scholarly journals Crack initiation characteristics of ring chain of heavy-duty scraper conveyor under time-varying loads

2019 ◽  
Vol 11 (9) ◽  
pp. 168781401988036
Author(s):  
Dagang Wang ◽  
Jun Zhang ◽  
Zhencai Zhu ◽  
Shen Gang ◽  
Li Xiang
Keyword(s):  
Crack Initiation ◽  
Equivalent Stress ◽  
Three Dimensional ◽  
Contact Fatigue ◽  
Time Varying ◽  
Heavy Duty ◽  
Chain Ring ◽  
Adjacent Chain ◽  
Scraper Conveyor ◽  
Vertical Chain

Crack initiation characteristics of ring chain of heavy-duty scraper conveyor under time-varying loads were investigated in this study. The dynamic tension of ring chain of the heavy-duty scraper conveyor was obtained using the time-varying dynamic analysis. Finite element analyses of three-dimensional contacts between adjacent chain rings at straight and bending segments were carried out to explore three-dimensional stress distributions of chain rings. The crack initiation life of chain ring was predicted employing the multiaxial fatigue theory. The results show that the ring chain is subjected to time-varying dynamic tensions during operation. During tension-tension contact fatigue, as compared to the straight segment of ring chain, the bending segment engaging in the sprocket presents an overall lower (or higher) equivalent stress distribution in the case of flat (or vertical) chain ring, respectively. Maximum equivalent stresses at the contact regions of adjacent chain rings both present time-varying dynamic characteristics similar to evolutions of dynamic tension. During tension-torsion contact fatigue, an increase in torsion angle level causes unobvious difference between equivalent stress distributions at contact regions of adjacent rings. Predicted crack initiation lives of chain rings during tension-tension contact fatigue indicates more severe fatigue damages of the vertical chain ring at the straight segment and of the flat chain ring at the right bending segment.

Semi-Analytical Modeling of Crack Initiation Dominant Contact Fatigue Life for Roller Bearings

1997 ◽  
Vol 119 (2) ◽  
pp. 233-240 ◽  
Author(s):  
Wangquan (Winston) Cheng ◽  
Herbert S. Cheng
Keyword(s):  
Shear Stress ◽  
Fatigue Life ◽  
Crack Initiation ◽  
Maximum Shear Stress ◽  
Equivalent Stress ◽  
Roller Bearing ◽  
Contact Fatigue ◽  
New Model ◽  
Roller Bearings ◽  
Contact Width

The fatigue test of a needle roller bearing suggests that the dominant failure mechanism is subsurface crack initiation and propagation. Therefore, a new semi-analytical contact fatigue model is derived from a micromechanics based crack initiation model. The analysis indicates that in the life calculation the selection of the critical stress, such as the maximum orthogonal shear stress, maximum shear stress, octahedral shear stress, or von Mises equivalent stress, becomes arbitrary under the nonfrictional Hertzian line contact condition. The fatigue life of roller bearings under the pure rolling condition can be predicted by simply knowing the Hertzian contact pressure and the contact width, which avoids complicated calculation of the subsurface stresses. The film thickness, roughness, and the material hardness effects on contact fatigue are also included in the new model. The comparisons with different models and the experimental data indicate that the new model makes similar life predictions as the Ioannides-Harris model, but the new model is much simpler to use. The Lundberg-Palmgren model does not fit with the experiment data.

scholarly journals Coupled Fluid–Solid Numerical Simulation for Flow Field Characteristics and Supporting Performance of Flexible Support Cylindrical Gas Film Seal

Aerospace ◽  
2021 ◽  
Vol 8 (4) ◽  
pp. 97
Author(s):  
Junfeng Sun ◽  
Meihong Liu ◽  
Zhen Xu ◽  
Taohong Liao ◽  
Xiangping Hu ◽  
...  
Keyword(s):  
Flow Field ◽  
Film Thickness ◽  
Fluid Dynamic ◽  
Structural Characteristics ◽  
Structural Parameters ◽  
Equivalent Stress ◽  
Three Dimensional ◽  
High Rotational Speed ◽  
Flexible Support ◽  
Flow Field Characteristics

