Radial Load Research Articles

Stiffness Optimization of Squirrel Cage in Aircraft Engines

squirrel cage is a component used in engine shafts to make the shaft stiffer and able to withstand high cycle fatigue loads continuously for a long time. A squirrel cage can be of many shapes and sizes. The critical speed and the stresses acting on the shaft play a key role in determining the performance of shafts in engines. The squirrel cage in the shaft absorbs stress and extends shaft life. This paper deals with the structural design and analysis of the squirrel cage of an aircraft engine. The design of the squirrel cage was done on SolidWorks, and analysis was carried out on the Ansys workbench. To meet the strength and stiffness, the squirrel cage was optimized by introducing slots in it. Stress analysis of the bearings has been carried out for axial and radial loads from 1 to 20 kg. The radial load is applied to individual bearings, and then the axial load is applied to only one bearing. Then results are plotted into curves, and a slope is obtained based on deformations obtained. The stiffness value is noted, and the same procedure is performed for an optimized slotted squirrel cage. These values are compared, and then the squirrel is proved to be weight optimized and has improved stiffness.

The Effect of Air–Water Mixture on the Dynamic Response of a Hydrodynamic Journal Bearing With Inclined Grooves

Abstract Water-lubricated hydrodynamic journal bearings with deep inclined grooves are often used to support radial loads and dampen pump vibrations in nuclear power plants. The inclined grooves increase the pumping effect of the lubricant thus reducing wear and friction during rotor startup and coast-down. The deep grooves also facilitate the removal of debris without damaging the bearing. The load capacity and the stability of this type of bearing are studied in the present work. A sensitivity study of the impact of the number of grooves on bearing performance underlined the superiority of the journal bearing with two inclined grooves. Moreover, these journal bearings may operate with a mixture of water and air. This compressible two-phase lubricant will modify the load capacity and the stability of the journal bearing. The impact of the ingested volume fraction of air is therefore investigated. A physical model of the homogeneous air–water mixture linking the local air volume fraction with the pressure was used in conjunction with the numerical solution of the compressible Reynolds equation on an unstructured grid. It was found that the air ingestion in the two-inclined grooves journal bearing decreases the load capacity but improves the stability for mild and low loads.

Quasi-static/dynamic energy absorption characteristics and micromechanical behavior of Al/Ep cast metal braided tubular structures

As a low-density, high-strength material with high energy release potential, Al/Ep cast metal braided tubes have a wide range of application prospects in the combatant shell, which is one of the most important means to realize the integrated destructive effect of kill and blast. In this paper, Al/Ep composites with mass ratios of 3:7, 4:6 and 5:5 were prepared, and the intrinsic model of Al/Ep was established by studying its quasi-static and dynamic mechanical properties. The Al/Ep cast three-dimensional braided metal skeletons were used to obtain the required cast braided tubes with different mass ratios, and the destruction behaviors of the tubes under axial and radial compressive loads were analyzed by a combination of experimental and numerical simulations. The results show that the addition of Al particles can significantly improve the elastic-plastic properties of Al/Ep composites, and the energy storage and absorption capacities are positively correlated with the ratio of the relative contents of Al powder. When the mass ratio of Al powder to epoxy resin is 5:5, the energy absorption of Al/Ep composites is 23.16 MJ/m3, which is optimal among similar specimens and much higher than that of pure epoxy resin materials (the energy absorption of epoxy resin is 9.63 MJ/m3). The strength of binary resin matrix composites is improved, and the intrinsic models of three kinds of different mass ratios of Al/Ep composites are obtained. The intrinsic models of various Al/Ep cast braided tubes with crushing force efficiency CFE, energy absorption capacity, and specific energy absorption SEA decreased with the ratio of mass occupied by the braided filaments.

