Contact Stress Research Articles

Detection method for contact stress distribution of tapered roller bearings

The axle box of high-speed train adopts double row tapered roller bearings as transmission parts, and the reliability of bearings directly affects the safety of train operation. Tapered roller bearings can withstand axial and radial loads, their service life being closely related to the distribution of contact stress. The test object is the axle box bearing of high-speed train. According to bearing’s structural characteristics, based on the digital speckle correlation method (DSCM) and machine vision, the contact stress distribution detection devices for rollers and complete sets of bearings are developed respectively and an effective detection method is proposed. The contact stress data of the bearing which has reached the service life and the new bearing under the condition of no lubrication and grease lubrication are collected and normalized. Through the geometric relationship, based on the measured data of the selected detection points, the normal and tangential contact stress distribution of the roller and raceway under different contact conditions is obtained by data fitting. The test can be used as an evaluation basis for the effectiveness of bearing modification and provide reference for bearing design.

Elastic and Elastoplastic Contact Mechanics of Concentrated Coated Contacts

Machines operate under increasingly harsher contact conditions, causing significant wear and contact fatigue. Sub-surface stresses are responsible for the premature contact fatigue of rolling element bearings, meshing gears, and cam–follower pairs. Surface protection measures include hard, wear-resistant coatings. Traditionally, contact integrity has been predicted using classical Hertzian contact mechanics. However, the theory is only applicable when the contact between a pair of ellipsoidal solids of revolution may be considered as a rigid indenter penetrating a semi-infinite elastic half-space. Many coatings act as thin bonded elastic layers that undergo considerably higher pressures than those predicted by the classical theory. Furthermore, inelastic deformation of bonded solids can cause plastic flow, work-hardening, and elastoplastic behaviour. This paper presents a comprehensive, integrated contact mechanics analysis that includes induced sub-surface stresses in concentrated counterformal finite line contacts for all the aforementioned cases. Generated pressures and deformation are predicted for hard coated surfaces, for which there is a dearth of relevant analysis. The contact characteristics, which are of particular practical significance, of many hard, wear-resistant advanced coatings are also studied. The paper clearly demonstrates the importance of using efficient semi-analytical, detailed holistic contact mechanics rather than the classical idealised methods or empirical numerical ones such as FEA. The novel approach presented for the finite line contact of thin-layered bonded solids has not hitherto been reported in the open literature.

Analysis of the Influence of Contact Stress on the Fatigue of AD180 High-Carbon Semi-Steel Roll

In this study, to investigate the problem of contact fatigue and the damage mechanism of an AD180 high-carbon semi-steel roll, rolling contact fatigue tests were conducted using specimens cut from the periphery of a roll ring. These specimens were characterized under different contact stresses using SEM, a profile system, an optical microscope, and a Vickers hardness tester. The results indicates that the main forms of fatigue damage of an AD180 high-carbon semi-steel roll are peeling, pitting corrosion, and plowing. Moreover, the surface of the roll exhibits delamination and plastic deformation characteristics under high contact stress. Meanwhile, the size and depth of peeling, as well as the amount of pitting corrosion, increase with the contact stress. Peeling is mainly caused by a crack that originates at the edge of the specimen surface and propagates along the pearlite structure and the interface between pearlite and cementite. High contact stress can lead to an increase in the crack propagation depth and angle, resulting in the formation of larger peeling. Under cyclic loading, the near-surface microstructure of the specimen hardens due to grain refinement and dislocation strengthening, and the depth of the hardened layer increases with the increase in contact stress. When the contact stress reaches 1400 MPa, the near surface structure of the specimen changes from pearlite to troostite.

Study on the sealing performance of high-pressure flanges by a magnetic measurement method of bolt axial force

Under high-pressure conditions, flange sealing often fails due to inadequate bolt pre-tension, leading to unstable pressurization or leakage. Assessing the integrity of high-pressure flange sealing presents challenges, constrained by operational conditions, complex equipment integration, and associated costs. This study introduces a method to evaluate flange sealing using magnetic measurements of bolt axial forces. A novel device developed using the magnetoelastic method efficiently and conveniently measures these forces under various internal pressures. The results show a linear relationship between magnetic signals and bolt axial forces at nominal pressures, whereas excessively high pressures cause anomalous changes in magnetic signals, indicative of bolt plastic deformation. Finite element simulation analyzed the changes in bolt axial force and gasket contact stress due to internal pressures, leading to an empirical formula that correlates these variables under varying pressures. The study also explored the impact of uneven pre-tensioning and gasket material on sealing contact stress. A sealing contact surface model, established based on actual roughness profile parameters, enabled the simulation and formulation of an exponential relationship between contact stress and sealing clearance. This foundation facilitated the creation of a leakage prediction model that incorporates bolt axial force parameters, thus enabling a quantitative assessment of flange sealing performance. This research provides a practical approach to evaluating the sealing performance of operational high-pressure flanges.

