Optimal shapes of contact interfaces due to sliding wear in the steady relative motion

The transient wear process at contact frictional interface of two elastic bodies in relative steady motion induces evolution of shape of the interface. A steady wear state may be reached with uniform wear rate and fixed contact surface shape. In this paper, the optimal contact shape is studied by formulating several classes of shape optimization problems, namely minimization of generalized wear volume rate, friction dissipation power and wear dissipation rate occurring in two bodies. The wear rule was assumed as a nonlinear dependence of wear rate on friction traction and relative sliding velocity, similar to the Archard rule. The wear parameters of two bodies may be different. It was demonstrated that different optimal contact shapes are generated depending on objective functional and wear parameters. When the uniform wear rate is generated at contact sliding surfaces, the steady state is reached. It was shown that in the steady state the wear parameters of two bodies cannot be independent of each other. The solution of nonlinear programming problem was provided by the iterative numerical procedure. It was assumed that the relative sliding velocity between contacting bodies results from translation and rotation of two bodies. In general, both regular and singular regimes of wear rate and pressure distribution may occur. The illustrative examples of drum brake, translating punch and rotating annular punch (disc brake) provide the distribution of contact pressure and wear rate for regular and singular cases associated with the optimality conditions. It is shown that minimization of the generalized wear dissipation rate provides solutions assuring existence of steady wear states.     

Nonlinear dynamics of mistuned bladed disks with ring dampers

In turbomachinery applications, rotating bladed disks (blisks) are often subject to high levels of dynamic loading, such as traveling wave excitations, which result in large response amplitudes at resonance. To prevent premature high cycle fatigue, various dry friction dampers are designed for blisk systems to reduce the forced responses. Ring dampers are located in the disk, underneath the blades, and are held in contact with the blisk by centrifugal loading. Energy is dissipated by nonlinear friction forces when relative motions between the ring damper and the blisk take place. To investigate the dynamic responses of blisk–damper systems in the presence of the nonlinear frictional contacts, conventional methods based on numerical time integration are not suitable since they are computationally expensive. This paper presents a reduced-order modeling technique to efficiently capture the nonlinear dynamic responses of the blisk–damper systems. Craig–Bampton component mode synthesis (CB-CMS) serves as the first model reduction step. A novel mode basis that mimics the contact behavior under sliding and sticking conditions is developed to further reduce the CB-CMS model while maintaining its accuracy. The resulting reduced nonlinear equations of motion are solved by a hybrid frequency/time domain (HFT) method. In the HFT method, the contact status and friction forces are determined in the time domain by a three-dimensional contact model at each contact point, whereas the reduced equations of motion are solved in the frequency domain according to a harmonic balance formulation. Moreover, to investigate the effects of blade mistuning, which can lead to drastic increase of forced responses, an extension of the reduced-order models (ROMs) is developed based on component mode mistuning. Forced responses computed by the proposed ROMs are validated for both tuned and mistuned systems. A statistical analysis is performed to study the effectiveness of ring dampers under random blade mistuning patterns.     

Contact analysis of a flexible bladed-rotor

This paper presents a model of fully flexible bladed rotor developed in the rotating frame. An energetic method is used to obtain the matrix equations of the dynamic behaviour of the system. The gyroscopic effects as well as the spin softening effects and the centrifugal stiffening effects, taken into account through a pre-stressed potential, are included in the model. In the rotating frame, the eigenvalues' imaginary parts of the latter matrix equation give the Campbell diagram of the system and its stability can be analysed through its associated eigenvalues' real parts. The turbo machine casing is also modelled by an elastic ring in the rotating frame through an energetic method. Thus, in some rotational speed ranges the contact problem between the rotor and the stator can be treated as a static problem since both structures are stationary to each other. Prior to the study of the complete problem of contact between the flexible blades of the rotor and the flexible casing, a simple model of an elastic ring having only one mode shape, excited by rotating loads is developed in the rotating frame too, in order to underline divergence instabilities and mode couplings. Then, the complete problem of frictionless sliding contact between the blades and the casing, without rubbing, is studied. The stable balanced static contact configurations of the structure are found as function of the rotational speed of the rotor. Finally, the results are compared to these of the simple model of rotating spring-masses on an elastic ring, showing good adequacy. The present model of rotor appears thus particularly adapted to the study of blades-casing contacts and highlighted an unstable phenomenon near the stator critical speed even in case of frictionless sliding.     

