility. Comparisons of numerical results show that the rigid housing can be neglected for its little effect on the dynamic analysis. The flexibility of the housing slightly reduces the natural frequencies of the gear transmission system, and the maximum reduction is 6.05%. Meanwhile, the amplitudes of the first two resonance peaks of the dynamic transmission error decrease by 9.5% and 5.05%. Besides, more response peaks emerge at higher speeds when the flexibility of housing increases. The complete phenomena of dynamic behaviors of the gear transmission system can be obtained by considering the housing flexibility.

On modeling the static shape control of an adaptive air foil bearing

Aerodynamic foil bearings are used in various industrial applications, e.g. in cooling turbines, small gas turbines or exhaust gas turbochargers, to support light, high-speed rotors under extreme operating conditions. Air (or another gas) is used as a lubricant in these bearings. In addition, the possible thermal deformations and production errors can be compensated by a flexible foil structure between the lubricant film and the bearing housing in air foil bearings. Since many static and dynamic properties of the lubricant are strongly dependent on the inner contour of the bearing, the idea of an adaptive air foil bearing (AAFB) is developed to optimize the performance of the bearing at different operating points. This paper focuses on a semi-analytical approach based on plate theory and the Ritz method for approximating the static shape control of a piezoelectrically actuatable AAFB. The main objective of this study is to consider adaptive bearing shells in calculating the behavior of an AAFB, as they provide additional degrees of freedom to a passive air foil bearing without adaptivity. Before the final step is taken, the model presented in this analysis is used for the shape optimization of the adaptive frame of AAFB in order to achieve the most efficient shape adaption with regard to target shapes.

Jig and fixture Redesign for Main Bearing Housing Component

Main bearing housing is one of the gear transmission product components. The production process of this component needs to be repaired. The repair process is carried out on the fixture construction used today. Redesign is done as one of the solution to improve of the existing fixture design. The measurement results of the products that are machined with the existing fixture are still not in accordance with the requirements of the released product drawing. This is thought to occur because of an error in determining the operating procedur of the machining process that has an impact on the design of the fixture, especially in determining the reference to each machining processes carried out. Therefore, the new fixture needs to be designed so that the resulting product can fit the drawing demands. The repair process is carried out through a gradual study that refers to the methodology of the SME in order to be systematic and structured. Each stage of the design is carried out in detail starting from the study of product analysis, machining analysis, machine analysis, operator analysis and economic analysis. Based on the results of a product analysis study, a new machining process sequence has been produced. The new fixture design has been produced based on this sequence of machining processes. Based on the results of the study, it shows that the results of the redesign of the fixture repair show the conditions that are in accordance with the demands of the product images of the main bearing housing

Distribution characteristics of stress and displacement of rings of cylindrical roller bearing

In this paper, the developed finite element model of the shaft-cylindrical roller bearing–bearing housing system is established considering the temperature effect and clearance change. The displacement, raceway stress, and bearing stiffness characteristics of the inner and outer rings of the bearing are systematically investigated. The proposed finite element model is validated through adjusting mesh size of the bearing and the comparison of the elastic deformation of the bearing with the experiment. The influence of load, clearance, and temperature expansion on the displacement distribution of the inner and outer rings of the bearing, raceway stress, and stiffness characteristics are all discussed. The obtained results indicate that an appropriate selection of thermal expansion stress can obtain desirable working ambient temperature of the bearing under different clearances, which can serve as an efficient tool in the design of bearing parameters.

Effects of Tooth Modifications on the Mesh and Dynamic Characteristics of Differential Gearbox Used in Electric Vehicle

In order to reduce the vibration and noise for the differential gearbox used in electric vehicle, a coupled gear–shaft–bearing–housing dynamic model was developed considering the elastic support by shaft, bearing and housing. Three tooth modification schemes were proposed to investigate the effects of modification type on the mesh behaviors. Results show that the tooth modification scheme with a combined drum–tooth end modification for lead direction and linear addendum modification for profile direction can make the contact load distribution better. The contact pattern was located in the middle of the tooth, and the maximum contact pressure was decreased by 19% to 937 MPa. And the peak–peak value of transmission error was decreased by 33% for high-speed stage and 26% for intermediate stage. The tooth modifications tend to decrease the acceleration responses obviously, especially for the high-frequency range. The structure noise was reduced about 3.5–4.5 dB in x, y and z directions for the selected bearing locations. The analysis results can be applied to guide the design of electric vehicle differential gearbox with low noise level.