Dynamic reliability analysis of angular contact ball bearing based on maximum entropy quadratic fourth moment method*

ABSTRACT Bearing failure occurs when the dynamic contact stress exceeds the yield strength of the bearing material during operation. To minimise the risk of bearing failure, a new reliability theory method is proposed based on the stress-strength model of bearings, incorporating random input variables to analyse the reliability of angular contact ball bearings (ACBBs) and quantify their dynamic performance. The maximum entropy quadratic fourth moment method is used to calculate the probability distribution of maximum orthogonal shear stress-strength of bearing, and the maximum entropy principle is used to obtain the approximation of the minimum human error factors. Additionally, reliability-based sensitivity indices are derived to investigate the parametric significance of random input variables. Using B218 bearing as an example, the engineering application of this method in dynamic reliability and reliability-based sensitivity analysis is illustrated. Monte Carlo simulation is performed to verify the accuracy and effectiveness of the method to provide benchmark results. The results show that the Poisson’s ratio have a greater influence on the dynamic reliability of ACBBs than other parameters. Improving parameters such as ball diameter, raceway groove curvature radius and contact angle can also improve the reliability of bearings to some extent.

Preparation and self-lubricity investigation of CNTs/Ni composite coatings under severe conditions

Carbon nanotubes (CNTs) demonstrate the potential to improve the tribological properties of nanocomposite coatings. Herein, CNTs/Ni composite coatings were quickly fabricated by the direct current (DC) electrodeposition. The adhesion strength was estimated by the scratch test incorporation with an acoustic emissive signal. Much attention was paid on the self-lubricity of the CNTs/Ni composite coating under severe conditions. Results indicated that presence of CNTs enhanced the adhesion strength of the pure Ni coating. Notably, CNTs contributed towards 54.5 % of friction reduction in comparison to the pure Ni coating at dry friction. The improvement of tribological properties was attributed to that under high contact stress the embedded CNTs were crushed to tiny lubricating particles and produced protective film on rubbing surfaces.

Examining the contact problem of a functionally graded layer supported by an elastic half‐plane with the analytical and numerical methods

This study offers a comparative study of the analytical and numerical methods for investigating a contact problem. The contact problem comprises a functionally graded layer supported by a half‐plane and loaded with a distributed load from the top surface. First, the analytical and numerical solutions to the problem are acquired by utilizing a theory of elasticity and finite element method, respectively. The problem is transformed into a system of integral equations in which the contact stress is an unknown function. The solution of the integral equation was achieved with Gauss–Jacobi integration formulation. The finite element model of the problem is created using ANSYS software, and the two‐dimensional analysis of the problem is performed. Results were obtained from the samples for different material properties and loading conditions. The distributed load width and non‐homogeneity parameters significantly impact on contact mechanics. The results indicate that the contact area and the contact stress obtained from finite element method (FEM) are close to the analytical results. As a result, acceptable error rates were obtained. Finally, this study provides evidence of a good agreement between the two methods.

Multi-objective design optimization of polymer spur gears using a hybrid approach

Polymer gears are used in applications requiring small to moderate loads to effectively transmit power and use the limited place available as possible. Various commercial standards have been provided designers with the rating criteria and acquaintance of different polymer material properties for the process of design. However, the result was unsatisfactory in terms of economy, time, and the optimality of the product. Thus, classic and stochastic algorithms have been embraced to reach the best design of polymer gears. Taking advantage of the former and latter algorithm’ methods, optimal design of gears could be attained with an increased gear life span and decreased failure modes. In this study, polyoxymethylene (POM) spur gear set has been optimized combining the mathematical model from plastic standards and hybrid optimization approach of multi-objective genetic algorithm (MOGA) and sequential quadratic programming (SQP). Weight and power loss were the objective functions. Five design variables were optimized with the satisfaction of bending and contact stresses, temperature, wear, and deformation as constraints. Solutions of the problem were formulated as Pareto optimal set. The results of multi-objective were compared with previously published single-objective optimization. The results favored multi-objective optimization (82.67%, 31.39% reduction in weight and power loss respectively) as it gave the best applicable solution fitting in real life situations. The results also went hand in hand with literature confirming the efficiency of the proposed algorithm. With the variation of operating parameters, various optimal designs could be obtained where the designers can choose the design that is suitable for a particular application.