Investigating the mechanical properties and crashworthiness of hybrid PLA/GFRP composites fabricated using FDM-filament winding

The failure and crashworthiness performance of hybrid Polylactide (PLA)/Glass Fiber Reinforced Polymer (GFRP) composite tubes subjected to axial and radial quasistatic compression loads were investigated in the present study. The composite tubes are fabricated using hand lay-up and Fused Deposition Modeling (FDM)-filament winding processes. The crashworthiness performance was studied using parameters such as the peak load, energy absorption, crush load, crushing load efficiency, and specific energy absorption. The highest peak loads from the compression test results in the axial and radial directions are calculated using variations in the filament winding PLA/GFRP (FPG) specimen, whose values were 16130.50 N and 12077.33 N, respectively. The highest mean crush load is found in the material variation with the FPG specimen, which is 5734.43 J/mm for axial loading and 4886.75 J/mm for radial loading. The highest energy absorption (EA) value is found in the material variation with the FPG specimen, which is 262.18 J for axial direction loading and 94.02 J for radial direction loading. The highest specific energy absorption (SEA) value is found in the material variation with the specimen Filament Winding PLA/GFRP, which is 16.92 J/g for axial loading and 10.98 J/g for radial loading. There are three main types of failure of the composite: matrix cracking, fiber damage, and folding. The study showed that by combining Additive Manufacturing and composite lamination, the hybrid PLA/GFRP specimen outperformed the existing structures.

Film Thickness in Grease-Lubricated Deep Groove Ball Bearings—A Master Curve

Film thickness in a grease-lubricated bearing is a critical bearing operation parameter, yet there are no models available to predict it. Our recent articles demonstrated that the relative film thickness ( h g / h ff ) can be predicted using the base oil viscosity ( η ), half contact width (b), and linear speed (u) for any axially loaded deep groove ball bearing. In this article, we extend this study to include radial loads and combined—axial and radial—loads. Radial load application causes an additional replenishment in the unloaded zone, introducing a new length variable z r and surface tension σ . A universal power-law relationship between the relative film thickness in a deep groove ball bearing and the nondimensional number ( η bu ) / ( z r σ ) for all loading and grease lubrication conditions is presented for use in predicting film thickness.

Dynamic Modeling and Behavior of Cylindrical Roller Bearings Considering Roller Skew and the Influence of Eccentric Load

At high speeds, skew and skid may frequently occur for the rollers in cylindrical roller bearings, especially when under eccentric load, as the uneven load distribution along the generatrix of the roller further aggravates this phenomenon. In this paper, a dynamic model of a cylindrical roller bearing was established, taking into account roller skewing and interactions with the cage. Firstly, the interaction between the roller and the raceway was calculated by slicing the roller along its generatrix. Furthermore, the computation of the interaction between the roller and the cage is based on elastic theory, taking into account pocket clearance. Subsequently, the dynamic equations for both rollers and cage were derived. Based on this foundation, an investigation was conducted to reveal how rotational speed, radial loads, and moment loads affect roller slipping, skewing characteristics, and interactions with the cage under uneven load conditions. The findings indicate a direct proportionality between roller slipping and bearing speed while exhibiting an inverse relationship with load magnitude. Additionally, it was observed that both bearing speed and load have a direct influence on roller skewing angle. Moreover, normal interaction force between the roller and cage demonstrates a direct proportionality to bearing speed while inversely correlating with load magnitude.

Radial compression performance of glass fiber reinforced polyurethane composite tube with open-hole

Glass fiber reinforced polyurethane matrix composite (GFRP) is a novel composite material. GFRP circular tubes are widely used in engineering because of its excellent mechanical properties. It is inevitable to open holes on GFRP circular tubes when connecting with other components due to the use requirements and structural needs. The radial compression test, theoretical analysis, and finite element calculation of GFRP circular tubes produced by the braiding-winding-pultrusion process are carried out, to study the influence of holes on the compression performance of tubes. The GFRP circular tube has four layers with different fiber angles. From the inner to the outer structure layer, they are the inner woven layer, winding layer, longitudinal fiber layer, and outer woven layer. The mechanical properties of a 0° unidirectional plate are better than those of a 90° unidirectional plate according to the mechanical properties test. The radial compression tests are carried out on GFRP circular tubes with a length of 300 mm, an outer diameter of 140 mm, and a wall thickness of 6 mm. The theoretical calculation of the bearing capacity of the GFRP circular tube under the radial compression load in the elastic stage and the failure stage is well matched with the bearing capacity obtained from the test. The theoretical calculation can effectively predict the bearing capacity of the GFRP circular tube. The radial compression test of GFRP tubes is simulated by ABAQUS, which is a finite element software. The good agreement between the finite element calculation results and the test results verifies the feasibility of the finite element. Based on the above research, finite element models are established for different types of GFRP circular tubes to study the influence of opening ratio on the load borne by GFRP circular tubes. The results show that the hole with the opening rate less than or equal to 1/10 has little effect on the load of the GFRP circular tube. This paper studies the influence of opening on the radial compression properties of GFRP tubes, which has certain reference value for the opening of composite tubes in engineering.

