Torsional fretting fatigue strength of a shrink-fitted shaft with a grooved hub

Fretting causes considerable reduction in the fatigue strength of a shrink-fit assembly and failures through fretting are as numerous as failures from normal fatigue. The purpose of this investigation was to determine the effect of contact pressure and slip amplitude on the fatigue limit, and a favourable value for overhang of hub and fillet radius with constant diameter ratio, at which fretting failure can be avoided and the maximum normal fatigue strength will be obtained. The torsional fatigue strength of shrink-fitted shaft couplings was estimated by tests performed by varying the overhang of the hub, the fillet radius of the shaft and the contact pressure of the shrink-fitted assembly. Press-fitting of the hub overhanging the shoulder was used to increase the contact pressure. The tests were performed using a grooved hub. These experiments showed that fretting was reduced with an increase in contact pressure, because the slip amplitude decreased. The shaft was fractured just inside the end of the fit by fretting fatigue with low contact pressure, but if the contact pressure was very high, the shaft fractured at the fillet by normal fatigue. The fretting fatigue limit at a constant diameter ratio increases with an increase in the fillet radius, and reaches its maximum value at a certain radius using the grooved hub.     

大型齿轮箱结构分析与结构优化

对大型齿轮箱进行了有限元强度分析,然后以应力和位移为约束条件,以重量为目标函数,对齿轮箱进行了优化设计,取得了良好的优化效果,使重量减少了3746kg,比原设计减轻了23.18%.优化结果为齿轮箱的结构设计、减轻齿轮箱的重量提供了良好的参考依据.     

起落架刹车拉杆的可靠性减重设计

通过对某型飞机起落架刹车拉杆截面尺寸的静强度和疲劳强度可靠性校核．在强度裕度很大的情况下，按照给定可靠度，进行了截面尺寸最佳设计。结果表明，对该零件进行截面可靠性设计后，在保证零件使用性能的基础上，实现了有效减重。     

基于邻域属性重要度与主成分分析的齿轮箱故障特征约简

为有效降低齿轮箱故障特征的维数并提高诊断效率,提出了基于邻域属性重要度与主成分分析法相结合的齿轮箱故障特征约简方法,并利用支持向量机和BP神经网络对诊断的准确率进行对比分析。针对齿轮箱中具有不同程度裂纹的齿轮,选取其时域、频域和基于希尔伯特变换的36个特征;将邻域模型引入到特征属性的约简,构造前向贪心算法,以邻域属性重要度较大的9个特征作为特征集,提取累积贡献率达到95%以上的主成分,分别输入支持向量机和BP神经网络分类器中进行分类识别,并与不经过特征优选的主成分特征融合相对比。结果表明,采用基于邻域属性重要度与主成分分析法相结合的特征约简方法,既可以降低齿轮箱故障特征的维数,又不影响对其运行状态的表征,有助于识别不同裂纹水平的齿轮,与不经过特征优选直接进行融合的方法相比,所提出方法诊断准确率更高,训练时间更短。     

高速列车车轮多边形对齿轮箱疲劳寿命的影响

车轮多边形是高速列车运行过程中常见的磨耗现象,该现象使轮轨作用力增大,齿轮箱持续异常振动,并会影响其疲劳寿命。为研究高速列车车轮多边形对齿轮箱疲劳寿命的影响,建立了含有齿轮箱支撑轴承的驱动系统和柔性齿轮箱的刚柔耦合整车动力学模型,采用数值仿真分析方法,通过分析不同车轮多边形幅值下轮轨垂向力和齿轮箱垂向振动加速度确定极端工况,对该工况下的齿轮箱进行应力分析并确定危险点,进而分析这些点的疲劳寿命。研究发现:列车在350 km/h三阶0.1 mm车轮多边形极端工况时,轮轨垂向力及齿轮箱垂向加速度明显增大,齿轮箱剧烈振动,此时齿轮箱多处出现应力集中,存在多个危险点。其中齿轮箱输出轴轴承端支撑筋处应力最大,该危险点疲劳寿命只能达到256万km,远小于1200万km的正常寿命。因此,在高速列车实际运营中要高度重视车轮多边形对齿轮箱疲劳寿命带来的影响,可通过车轮镟修来降低车轮多边形对齿轮箱疲劳寿命的影响。     

NGWN(Ⅱ)型行星减速器基于Matlab的优化设计

针对NGWN(Ⅱ)型行星齿轮减速器提出了侧重于配齿计算、啮合及几何参数计算等的专用设计软件,建立了以减速器体积最小为目标,以齿轮强度要求等为主要约束条件的优化设计模型,并进行了基于Matlab的优化设计,获得了理想的、具备工程实用价值的综合设计效果.     