Comparative analysis of dynamic load characteristics of artillery steering gear based on different MBD methods

The multi-body dynamics analysis model of the steering gear of a certain type of artillery was established. The dynamic load characteristics of the output gear of the steering gear motor and its driven gear under the given speed and load conditions were calculated based on the three different MBD analysis methods, such as the speed, meshing force, and contact stress. Through the comparative analysis, it was concluded that the calculation results of rigid-flexible coupling analysis were closer to the theoretical value and the fluctuation range was smaller, which provides reference and basis for the prediction of gear fatigue life and the optimization design under dynamic load conditions.

Normative contact mechanics of the ankle Joint: Quantitative assessment utilizing bilateral weightbearing CT

Alterations in ankle’s articular contact mechanics serve as one of the fundamental causes of significant pathology. Nevertheless, computationally intensive algorithms and lack of bilateral weightbearing imaging have rendered it difficult to investigate the normative articular contact stress and side-to-side differences. The aims of our study were two-fold: 1) to determine and quantify the presence of side-to-side contact differences in healthy ankles and 2) to establish normative ranges for articular ankle contact parameters. In this retrospective comparative study, 50 subjects with healthy ankles on bilateral weight-bearing CT were confirmed eligible. Segmentation into 3D bony models was performed semi-automatically, and individualized cartilage layers were modelled based on a previously validated methodology. Contact mechanics were evaluated by using the mean and maximum contact stress of the tibiotalar articulation. Absolute and percentage reference range values were determined for the side-to-side difference. Amongst a cohort of individuals devoid of ankle pathology, mean side-to-side variation in these measurements was < 12 %, while respective differences of > 17 % talar peak stress and > 31 % talar mean stress indicate abnormality. No significant differences were found between laterality in any of the evaluated contact parameters. Understanding these values may promote a more accurate assessment of ankle joint biomechanics when distinguishing acceptable versus pathological contact mechanics in clinical practice.

Failure analysis and pin hole profile optimization design of combined piston for marine diesel engine based on Kriging model and NSGA-Ⅱ algorithm

Amidst the drive for enhanced performance and reliability in marine diesel engines, anti-fatigue design has emerged as a pivotal factor in ensuring safe operation. To investigate the cracking of a steel-topped aluminum-skirted combined piston in a marine diesel engine, thorough analyses were conducted on mechanical properties, chemical composition, and microscopic morphology. Subsequently, a piston thermo-mechanical coupling (TMC) model was established to simulate stress distribution and fatigue strength. Findings revealed that loose defects in the material and deformation mismatch in the pin hole bearing TMC were the primary factors contributing to cracking. Based on this, a multi-objective optimization (MOO) design method for piston pin hole profiles was proposed. Optimal pin hole profile design parameters were determined using the Kriging surrogate model and the second generation non-dominated sorting genetic algorithm (NSGA-II), and the nonlinear relationship between the design variables and the response objectives was obtained. Post-optimization, stress in the piston cracking source region decreased by 40.6%, peak contact pressure and stress in the pin hole decreased by 59.2% and 49.1%, respectively. Furthermore, the minimum fatigue safety coefficient improved from 0.86 to 1.18.

Investigation into the effect of deltoid ligament injury on rotational ankle instability using a three-dimensional ankle finite element model.

Injury to the lateral collateral ligament of the ankle may cause ankle instability and, when combined with deltoid ligament (DL) injury, may lead to a more complex situation known as rotational ankle instability (RAI). It is unclear how DL rupture interferes with the mechanical function of an ankle joint with RAI. To study the influence of DL injury on the biomechanical function of the ankle joint. A comprehensive finite element model of an ankle joint, incorporating detailed ligaments, was developed from MRI scans of an adult female. A range of ligament injury scenarios were simulated in the ankle joint model, which was then subjected to a static standing load of 300N and a 1.5Nm internal and external rotation torque. The analysis focused on comparing the distribution and peak values of von Mises stress in the articular cartilages of both the tibia and talus and measuring the talus rotation angle and contact area of the talocrural joint. The dimensions and location of insertion points of ligaments in the finite element ankle model were adopted from previous anatomical research and dissection studies. The anterior drawer distance in the finite element model was within 6.5% of the anatomical range, and the talus tilt angle was within 3% of anatomical results. During static standing, a combined rupture of the anterior talofibular ligament (ATFL) and anterior tibiotalar ligament (ATTL) generates new stress concentrations on the talus cartilage, which markedly increases the joint contact area and stress on the cartilage. During static standing with external rotation, the anterior talofibular ligament and anterior tibiotalar ligament ruptured the ankle's rotational angle by 21.8% compared to an intact joint. In contrast, static standing with internal rotation led to a similar increase in stress and a nearly 2.5 times increase in the talus rotational angle. Injury to the DL altered the stress distribution in the tibiotalar joint and increased the talus rotation angle when subjected to a rotational torque, which may increase the risk of RAI. When treating RAI, it is essential to address not only multi-band DL injuries but also single-band deep DL injuries, especially those affecting the ATTL.