Stability and Hamiltonian Hopf bifurcation for a nonlinear symmetric bladed rotor

The modal interaction which leads to Hamiltonian Hopf bifurcation is studied for a nonlinear rotating bladed-disk system. The model, which is discussed in the paper, is a Jeffcott rotor carrying a number of planar blades which bend in the plane of the motion. The rigid rotating disk is supported on nonlinear bearings. It is supposed that this dynamical system is a Hamiltonian system which is perturbed by small dissipative and nonlinear forces. Krein’s theorem is employed for obtaining a stability criterion. The nonlinear eigenvalue equations on the stability boundary are turned into ordinary differential equations (ODEs) by differentiating them over the rotating speed. By solving these ODEs, the eigenmodes and the eigenvalues on the stability boundary are obtained. The bifurcation analysis is performed by applying multiple scales method around the boundary. The rotor nonlinear behavior and damping effects are studied for different conditions on the rotating speed and nonlinearity type by the bifurcation equation. It is shown that the damping distribution between the blades and bearings may shift the unstable mode. Depending on the nonlinearity type, subcritical and supercritical Hopf bifurcation are possible.     

Analysis of an elastic ring tourniquet (ERT) using the theory of a Cosserat curve and finite elements

A-TT™ and S-MART™ are novel elastic ring tourniquets (ERTs) used for the control of hemodynamic shock and for bloodless surgical procedures on limbs. The ERT device is essentially a silicone ring surrounded by a stockinette sterile gauze. Since the contact pressure applied by the ERT is determined by its geometric and mechanical properties and cannot be adjusted, it is important to develop a mechanical model that can be used to ensure that the contact pressure remains low enough not to cause local tissue damage. Although the calculation of the contact pressure applied by a silicone ring seems to be a simple classical problem, it is shown that the accurate prediction of this contact pressure requires analysis of a number of complicating features, which are related to nonlinear geometric and material influences. This paper presents a hierarchy of mechanical models which include: a simple strength of materials model; models based on the theory of a Cosserat curve and a generalized string (which includes deformation of the cross-section); exact axisymmetric plane strain nonlinear elasticity; and axisymmetric nonlinear finite element analysis. It is shown that the Cosserat model provides reasonable predictions of the response of the silicone ring. Since numerical simulations with the Cosserat model are much faster than those with the finite element model, the Cosserat analysis is more suitable for optimization of the thickness of the stockinette, which can significantly reduce both the maximum and average contact pressures applied by the ERT on the skin.     

柔性梁刚柔耦合碰撞动力学及变形传播研究

运用柔性多体系统刚柔耦合动力学理论,研究了作大范围回转运动柔性梁的碰撞动力学问题.考虑柔性梁的横向变形,以及横向变形引起的纵向缩短项即非线性耦合变形项.采用基于Hertz接触理论及非线性阻尼理论的非线性弹簧阻尼模型来求解碰撞过程中产生的碰撞力,运用第二类拉格朗日方程建立了系统的刚柔耦合碰撞动力学方程.编制仿真软件进行动力学仿真计算,得到了碰撞力和系统动力学响应,对比分析了不同动力学模型对系统动力学响应的影响.同时研究了碰撞导致的柔性梁横向变形传播的波动特性.     

Passive control of vibration of thin-walled gears: advanced modelling of ring dampers

Vibrations on gears are mainly induced by the gear mesh contact. Resonance conditions of the gear may occur during service if the mesh frequency is close to the natural frequencies of the system at the designed speed of the shaft. Since detuning is not always possible in gears, the response level must be reduced by increasing the damping of the system. In this paper, a passive approach based on the application of a ring damper to reduce the vibration level is presented. The ring damper is placed in a groove underneath the outer rim of the gear. The contact is guaranteed by the preload due to the elasticity of the ring damper itself and above all by the centrifugal force that presses the damper against the groove during rotation. The relative motion of the two components at the contact interface dissipates energy by friction, and hence damping is generated. The vibration amplitude is reduced by optimizing the material and geometrical properties of the ring damper. One of the most important parameters in the determination of the amount of damping due to friction phenomena is the static normal load at the contact, which depends on the mass, the shape, and the material of the ring damper. A numerical method is presented, which couples the static and dynamic equilibrium equations of the assembly. The core of the proposed method is the contact element that takes into account local stick–slip–lift off of the contact and determines the contact forces in terms of static and dynamic loads, which are then used to solve the coupled static and dynamic equilibrium. Since the ring damper has a cut that breaks its continuous circular shape in order to be fitted on the groove, the hypothesis of cyclic symmetry for the gear/ring–damper assembly fails. As a consequence, an appropriate reduced-order modeling is presented to allow the forced response calculations. The algorithm is applied to a dummy bevel gear and to a ring damper having a flat punch contact area. The forced response calculations are performed to highlight the nonlinear interaction between the gear and damper by varying the parameters that mainly affect the amount and distribution of the contact forces and therefore the response level.     