Evaluation of stresses on the surface of production columns equipped with sand filters when downing into a horizontal well

Relevance. The need to estimate the time of formation sand accumulation near the annulus of a horizontal well and the unit length of filter elements in the bottom of production strings and to determine the stresses on the surface of production strings equipped with sand filters when lowering into the well. Aim. Based on a study of the reasons for the continued flow of sand into wells equipped with anti-sand filters, to develop and propose measures related to the need to choose a reduction in the number of filters that provide the design flow rate of a horizontal well or a significant increase in the length of the filtering surface of the filters in order to reduce erosive wear of the wire winding. Objects. We are considering a well with a horizontal section, equipped with sand filters, the same size as the casing strings. It was assumed that the integrity of the surface of the filter elements would be preserved and the conditions for their destruction would be eliminated when lowering into the horizontal shaft. This presupposes the necessary efficient operation of the well throughout the entire operational period. The section of the first set of curvature and the forces arising during this are considered as wellas stability of a pipe string during possible stops. Centralizers are evenly located along the length of the column, then in some sections we will have a multi-span statically indeterminate beam, in each section of which a radial load acts. Methods. When studying the time of formation sand accumulation in the annular space of a horizontal well and a unit length of filter elements in the bottom of production strings, it is necessary at the first stage to determine the stresses on the surface of production strings equipped with sand filters when lowering into the well. Studying the assessment of the existence time of the transition period is of particular interest. This is, in other words, during what operational period there is a complete accumulation of formation sand in the annular space and the transition of formation drainage along the entire length of the horizontal wellbore to drainage of only zones adjacent to the filters. To calculate the fluid flow rate when the annular space of the horizontal well is completely filled with sand, the design values ​​of the AC4.8 formation parameters were used. The maximum value of depressions used in the calculations is assumed to be 1.5 MPa. Results. Consideration of situations that arise when filters are lowered into horizontal wells indicates that the outer surface of the filter elements is not protected from destruction as a result of contact stresses with the walls of the drilled wellbore. To protect against destruction and rubbing open gaps by clay-containing rocks, rigid centralizers should be installed along the edges of the filter elements, the maximum allowable distances between which should not exceed 4.0–4.5 m.

Data-Driven Radial Compressor Design Space Mapping

Abstract Estimates of turbomachinery performance trends inform system-level compromises during preliminary design. Existing empirical correlations for efficiency use limited experimental data, while analytical loss models require calibration to yield predictive results. From a set of 3708 radial compressor computations, this paper maps efficiency as a function of mean-line aerodynamics, and determines the governing loss mechanisms. An open-source turbomachinery design code creates annulus and blade geometry, then runs a Reynolds-averaged Navier–Stokes simulation for compressors sampled from the mean-line design space. Polynomial surface fits yield a continuous eight-dimensional representation of the design space for analysis, predicting efficiency with a root-mean-square error of 1.2% points. The results show a balance between surface dissipation in boundary layers and mixing loss due to casing separations sets optimum values for inlet Mach number, hub-to-tip ratio, de Haller number, and backsweep angle. Surface dissipation drives the effect of flow coefficient, with high surface areas at low values, and high velocities at high values. Compact compressor designs are achieved by increasing inlet Mach number, reducing hub-to-tip ratio, and minimizing the radial loading coefficient—all of which reduce efficiency approaching design space boundaries. An interactive web-based tool makes the results available to practising engineers, demonstrating large ensembles of automated designs and simulations as a higher-fidelity replacement for legacy empirical correlations in preliminary design.