Вплив схеми базування на першій операції на величину припуску для розточування отворів в заготовках корпусних деталей на настроєних верстатах

Three variants of the scheme of basing the body part billet on the first machining operation are considered. The first two options solve the problem of providing dimensional communication between treated and untreated surfaces; the third option is the task of removing the minimum uniform allowance from the surface of the main hole. The aim of the work is to identify the influence of the base scheme in the first operation of the technological process of machining a batch of body parts on a tuned machine on the quantitative values of allowances for the main hole boring. The studies were carried out on the example of machining a workpiece of a part of the "Bearing housing" type under mass production conditions. To determine the allowances, the calculation and analytical method proposed by Professor V. M. Kovan was used. For the three variants of basing schemes, all elements of intermediate allowances, minimum, maximum and general allowances are calculated. It is established that the use of the first two variants of the base scheme causes the magnitude of the displacement of the hole axis in the initial billet relative to the technological bases for the operation of its boring approximately ten times greater than the use of the third variant of the base pattern. The magnitude of the offset of the axis of the hole in the original billet is determined by building the appropriate technological dimensional chains. An assessment of the possibility of using standard values of allowances, determined without taking into account the base scheme at the first operation, showed that if the value of the minimum start-up is significantly influenced by the offset value of the bore axis in the original billet relative to the technological bases, then for its full account in specific technological conditions should use the analytical method.

A Combined EFEM–Discrete Element Method Dynamic Model of Rotor–Bearing–Housing System

In this paper, a model was developed to study the effects of rotor and support flexibilities on the performance of rotor–bearing–housing system. The system is composed of a flexible rotor and two supporting deep-groove ball bearings mounted in flexible bearing housings. The dynamics of the ball bearings were simulated using an existing dynamic bearing model, which was developed using the discrete element method (DEM). The explicit finite element method (EFEM) was used to model the flexibilities of the rotor and bearing support. In order to combine the dynamic bearing model with finite element rotor and support system, new contact algorithms were developed for the interactions between the various components in the system. The total Lagrangian formulation approach was applied to decrease the computational effort needed for modeling the rotor–bearing–housing system. The combined model was then used to investigate the effects of bearing clearances and housing clearances. And it was found that, as the rotor is deformed due to external loading, the clearances have a significant impact on the bearing varying compliance motion and reaction moments. Results also show that deformation of the flexible housing depends on the total force and moment generated within the bearing due to rotor deformation. The first critical speed of rotor was simulated to investigate the unbalance response of the rotor–bearing system. It was demonstrated that rotor critical speed has a significant effect on inner race displacement and reaction moment generated at bearing location.

Ground-Based Response of a Spinning, Cyclic Symmetric Rotor Assembled to a Flexible Stationary Housing Via Multiple Bearings

This paper is to study ground-based response of a spinning, cyclic symmetric rotor assembled to a flexible housing via multiple bearings. In particular, interaction of the spinning rotor and the flexible housing is manifested theoretically, numerically, and experimentally. In the theoretical analysis, we show that the interaction primarily appears in coupled rotor–bearing–housing modes whose response is dominated by the housing. Specifically, let a housing-dominant mode have natural frequency ω(H) and the spin speed of the rotor to be ω3. In rotor-based coordinates, response of the spinning rotor for the housing-dominant mode will possess frequency splits ω(H)±ω3. In ground-based coordinates, response of the spinning rotor will possess alternative frequency splits ω(H)-(k+1)ω3 and ω(H)-(k-1)ω3, where k is an integer determined by the cyclic symmetry of the rotor and the housing-dominant mode of interest. In the numerical analysis, we study a benchmark model consisting of a spinning slotted disk mounted on a stationary square plate via two ball bearings. The numerical model successfully confirms the frequency splits both in the rotor-based and ground-based coordinates. In the experimental analysis, we conduct vibration testing on a rotor–bearing–housing system that mimics the numerical benchmark model. Test results reveal two housing-dominant modes. As the rotor spins at various speed, measured waterfall plots confirm that the housing-dominant modes split according to ω(H)-(k+1)ω3 and ω(H)-(k-1)ω3 as predicted.