Research on non-contact dynamic stress calibration method of fan blade on simulation

In order to establish the non-contact measurement method of fan blade dynamic stress, the most important thing is to establish the method of fan blade dynamic stress calibration. In this paper, the static virtual loading and harmonious response analysis of fan blades in the simulation platform, and the calibration equation between the blade tip displacement and the blade dynamic stress is established. Finally, the calibration equation is verified and the error analysis is carried out by simultaneously carrying out contact and non-contact dynamic stress measurement tests on the rotor test bench.

Comparison of the reliability of strength limit calculation methods for prismatic samples with different spreading of normal contact stresses in their wedge failure shape

This article explores methods for calculating the strength limits of solid objects subjected to compression. Traditionally, two stress distribution patterns are used: the exponential pattern by E.P. Unksov and the linear pattern by L. Prandtl. The authors introduce an enhanced stress distribution method. They compare the accuracy of these methods in calculating strength limits and constructing “normal stress - longitudinal strain” diagrams for wedge-shaped failures in rock samples. Four properties are considered: shear strength, coefficients of internal and external friction, and elasticity modulus. The results show that, with an external friction coefficient up to 0.3, all methods yield similar accuracy in strength limit calculations and ultimate stress-strain curves. Some curves exhibit stress drops, explained by a transition from convex to concave slip lines during failure. Additionally, there are hardening curves in the ultimate curves without theoretical justification. The comparison of calculated strength limits with experimental data confirms the method’s accuracy: 13.7% error for the exponential method, 11.4% for the linear method, and 8.1% for the enhanced distribution, especially for low contact friction values (up to f c=0.3).

THE METHOD OF SELECTING THE MOST APPROPRIATE MODIFICATION OF THE MECHANISM USING COMPUTER TECHNOLOGIES

The article presents a method for identifying the most appropriate modification of the mechanism with the required output shaft rotation frequency by constructing various geometric models and calculation schemes. This technique based on the design and analysis of modification of the vibration stand mechanism for testing measuring equipment and products for vibration resistance and vibration resistance. The strength analysis of contact stresses and bending stresses in the engagement zone of the elements under various external and boundary conditions was performed using analytical and computer methods. A 3D geometric model of the parts is being created with the display of traces of operation on the surface of the parts, anticorrosion coatings, using materials of various heat treatment in the Compass 3D V.21 package. The most appropriate modification of the mechanism is identified by analyzing the distributions of maximum equivalent stresses according to Mises, the main stresses according to geometric models of parts. If these stresses exceed the limit values or the mechanism is underloaded, the geometric dimensions of the transmission parts should be changed, another material for the transmission parts should be selected and the strength calculations should be repeated.

Finite Element Analysis of Spur Gear Set in Noodles-making Machine Using Different Materials and Face Widths

This paper focuses on the design and structural analysis of a spur gear set for a noodles-making machine by changing three different materials (ASTM A 536, ASTM A 220, and AISI 1020) and gear face widths. Gear corrosion occurs at contact points as a result of bending stress and contact stress. This is the major source of the gear failure of the noodles-making machine. Pitch diameters of 50mm and modules of 5mm spur gears are selected in the design of the roller gear set. In theoretical analysis, the AGMA contact stress equation was used based on the Hertzian theory. The minimum von Mises stress and effective strain are found on AISI 1020 carbon steel by using ANSYS 17.0 software. In this paper, von Mises stress and effective strain are analyzed by changing the face widths of spur gear set to 8mm, 10mm, 12mm, 14 mm, and 16mm and using finite element analysis (FEA). Although all face widths are safe for this design, 12mm is chosen in this paper due to power consumption and strength points of view.