Nonlinear stability analysis of a disk brake model

It has become commonly accepted by scientists and engineers that brake squeal is generated by friction-induced self-excited vibrations of the brake system. The noise-free configuration of the brake system loses stability through a flutter-type instability and the system starts oscillating in a limit cycle. Usually, the stability analysis of disk brake models, both analytical as well as finite element based, investigates the linearized models, i.e. the eigenvalues of the linearized equations of motion. However, there are experimentally observed effects not covered by these analyses, even though the full nonlinear models include these effects in principle. The present paper describes the nonlinear stability analysis of a realistic disk brake model with 12 degrees of freedom. Using center manifold theory and artificially increasing the degree of degeneracy of the occurring bifurcation, an analytical expression for the turning points in the bifurcation diagram of the subcritical Hopf bifurcations is calculated. The parameter combination corresponding to the turning points is considered as the practical stability boundary of the system. Basic phenomena known from the operating experience of brake systems tending to squeal problems can be explained on the basis of the practical stability boundary.     

摩擦粒子填充材料对高速列车闸片制动性能的影响

在自行研制的制动缩比试验台上,对中心孔填充不同材料的高速列车制动闸片摩擦粒子进行拖曳制动试验,并采用有限元分析方法进行制动系统复特征值和接触应力分析,探讨填充不同材料对磨损特性、振动噪声和热分布的影响. 结果表明:原始摩擦粒子中心孔填充材料后,对制动系统的摩擦系数和模态耦合特性未产生显著影响,但对界面磨损行为和系统振动噪声特性产生明显影响. 填充粉末冶金后排屑行为下降,磨损行为更为复杂,制动系统产生的噪声增大;而填充紫铜、石墨和铸铁后的制动噪声均有所降低,尤其填充铸铁后表面磨损相对均匀,其摩擦学性能相较于其他粒子得到一定的改善. 填充材料产生的磨屑及相应的界面磨损行为是影响制动摩擦振动噪声和表面热分布的关键因素,填充合理的材料有助于降低制动噪声和改善制动界面磨损行为及表面热分布.      

Bifurcations in the response of a rigid rotor supported by load sharing between magnetic and auxiliary bearings

Auxiliary bearings are utilized in practical installations of magnetically suspended rotating machines with the main functions to provide support to the rotating machines during their non-operational period, and to protect the magnetic bearings and the rotating assembly from being damaged due to power loss during operation. The relatively small clearances of these bearings, which are typically half of that of the magnetic bearings, may at time cause contact between the rotor and these bearings to occur even during normal operation of the rotating machines. The work presented herein examines the bifurcations in the response of a rigid rotor supported by load sharing between magnetic and auxiliary bearings, which occurs during contact between the rotor and the auxiliary bearings. Numerical results revealed the occurrence of period-doubling bifurcation resulting in vibrations of period-2, -4, -8, -16 and -32, as well as quasi-periodic and chaotic vibrations. The results further showed that for a relatively small rotor imbalance magnitude, which is within the prescribed level of certain classes of practical rotating machinery, such nonlinear dynamical phenomena would not have been discovered had the auxiliary bearings forces been omitted in the model of the rotor-bearing system. As these bearings are essential elements in practical installations of magnetically supported rotating machines, failure to include them in the rotor-bearing model may result in incorrect prediction of the rotor’s vibration response.     

Energy consumed by a bearing supported spindle in the presence of a dynamic cutting force and of defects

A machine tool spindle system model is proposed in this paper to investigate the non-linear face-milling cutting forces behavior, which are neglected in the literature, in order to predict the total mechanical power of a spindle. A simulation of the structure of the spindle based on the finite-element method is elaborated to estimate the variable cutting forces and then the variable power loss generated by bearings, considering the angular position and contact angles of the variable balls. Experiments are elaborated to compare the experimental power values with the predicted results. Particular attention is paid to different types of defects (inner ring spalling, outer ring spalling, eccentricity, and unbalance) in order to study their impact on the power consumed by the spindle during the approach and cutting phases under different rotating conditions.     