Bending fatigue characteristics of wire rope

Wire rope in elevators can become disconnected by tensile stress from friction between the rope and sheave, and by repeated stress including bending stress from various effects formed during contact between the rope and sheave. It is known that in designing wire rope, its strength is affected when wire disconnection occurs. However, insufficient related data is available. Therefore, fracture strength reduction and the effect of bending fatigue on wire rope life is difficult to evaluate. We considered the effects of wire rope diameter and tensile stress on fracture strength and wire rope life. We observed that fracture strength rapidly decreased when bending fatigue accumulated at the same time that the wire became disconnected. Moreover, bending fatigue was shown to be a crucial factor in decreased wire rope life.     

Fretting fatigue in hydrogen gas

To clarify the effect of hydrogen gas on fretting fatigue strength of the materials, which supposed to be used for hydrogen utilization machines, fretting fatigue tests were conducted in hydrogen gas. It is important to take fretting fatigue into account in strength design, because many fatigue failure accidents have occurred at joints or contact parts between components. As a part of the experiments, an austenitic stainless steel was focused in this paper. The material was SUS 304. Fretting fatigue strength in hydrogen gas decreased compared with that in air. Tangential force coefficient increased in the reverse order of fretting fatigue strength. Therefore, one of the reasons of the decrease of fretting fatigue strength was that tangential force was different depending on the environment. Absorption of hydrogen occurred during fretting in hydrogen gas was detected. The absorption could be considered as one of the causes of the decrease of fretting fatigue strength, since fretting fatigue life of pre-charged specimen was decreased and also the crack propagation threshold of short fatigue crack was reduced by hydrogen charge.     

蒸汽发生器人孔焊接密封的螺栓疲劳分析

采用方法简单、操作性好的二维轴对称单元对蒸汽发生器焊接密封结构的人孔螺栓进行疲劳分析,并按ASME Ⅲ-NB标准进行评定。将计算结果进行对比分析,发现螺纹疲劳减弱系数对螺栓疲劳强度的影响非常大。螺纹加工方法和螺纹牙底圆角是影响螺栓疲劳强度的关键性因素。同时,根据分析结果给出了提高螺栓疲劳强度的措施,并针对蒸汽发生器焊接密封结构人孔螺栓给出了处理方法。     

太重Ⅲ型风力发电增速齿轮箱有限元分析

风电增速齿轮箱在兆瓦级风力发电机中属易过载和损坏率较高的部件,对其性能进行分析,预测其性能并进行优化是十分必要的.本文中利用ANSYS软件对太重Ⅲ型两级行星一级平行轴1.5MW风力发电增速齿轮箱进行有限元分析,对太重Ⅲ型风力发电增速齿轮箱各级齿轮强度进行校核,得到了各级齿轮副的齿廓和齿向修形数据;对行星轮系载荷均载特性、主箱体组件、行星架、花键联接等进行分析,得到了风力发电增速齿轮箱各级零部件强度和刚度等相关数据,为风电增速齿轮箱的可靠性评估及优化设计奠定基础.     