A new type of cylindrical gas film seal (CGFS) with a flexible support is proposed according to the working characteristics of the fluid dynamic seal in high-rotational-speed fluid machinery, such as aero-engines and centrifuges. Compared with the CGFS without a flexible support, the CGFS with flexible support presents stronger radial floating characteristics since it absorbs vibration and reduces thermal deformation of the rotor system. Combined with the structural characteristics of a film seal, an analytical model of CGFS with a flexible wave foil is established. Based on the fluid-structure coupling analysis method, the three-dimensional flow field of a straight-groove CGFS model is simulated to study the effects of operating and structural parameters on the steady-state characteristics and the effects of gas film thickness, eccentricity, and the number of wave foils on the equivalent stress of the flexible support. Simulation results show that the film stiffness increases significantly when the depth of groove increases. When the gas film thickness increases, the average equivalent stress of the flexible support first decreases and then stabilizes. Furthermore, the number of wave foils affects the average foils thickness. Therefore, when selecting the number of wave foils, the support stiffness and buffer capacity should be considered simultaneously.

Development and Validation of a Three-Dimensional Multiphase Flow CFD Analysis for Journal Bearings in Steam and Heavy Duty Gas Turbines

2012 ◽  
Author(s):  
Stephan Uhkoetter ◽  
Stefan aus der Wiesche ◽  
Michael Kursch ◽  
Christian Beck
Keyword(s):  
Experimental Data ◽  
Multiphase Flow ◽  
Gas Turbines ◽  
High Speed ◽  
Three Dimensional ◽  
Air Entrainment ◽  
Journal Bearings ◽  
Heavy Duty ◽  
Present Contribution ◽  
Two Phase

The traditional method for hydrodynamic journal bearing analysis usually applies the lubrication theory based on the Reynolds equation and suitable empirical modifications to cover turbulence, heat transfer, and cavitation. In cases of complex bearing geometries for steam and heavy-duty gas turbines this approach has its obvious restrictions in regard to detail flow recirculation, mixing, mass balance, and filling level phenomena. These limitations could be circumvented by applying a computational fluid dynamics (CFD) approach resting closer to the fundamental physical laws. The present contribution reports about the state of the art of such a fully three-dimensional multiphase-flow CFD approach including cavitation and air entrainment for high-speed turbo-machinery journal bearings. It has been developed and validated using experimental data. Due to the high ambient shear rates in bearings, the multiphase-flow model for journal bearings requires substantial modifications in comparison to common two-phase flow simulations. Based on experimental data, it is found, that particular cavitation phenomena are essential for the understanding of steam and heavy-duty type gas turbine journal bearings.

scholarly journals Investigation on the Crack Initiation of V-Shaped Notch Tip in Precision Cropping

2014 ◽  
Vol 2014 ◽  
pp. 1-8 ◽  
Author(s):  
Lijun Zhang ◽  
Shengdun Zhao ◽  
Zhenwei Wang
Keyword(s):  
Crack Initiation ◽  
Equivalent Stress ◽  
Initiation Time ◽  
Initiation Point ◽  
Change Rate ◽  
Crack Initiation Angle ◽  
Notch Tip ◽  
Crack Initiation Life ◽  
Microscopic Measurement ◽  
Displacement Extrapolation Method

The crack initiation of V-shaped notch tip has a very important influence on the cross-section quality and the cropping time for every segment of metal bar in course of low stress precision cropping. By the finite element method, the influence of machining precision of V-shaped notch bottom corner on the crack initiation location is analyzed and it is pointed out that the crack initiation point locates in the place at the maximal equivalent stress change rate on V-shaped notch surface. The judgment criterion of the crack initiation direction is presented and the corresponding crack initiation angle can be calculated by means of the displacement extrapolation method. The factual crack initiation angle of the metal bar has been measured by using the microscopic measurement system. The formula of the crack initiation life of V-shaped notch tip is built, which mainly includes the stress concentration factor of V-shaped notch, the tensile properties of metal material, and the cyclic loading conditions. The experimental results show that the obtained theoretical analyses about the crack initiation location, the crack initiation direction, and the crack initiation time in this paper are correct. It is also shown that the crack initiation time accounts for about 80% of the cropping time for every segment of the metal bar.