High-performance bamboo-wood composite materials based on the natural structure and original form of bamboo: Fracture behavior and mechanical characterization

Reducing the destruction of bamboo's original structure to produce high-utilization and high-performance engineered bamboo products has long been a goal in the industry. This study developed a new natural arc-shaped laminated bamboo-wood lumber (NALBWL) based on the natural structure and original form of bamboo, using equal arc-shaped bamboo split (EASB) and poplar veneer. A multi-scale analysis of the bending performance and crack propagation dynamics of EASB and NALBWL was conducted. EASB's modulus of elasticity (MOE) and rupture (MOR) were 1.06 and 1.17 times higher than those of air-dried bamboo, respectively, exhibiting excellent mechanical properties. Additionally, its toughness in the full and elastic-plastic stages were 1.24 and 1.38 times higher than those of air-dried bamboo. NALBWL's MOE and MOR were 12.73 GPa and 174.41 MPa, fully meeting structural material requirements and even surpassing most engineered bamboo products. Moreover, NALBWL's radial bending load values were 2.29 and 2.24 times higher than that of EASB and air-dried bamboo, respectively, and it also demonstrated excellent water heat and drying resistance in impregnation and peeling performance. Real-time crack propagation analysis indicated that NALBWL's superior mechanical properties benefited from the respective advantages of bamboo and poplar veneer. This work showcased the application of "natural form-inspired design" in developing bamboo-wood composite materials, and the conclusion provided a reference for the sustainable development of engineered bamboo products and the study of biomass material fracture mechanisms.

Numerical Prediction of Ride Comfort of Tracked Vehicle Equipped with Novel Flexible Road Wheels

Enhancing ride comfort has always constituted a crucial focus in the design and research of modern tracked vehicles, heavily reliant on the driving system’s performance. While the road wheel is a key component of the driving system, traditional road wheels predominantly adopt a solid structure, exhibiting subpar adhesion performance and damping effects, thereby falling short of meeting the demands for high-speed, stable, and long-distance driving in tracked vehicles. Addressing this issue, this paper proposes a novel type of flexible road wheel (FRW) characterized by a catenary construction. The study investigates the ride comfort of tracked vehicles equipped with flexible road wheels by integrating finite element and vehicle dynamic. First, three-dimensional (3D) finite element (FE) models of both flexible and rigid road wheels are established, considering material and contact nonlinearities. These models are validated through a wheel radial loading test. Based on the validated FE model, the paper uncovers the relationship between load and radial deformation of the road wheel, forming the basis for a nonlinear mathematical model. Subsequently, a half-car model of a tracked vehicle with seven degrees of freedom is established using Newton’s second law. A random road model, considering the track effect and employing white noise, is constructed. The study concludes by examining the ride comfort of tracked vehicles equipped with flexible and rigid road wheels under various speeds and road grades. The results demonstrate that, in comparison to the rigid road wheel (RRW), the flexible road wheel enhances the ride comfort of tracked vehicles on randomly uneven roads. This research provides a theoretical foundation for the implementation of flexible road wheels in tracked vehicles.

Investigation of the Electrical Impedance Signal Behavior in Rolling Element Bearings as a New Approach for Damage Detection

The opportunities of impedance-based condition monitoring for rolling bearings have been shown earlier by the authors: Changes in the impedance signal and the derived features enable the detection of pitting damages. Localizing and measuring the pitting length in the raceway direction is possible. Furthermore, the changes in features behavior are physically explainable. These investigations were focused on a single bearing type and only one load condition. Different bearing types and load angles were not considered yet. Thus, the impedance signals and their features of different bearing types under different load angles are investigated and compared. The signals are generated in fatigue tests on a rolling bearing test rig with conventional integrated vibration analysis based on structural borne sound. The rolling bearing impedance is gauged using an alternating current measurement bridge. Significant changes in the vibration signals mark the end of the fatigue tests. Therefore, comparing the response time of the impedance can be compared to the vibration signal response time. It can be shown that the rolling bearing impedance is an instrument for condition monitoring, independently from the bearing type. In case of pure radial loads, explicit changes in the impedance signal are detectable, which indicate a pitting damage. Under combined loads, the signal changes are detectable as well, but not as significant as under radial load. Damage-indicating signal changes occur later compared to pure radial loads, but nevertheless enable an early detection. Therefore, the rolling bearing impedance is an instrument for pitting damage detection, independently from bearing type and load angle.