Dynamic analysis and experimental study of a marine gearbox with crossed beveloid gears

Dynamic modeling of beveloid gears is less developed than that of conventional involute gears with parallel axis because of their complicated mesh mechanism and 3-dimensional dynamic coupling. For evaluating the dynamic characteristics of a marine gearbox with crossed beveloid gears more realistically, a systematic dynamic modeling approach was proposed based on the lumped parameter and the finite element method. Considering the time-varying mesh stiffness excitation, time-varying loaded translational transmission error excitation, sliding friction excitation and backlash nonlinearity, a coupled gear–shaft–bearing–housing dynamic model for a marine gearbox with crossed beveloid gears was developed based on the proposed modeling method. Then, numerical integrations applying the explicit Runge–Kutta formula and the implicit direct integration were used to solve the nonlinear dynamic model. The dynamic transmission error, dynamic mesh force, and dynamic equivalent shaft-bearing supporting force were obtained as well as the dynamic response of the housing. Finally, a test rig was established for the marine gearbox with crossed beveloid gears and vibration tests were performed to investigate the dynamic responses. Through analyzing the responses in time domain and frequency domain, the experimental results compared well with the theoretical dynamic results.

Developing an Intelligent Fault Diagnosis of MF285 Tractor Gearbox Using Genetic Algorithm and Vibration Signals

This article investigates a fault detection system of MF285 Tractor gearbox empirically. After designing and constructing the laboratory set up, the vibration signals obtained using a Piezoelectric accelerometer which has been installed on the Bearing housings are related to rotary gear number 1 in two directions perpendicular to the shaft and in line with the shaft. The vector data were conducted in three different speeds of shaft 1500, 1000 and 2000 rpm and 130 repetitions were performed for each data vector state to increase the precision of neural network by using more data. Data captured were transformed to frequency domain for analyzing and input to the neural network by Fourier transform. To do neural network analysis, significant features were selected using a genetic algorithm and compatible neural network was designed with data captured. According to the results of the best output mode for each position of the sensor network in 1000, 1500 and 2000 rpm, totally for the six output models, all function parameters for MATLAB Software quality content calculated to evaluate network performance. These experiments showed that the overall mean correlation coefficient of the network to adapt to the mechanism of defect detection and classification system is equal to 99.9%.

Optimal Bearing Housing Designing Using Topology Optimization

The internal load distribution in rolling bearings has a high impact on the bearing fatigue life. This study presents a method to optimize roller bearing housing design in order to maximize the bearing fatigue life by ensuring an optimal internal load distribution. An FE-model of a cylindrical roller bearing utilizing nonlinear springs in the roller modeling is presented, which is capable of simulating the bearing load distribution efficiently. The optimal load distribution is achieved by specifying the desired internal load distribution as design constraints in a topology optimization of the bearing housing design. The superiority of the method is clearly demonstrated through case studies involving a cylindrical roller bearing, where it is shown that the fatigue life is increased and the bearing housing mass and roller contact misalignment is reduced.

Simulation of Benzene Exposure during Use of a Mineral Spirit Solvent to Clean Elevator Bearing Housings

ABSTRACT An exposure simulation was conducted to reconstruct and assess a sheet-metal worker's historical exposure to benzene associated with the degreasing and cleaning of parts and equipment during the repair of a soybean elevator head pulley. The simulation was based on an employee description of the specific activities performed in the 1980s. Bulk solvent and airborne benzene concentrations associated with the degreasing and cleaning of parts and equipment using a bucket of mineral spirits solvent and soaked shop towels were measured during the simulation. The mineral solvent was spiked with benzene to represent the historical product formulation. Benzene concentrations in personal and background air samples were below the limits of analytical detection. These data were used to estimate a worker's inhalation and dermal exposure to benzene from the cleaning and degreasing task. The total dose of approximately 0.2 mg benzene estimated based on the simulation results is approximately equivalent to that received from non-occupational sources by individuals living in urban areas. This study demonstrated the utility of an exposure simulation in reconstructing and assessing historical worker exposures in a situation where no useful exposure data were available to characterize the exposure of interest.