Finite element investigations for chip scraping during orthogonal cutting process with micro-textured tools

Compared with the conventional tool (CT), the micro-textured tool (MTT) has the advantages of reducing cutting forces, lowering cutting temperatures and inhibiting tool wear. However, the chip scraping phenomenon generated in the cutting process has negative effects and degrades cutting performance when using the MTT with grooves perpendicular to the cutting edge. Due to the difficulty in observing and characterizing chip scraping in situ by experiments, its mechanism and influence on specific cutting forces and tool wear are not fully understood. To this end, finite element (FE) method is employed for simulating the cutting process with MTT. The simulation model is validated by comparing the predicted and measured specific cutting forces. The average prediction error of specific cutting and feed forces is 12.4 % and 18.8 %, respectively. The simulation results indicate that chip scraping mainly results from the discontinuity, non-uniformity and high contact stress state of the tool-chip interface. The minimum specific cutting force is achieved when the advantages of micro-texture and the chip scraping effects are balanced. The MTT rake face wear is subdivided into a severe and a sliding wear zone. This partition characteristic is closely associated with normal contact stress and temperature distributions. The work in this paper contributes to improving the understanding of chip scraping, optimizing micro-texture and cutting parameters, and promoting MTT applications in the manufacturing industry.

Research on hexagonal concrete-filled steel tubular transition pieces for wind turbine hybrid towers under axial compression

With the escalating height of wind turbine structures, wind turbine steel-concrete hybrid towers have gradually become a new type of structure to replace pure steel towers. As a component connecting the upper steel tower with the lower concrete tower, the transition piece assumes an indispensable role in the overall structure of the hybrid tower. The traditional reinforced concrete-type transition piece has necessitated enhancements owing to the complicated construction and concrete cracking problems. A hexagonal concrete-filled double skin steel tubular (CFDST) transition piece is proposed to fit the hexagonal steel-concrete hybrid tower. Studies that investigate the hexagonal CFDST structures are currently few. Based on this, three hexagonal CFDST stub columns were tested, with the variables in stiffened measures. The experimental portion included a thorough investigation of local buckling behaviors and failure modes in addition to the analysis of typical mechanical indexes. Further, the validated finite element (FE) model was then utilized for mechanism analysis about the contact stress between different interfaces, the stress distributions, and so on. Besides, a parametric study was done to identify the sensitive parameters affecting this kind of structure's peak loads. Ultimately, the peak load prediction formulas found in published studies and specifications were modified by incorporating the findings from this investigation.

A finite element model of human hindfoot and its application in supramalleolar osteotomy

BackgroundThe majority of the ankle osteoarthritis cases are posttraumatic and affect younger patients with a longer projected life span. Hence, joint-preserving surgery, such as supramalleolar osteotomy becomes popular among young patients, especially those with asymmetric arthritis due to alignment deformities. However, there is a lack of biomechanical studies on postoperative evaluation of stress at ankle joints. We aimed to construct a verifiable finite element model of the human hindfoot, and to explore the effect of different osteotomy parameters on the treatment of varus ankle arthritis. MethodsThe bones of the hindfoot are reconstructed using normal CT tomography data from healthy volunteers, while the cartilages and ligaments are determined from the literature. The finite element calculation results are compared with the weight-bearing CT (WBCT) data to validate the model. By setting different model parameters, such as the osteotomy height (L) and the osteotomy distraction distance (h), the effects of different surgical parameters on the contact stress of the ankle joint surface are compared. FindingsThe alignment and the deformation of hindfoot bones as determined by the finite element analysis aligns closely with the data obtained from WBCT. The maximum contact stress of the ankle joint surface calculated by this model increases with the increase of the varus angle. The maximum contact stresses as a function of the L and h of the ankle joint surface are determined. InterpretationThe relationship between surgical parameters and stress at the ankle joint in our study could further help guiding the planning of the supramalleolar osteotomy according to the varus/valgus alignment of the patients.

Mathematical Model and Analysis of Novel Bevel Gear with High Load-Capacity Based on the Geometric Elements

Load-capacity has always been one of the performances that is paid much attention to in the development of bevel gear transmission applications. Consequently, the mathematical model of novel bevel gear with high load-capacity based on geometric elements is proposed in this paper, which could be applied to the aviation, aerospace and other fields. In parallel, the design principle and design method of the novel bevel gear are introduced in detail. Subsequently, the conditions for tooth surface continuity and non-interference are derived. Furthermore, the model of novel bevel gear is established. Finally, the load-bearing characteristics are analyzed, revealing that an increase in the number of contact points could significantly enhance the load capacity of the bevel gear pairs. When the load torque applied to bevel gear II is 100 Nm, the contact pressure endured by the bevel gear pair with five-point contact is decreased by 41.37% compared to the bevel gear pair with single-point contact. When the number of contact points is the same, increasing the distance between the contact points could also reduce the contact stress. This provides strong theoretical support for the application of the bevel gear based on the geometric elements.