A Forward Sensitivity Analysis and Design of U-Shaped Bellows Considering the Radial Compensation Capability Under Internal Pressure

Abstract Bellows serve as integral component within a piping system, which withstand radial displacement loads and internal pressure loads. This study investigates the sensitivity analysis of structure design parameters, such as convolution height, convolution pitch, ply thickness, and convolution number, on radial compensation capability of U-shaped bellows under internal pressure. The influences of the geometric parameters on the strength performance of U-shaped bellows under internal pressure and radial displacement loads are also investigated. A forward design process considering the sensitivity of the structural parameters of the bellows to the bending stiffness and strength is provided. In order to improve the radial displacement compensation ability and to obtain better pressure resistance performance, a mathematical model is established to describe the performance of bellows, and multi-object optimization of bellows is conducted. The results show that the ply thickness has the greatest impact on bending stiffness and strength, and the optimized model has lower stiffness and higher strength compared to the initial model.

Mechanical properties of lotus petiole bio-inspired structures under quasi-static radial load

The lotus petiole in nature is characterized by its porous structure and high bending resistance. Inspired by this, in this paper, random sampling of lotus petiole was carried out to clarify the porous distribution pattern of lotus petiole in cross section. On this basis, the original structures with 12 and 13 wells (Os-12w, Os-13w) were constructed, and equal mass hollow circular tube (Emhct) was also designed for comparison. Based on the experimentally verified finite element models, Os-12w, Os-13w and Emhct were comparatively analyzed. In addition, comparisons were made with five other bionic circular structures Compared to the rest of the structures, Os-13w performs better in all comprehensive properties. The bending and traction in the core region of the bionic structure caused the surrounding structures to join in the buckling earlier, creating a global crushing trend. More interestingly, further bending and traction in the core region creates a negative Poisson's ratio phenomenon. In addition, the results of the parametric study show that the optimum loading angle of Os-12w is between 60° and 90°, and the proper adjustment of its core cross-section characteristics can improve the mechanical properties of the structure. This study provides some reference for the development of thin-walled porous structures under radial loading conditions.

Measured dynamic load distribution within the in situ axlebox bearing of high-speed trains under polygonal wheel–rail excitation

The dynamic load distribution within in-service axlebox bearings of high-speed trains is crucial for the fatigue reliability assessment and forward design of axlebox bearings. This paper presents an in situ measurement of the dynamic load distribution in the four rows of two axlebox bearings on a bogie wheelset of a high-speed train under polygonal wheel–rail excitation. The measurement employed an improved strain-based method to measure the dynamic radial load distribution of roller bearings. The four rows of two axlebox bearings on a wheelset exhibited different ranges of loaded zones and different means of distributed loads. Besides, the mean value and standard deviation of measured roller–raceway contact loads showed non-monotonic variations with the frequency of wheel–rail excitation. The fatigue life of the four bearing rows under polygonal wheel–rail excitation was quantitatively predicted by compiling the measured roller–raceway contact load spectra of the most loaded position and considering the load spectra as input.

Study of Plain and Textured Journal Bearings using Computational Fluid Dynamics

Journal Bearing is used to bear the load and confine the rotation of the shaft. A loaded rotating journal (Shaft) is supported by a circular bushing (sleeve or bearing), the diameter of the bearing is slightly more than the diameter of the journal, to provide clearance so a proper supply of lubrication oil is possible, which can enhance the performance characteristics of journal bearing. Journal bearing are mostly used to carry the radial loads of shafts working in dry and lubrication conditions. Journal bearing is used in various applications like sugar mill bearing, cement industry and turbine etc. Journal bearings may prematurely fail because of misalignment, irregular surface, lack of lubrication, contamination, etc., which impacts the industry's production costs are also hazardous for human life. When a bearing is used under diverse oil conditions, the temperature of the bearing has been seen increase in the industry. Because of this, the theoretical analysis of plain and texture (diamond shape) brass, bronze, and gun metal journal bearings lubricated with SAE-40 oil has been done in present study using ansys CFD. The inner diameter of the bearing has been subjected to internal knurling. In terms of temperature rise, the outcomes of two bearings are compared. Performance of the textured bearing has improved in comparison to the plain bearing.