Influence of Interference and Clamping on Fretting Fatigue in Single Rivet-Row Lap Joints

2000 ◽  
Vol 123 (4) ◽  
pp. 686-698 ◽  
Author(s):  
K. Iyer ◽  
C. A. Rubin ◽  
G. T. Hahn
Keyword(s):  
Crack Initiation ◽  
Three Dimensional ◽  
Fretting Fatigue ◽  
Cyclic Stress ◽  
Lap Joints ◽  
Element Analysis ◽  
Out Of Plane ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Fretting Damage

Primary fretting fatigue variables such as contact pressure, slip amplitude and bulk cyclic stresses, at and near the contact interface between the rivet shank and panel hole in a single rivet-row, 7075-T6 aluminum alloy lap joint are presented. Three-dimensional finite element analysis is applied to evaluate these and the effects of interference and clamping stresses on the values of the primary variables and other overall measures of fretting damage. Two rivet geometries, non-countersunk and countersunk, are considered. Comparison with previous evaluations of the fretting conditions in similar but two-dimensional connections indicates that out-of-plane movements and attending effects can have a significant impact on the fatigue life of riveted connections. Variations of the cyclic stress range and other proponents of crack initiation are found to peak at distinct locations along the hole-shank interface, making it possible to predict crack initiation locations and design for extended life.

Evaluation of contact fatigue life of a wind turbine carburized gear considering gradients of mechanical properties

2018 ◽  
Vol 28 (8) ◽  
pp. 1170-1190 ◽  
Author(s):  
Wei Wang ◽  
Huaiju Liu ◽  
Caichao Zhu ◽  
Zhangdong Sun
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Heavy Duty ◽  
Initial Residual Stress ◽  
Contact Fatigue Life ◽  
Carburized Gear ◽  
Load Conditions

Case hardening processes such as carburizing are extensively applied in heavy-duty gears used in wind turbines, ships, high-speed rails, etc. Contact fatigue failure occurs commonly in engineering practice, thus reduces reliabilities of those machines. Rolling contact fatigue life of a carburized gear is influenced by factors such as the gradients of mechanical properties and profile of initial residual stress. In this regard, the study of contact fatigue life of carburized gears should be conducted with the consideration of those aspects. In this study, a finite element elastic–plastic contact model of a carburized gear is developed which takes the gradients of hardness and initial residual stress into account. Initial residual stress distribution and the hardness profile along the depth are obtained through experimental measurements. The effect of the hardness gradient is reflected by the gradients of yield strength and fatigue parameters. The modified Fatemi–Socie strain-life criterion is used to estimate the rolling contact fatigue life of the heavy-duty carburized gear. Numerical results reveal that according to the Fatemi–Socie fatigue life criterion, rolling contact fatigue failure of the carburized gear will first initiate at subsurface rather than surface. Compared with the un-carburized gear, the rolling contact fatigue lives of the carburized gear under all load conditions are significantly improved. Under heavy load conditions, the carburized layer significantly reduces the fatigue damage mainly due to the benefit to inhibit the accumulation of plasticity. Influence of the residual stress is also investigated. Under the nominal load condition, compared with the residual stress-free case, the existence of the tensile residual stress causes remarkable deterioration of the rolling contact fatigue life while the compressive residual stress with the same magnitude leads to a moderate growth of the rolling contact fatigue life. As the load becomes heavier when plasticity becomes notable, the influence of the initial residual stress on the life is somewhat weakened.

Fanno Design of Blow-Off Lines in Heavy Duty Gas Turbine

2013 ◽  
Author(s):  
Marco Cioffi ◽  
Enrico Puppo ◽  
Andrea Silingardi
Keyword(s):  
Gas Turbines ◽  
Gas Flow ◽  
Initial Conditions ◽  
Three Dimensional ◽  
Design Procedure ◽  
Flow Equation ◽  
Heavy Duty ◽  
Cross Sectional ◽  
Pipe Length ◽  
Choked Flow

In typical heavy duty gas turbines the multistage axial compressor is provided with anti-surge pipelines equipped with on-off valves (blow-off lines), to avoid dangerous flow instabilities during start-ups and shut-downs. Blow-off lines show some very peculiar phenomena and somewhat challenging fluid dynamics, which require a deeper regard. In this paper the blow-off lines in axial gas turbines are analyzed by adopting an adiabatic quasi-unidimensional model of the gas flow through a pipe with a constant cross-sectional area and involving geometrical singularities (Fanno flow). The determination of the Fanno limit, on the basis of the flow equation and the second principle of thermodynamics, shows the existence of a critical pipe length which is a function of the pipe parameters and the initial conditions: for a length greater than this maximum one, the model requires a mass-flow reduction. In addition, in the presence of a regulating valve, so-called multi-choked flow can arise. The semi-analytical model has been implemented and the results have been compared with a three-dimensional CFD analysis and cross-checked with available field data, showing a good agreement. The Fanno model has been applied for the analysis of some of the actual machines in the Ansaldo Energia fleet under different working conditions. The Fanno tool will be part of the design procedure of new machines. In addition it will define related experimental activities.

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