The effect of rubber contact on the fretting fatigue strength of railway wheel tire

The cause of the ICE train derailment, which occurred in 1998 at Eschede, was fatigue failure originating on the inside of the wheel tire. Rubber-sprung resilient wheels were used for the trailer cars. The wheel tire is mounted on the wheel disc. Thirty-four rubber pads were arranged between the wheel disc and the wheel tire. It was postulated that fretting fatigue between the rubber block and the inner side of the tire might have an influence on the initiation of the incipient crack. In order to clarify the influence of the rubber contact on the fatigue strength of the tire, fretting fatigue experiments under rubber contact conditions were performed. During the fundamental fretting fatigue test using bridge pads and small size carbon steel specimens, no typical fretting damage such as fretting wear and minute cracks were observed due to contact of the rubber. Stress conditions of the rubber-sprung wheel under vertical and lateral wheel loads were evaluated by a three-dimensional elastic stress analysis. Since the rubber is a super-elastic material, the Mooney-Rivlin model was used in the FEM calculation. It was found that the wheel tire is subjected to a cyclic stress during one revolution of the wheel and the maximum stress occurred at the center of the inner surface of the tire where the fatigue crack initiated. Fatigue strength of the wheel tire was determined by the rotating bending fatigue testing of specimens taken from the tire. It was found that the tire with an 862 mm diameter at a wheel load of 80 kN had a safety factor more than 3.5 from a fatigue limit diagram with a failure probability of 0.01. To confirm the fretting damage under the rubber contact and the result of the fatigue strength evaluation, fatigue tests of a full size wheel were made. After 20 million cycles at the wheel load of 280 kN, which was just below the endurance limit estimated by the endurance limit diagram, no fretting damage and no fatigue cracks were observed. The wheel was, however, fractured at 1.56 million cycles under the maximum load of 308 kN, which was just above the endurance limit. The estimation of the safety factor of 3.5 estimated from the endurance diagram was confirmed by the full size fatigue testing. It was concluded that there was no effect of fretting due to the rubber contact on the fatigue strength of the rubber-sprung single-ring railway wheel.     

雷达天线座方位减速箱箱体的有限元分析

对箱体的方案设计进行有限元分析。运用Pro/E软件建模，考虑到分析的侧重点，对模型进行适当简化。用ANSYS软件对箱体结构进行分析，得到位移和应力分布以及固有频率等结果，藉此反映箱体的设计效率和可靠性，为箱体的优化设计提供帮助。     

数控龙门镗铣床主轴减速箱密封结构的改进

针对数控龙门镗铣床主轴减速箱出现的漏油、渗油问题,分析漏油原因,并提出改进方案:对减速箱体结构重新设计,新增一个贮油池,防止轴承端盖处的泄漏;在输出轴处,通过采用三级密封,解决输出轴处密封难的问题。     

The effect of hydrogen gas environment on fretting fatigue strength of materials used for hydrogen utilization machines

The objective of this study is the characterization of the fretting fatigue strength in a hydrogen gas environment. The test materials were a low alloy steel SCM435H, super alloy A286 and two kinds of austenitic stainless steels, SUS304 and SUS316L. The test was performed in hydrogen gas at 0.12 MPa absolute pressure. The purity of the hydrogen gas was 99.9999%. The fretting fatigue limit was defined by the fretting fatigue strength at 30 million cycles. For all materials, the fretting fatigue strength in the hydrogen gas environment increased in the short-life region. However, the fretting fatigue strength in the hydrogen gas environment decreased in the long-life region when exceeding 10 million cycles except for SCM435H, while there was no reduction in the fretting fatigue strength in air between 10 and 30 million cycles. The reduction rate was 18% for A286, 24% for SUS304 and 7% for SUS316L. The tangential force coefficient in the hydrogen gas environment increased when compared to that in air. It can be estimated that this increase is one of the causes of the reduced fretting fatigue strength found in a hydrogen gas environment. In order to discuss the extension of the fretting fatigue life in hydrogen gas observed at the stress level above the fretting fatigue limit in air, continuous measurement of the fretting fatigue crack propagation was performed in a hydrogen gas environment using the direct current potential drop method. As a result, it was found that the extension of the fretting fatigue life was caused by the delay in the start of the stable crack propagation.     

风力发电机齿轮箱扭力轴的疲劳分析

应用有限单元法,对风力发电机齿轮箱中的扭力轴的进行了疲劳寿命分析.利用Solid-works和ANSYS-Workbench软件建立了扭力轴的三维有限元模型,并在ANSYS-Workbench中对轴进行了结构疲劳分析,证明其疲劳寿命符合设计要求.     