Investigating the mechanism of flow of transonic compact crossover tandem diffuser

Dealing with high transonic airflow at the outlet of a mixed-flow impeller is a challenging issue in research on the design of efficient and compact diffusers. A low aspect ratio and an adverse pressure gradient in the passage of the diffuser can lead to flow separation on the hub side of the bend and the suction side of the aft blade. Tandem blading can be used to attain flow control through an appropriate relative circumferential tandem position (λ). However, a comprehensive understanding of flow in a compact crossover tandem diffuser (CTD) requires further investigation. This study provides a detailed analysis of the mechanism of flow in a compact crossover baseline tandem diffuser (CBTD) as well as the influence of different values of λ on the structure of flow of the CTD. The findings show that the CBTD can suppress secondary flow separation on the hub side of the bend by reasonably distributing the radial load. We also found that a value of λ of 75% can delay the point of separation on the suction side of the aft blade over a wide range of spans, where this inhibits the corner separation vortex and improves the structure of flow and performance of the diffuser. We also preliminarily explore the impacts of excitation of full-span jet intensities with different values of λ on the corner separation vortex on the suction side of the aft blade and offer guidance for the design of a compact and efficient CTD.

Effect of oil film stiffness on vibration of full ceramic ball bearing under grease lubrication

PurposeThis paper aims to understand the vibration characteristics of full ceramic ball bearings under grease lubrication, reduce the vibration of the bearings and improve their service life.Design/methodology/approachThe Hertz contact stiffness formula for full ceramic ball bearings is constructed; the equivalent comprehensive stiffness calculation model and vibration model of full ceramic ball bearings are established. The dynamic characteristic test of full ceramic ball bearing under grease lubrication was carried out by using the bearing life testing machine, and its vibration was measured, and its vibration acceleration root-mean-square was obtained by software calculation and compared with the simulation results.FindingsAt the rotational speed of 12,000 r/min, the root-mean-square value of vibration acceleration is maximum 10.82 m/s2, and the error is also maximum 7.49%. As the rotational speed increases, the oil film stiffness decreases. In the radial load of 600 N, the vibration acceleration root-mean-square is minimum 6.40 m/s2, but its error is maximum 6.56%. As the radial load increases, the vibration of the bearing decreases and then increases, so under certain conditions increasing the radial load can reduce the bearing vibration. With different types of grease, the best preload is also different; low-speed heavy load should be used when the viscosity of the grease is large, and high-speed light load should be used when the choice of smaller viscosity grease is made.Originality/valueIt provides a theoretical basis for the application of full ceramic ball bearings under grease lubrication, which is of great significance for reducing the vibration of bearings as well as enhancing the service life of bearings.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2024-0094/

Modeling of double-row cylindrical roller bearing under combined loads and angular misalignment

Abstract To enhance the reliability of the double-row cylindrical roller bearing (DCRB), a new quasi-static model, which is capable of considering inner ring misalignment and combined loads, has been established. This model was used to calculate the distribution of internal loads and contact pressure. First, the model was verified with published data. Secondly, systematic parameter analyses are conducted to investigate how axial load, inner ring misalignment and roller profile influence the contact performance. The results indicate that when the bearing is subjected to a combined load, the difference between the radial loads borne by the two rows increases with the increase of axial load. The combined load and misalignment of the inner ring would cause significant changes in the numerical value and distribution of contact load and pressure between the rollers and raceways. The roller profile optimization can reduce contact pressure and alleviate the edge effect.

An actuator sector model for wind power applications: a parametric study

Abstract. This paper investigates different actuator sector model implementation alternatives and how they compare to actuator line results. The velocity sampling method, tip/smearing correction, and time step are considered. A good agreement is seen between the line and sector model in the rotor plane and the wake flow. Using the sector model, it was possible to reduce the computational time by 75 % compared to the actuator line model as it is possible to run the simulations with a larger time step without compromising the accuracy considerably. The results suggest that the proposed velocity sampling method produces the closest results to the line model with different tip speed ratios. Moreover, the vortex-based smearing correction applied to the sector model results in the lowest error values, among the considered methods, to correct the radial load distributions. Also, it is seen that reducing the time step compared to the one used for the actuator disc/sector does not provide an advantage considering the increased computational time.