Fretting fatigue strength of SCM435H steel and SUH660 heat‐resistant steel in hydrogen gas environment

Utilisation of hydrogen is expected to be one of the solutions against the problems of exhaustion of fossil fuels and reduction of carbon dioxide emissions. Evaluation of the materials for hydrogen utilisation machines is required. The objectives of this study are the characterisation of fretting fatigue strength of low‐alloy steel SCM435H and heat‐resistant steel SUH660, and the validation of effectiveness of nitriding in hydrogen gas environment. Fretting fatigue tests were conducted up to 3 × 10⁷ cycles. The decrease of fretting fatigue strength in hydrogen gas environment was found at the long‐life region exceeding 10⁷ cycles. The amount of the decrease of the fretting fatigue limit at 3 × 10⁷ cycles was 11% for SCM435H and 15% for SUH660. However, at the stress level above the fretting fatigue limit in air, the finite life in hydrogen gas increased more than that in air. The cause of extension of fatigue life was the delay of start of stable crack propagation. Fretting fatigue crack, which was smaller than 200 µm in length, consumed approximately 60% of the fatigue life in hydrogen gas environment. Fretting fatigue crack was steadily propagated after the test was started in air. Observations of the fretted surface showed that the fretting wear process in hydrogen gas environment was dominated by adhesion. Tangential force coefficient was higher in hydrogen gas environment than that in air. It is considered that the adhesion has a close relation to crack initiation in hydrogen gas environment, and as a result, the failure of specimen occurred at a lower stress level comparing the fretting fatigue limit in air. Copyright © 2008 John Wiley & Sons, Ltd.     

齿轮箱系统动力响应分析及其噪声预测

齿轮箱系统的动力学特性对齿轮箱的工作性能、寿命、振动和噪声有着决定性的作用。为了更好地了解和掌握系统的动力学特性,首先采用ADAMS软件提取了齿轮副间的动态啮合力作为齿轮箱动力响应的激振源;再利用ANSYS Workbench软件对齿轮箱系统进行了谐响应分析,得到了动力响应曲线;最后对所得的动力响应曲线进行了1/3倍频处理以得到齿轮箱系统的噪声预估。仿真结果表明,采用该方法可获得较为理想的动力响应特性,可为齿轮箱设计改造、减小振动噪声提供参考依据。     

Service Loading of Rolling Bearings in Wind Turbine Gearboxes: X-ray Diffraction Material Response Analysis of White Etching Crack Premature Failures

Rolling bearings in wind turbine gearboxes occasionally fail prematurely due to white etching cracks. The appearance of preparatively opened fracture faces indicates damage initiation from the surface in most cases due to brittle spontaneous tensile stress–induced cracking. Under the influence of decomposition products of the penetrating lubricant, branching crack growth is subsequently driven by corrosion fatigue. The material response analysis of rolling bearings from all gearbox locations, based on X-ray diffraction residual stress measurements, reveals vibrations in service as the root cause of surface crack initiation. The occurrence of high local friction coefficients in the rolling contact is described by a tribological model. Depth profiles of the equivalent shear and normal stresses are respectively compared with the measured residual stress patterns and a relevant fracture strength. White etching crack failures are experimentally reproduced on a rolling contact fatigue test rig under increased mixed friction. Causative vibration loading is evident from material response analysis. The generation of compressive residual stresses by cold-working the surface is proven to be an effective countermeasure.     

起重机车轮的疲劳可靠性分析

根据起重机车轮的工作应力和疲劳强度的概率分布,采用疲劳可靠性设计方法,对车轮进行分析计算,建立车轮许用轮压与起重机机构工作级别、车轮直径、轨道曲率半径及材料疲劳强度极限等因素之间的关系,为起重机车轮的合理选用提供了一种理论依据。     

某型汽车变速箱用深沟球轴承故障分析

针对某型车变速箱轴承早期疲劳剥落、导致变速箱异响的问题,对故障轴承的外观、尺寸、硬度、组织、工作表面烧伤等情况进行了检测分析,确定了产生该现象的原因为异物进入。制定了相应的预防措施,避免该类故障的再次发生。