具有曲率和惯性非线性以及材料内阻的旋转复合材料轴的主共振

旋转复合材料轴作为一类典型的转子动力学系统,在先进直升机和汽车动力驱动系统中有着广阔的应用前景.研究旋转复合材料轴的非线性振动特性具有重要的理论与实用价值.然而,目前有关旋转轴的非线性振动研究仅限于各向同性金属材料轴,很少考虑材料内阻的影响.本文研究具有材料内阻的旋转非线性复合材料轴的主共振.非线性来源于不可伸长复合材料轴的大变形引起的非线性曲率和非线性惯性,材料内阻来源于复合材料的黏弹性.动力学建模计入转动惯量和陀螺效应.基于扩展的Hamilton原理,导出具有偏心激励的旋转复合材料轴的弯-弯耦合非线性振动偏微分方程组.采用Galerkin法将偏微分方程离散化为常微分方程,采用多尺度法对常微分方程进行摄动分析,导出主共振响应的解析表达式.对内阻、外阻、铺层角、长径比、铺层方式和偏心距进行数值分析,研究上述参数对旋转非线性复合材料轴的稳态受迫振动响应行为的影响.研究发现,角铺设复合材料轴的内阻系数随着铺层角的增大而增大;内阻对主共振响应特性的影响主要体现在对抑制振幅和改变频率响应的稳定性方面;发生在正进动固有频率附近的主共振响应具有典型的硬弹簧非线性特性.本文提出的模型能够用于描述旋转复合材料轴的主共振特性,是对不可伸长旋转金属轴非线性动力学模型的重要推广.     

On the dynamics of rings rotating with variable spin speed

This work investigates nonlinear dynamic response of circular rings rotating with spin speed which involves small fluctuations from a constant average value. First, Hamilton's principle is applied and the equations of motion are expressed in terms of a single time coordinate, representing the amplitude of an in-plane bending mode. For nonresonant excitation or for slowly rotating rings, a complete analysis is presented by employing phase plane methodologies. For rapidly rotating rings, periodic spin speed variations give rise to terms leading to parametric excitation. In this case, the vibrations that occur under principal parametric resonance are analyzed by applying the method of multiple scales. The resulting modulation equations possess combinations of trivial and nontrivial constant steady state solutions. The existence and stability properties of these motions are first analyzed in detail. Also, analysis of the undamped slow-flow equations provides a global picture for the possible motions of the ring. In all cases, the analytical predictions are verified and complemented by numerical results. In addition to periodic response, these results reveal the existence of unbounded as well as transient chaotic response of the rotating ring.     

Bending vibration analysis of rotating machineries using multibody dynamics technology — development of computer program RotB

This paper examines a computer program developed to analyze the vibration of rotating machineries based on theories of vibration and multibody dynamics (MBD). Bending vibration problems of rotating machineries have generally been categorized as either linear or nonlinear. Linear problems can be formulated by standard methods and nonlinear problems can be formulated by MBD methods. In our study, nonlinear problems are treated by the use of a general-purpose computer program, RecurDyn (RD). In the program we developed, rotor bending vibration analysis (RotB) structural properties such as shafts, rotating rotary disks, unbalanced masses and foundation structures are modeled as multibody elements. Also, nonlinearities such as contact, non-symmetrical shaft effects, bearing characteristics, nonlinear restoring and damping characteristics in the bearings are taken into account. The computational results demonstrate the validity of RotB.     

基于荧光法的滚动轴承内部润滑油层分布研究

润滑油在轴承内的分布及其变化规律对轴承的润滑性能有显著影响. 在本文中搭建了滚动轴承模拟试验台,基于激光诱导荧光方法实现了滚动轴承内钢球-外圈接触区附近润滑油分布的观察与测量,获得了润滑油供给油层分布的三维形貌图,研究了不同供油量和转速对轴承内部供给油层分布的影响规律. 试验结果表明充分润滑条件下相邻钢球-外圈接触区供给油池之间会形成相互连接的油带;在高速情况下,钢球-外圈接触区供给油层厚度受前一个接触区尾部空穴影响而减小;供油量的增加会增大表观油池,但并不意味着入口有效供油层的增加.      

Nonlinear vibration of a rotating laminated composite circular cylindrical shell: traveling wave vibration

In this paper, the large-amplitude (geometrically nonlinear) vibrations of rotating, laminated composite circular cylindrical shells subjected to radial harmonic excitation in the neighborhood of the lowest resonances are investigated. Nonlinearities due to large-amplitude shell motion are considered using the Donnell’s nonlinear shallow-shell theory, with account taken of the effect of viscous structure damping. The dynamic Young’s modulus which varies with vibrational frequency of the laminated composite shell is considered. An improved nonlinear model, which needs not to introduce the Airy stress function, is employed to study the nonlinear forced vibrations of the present shells. The system is discretized by Galerkin’s method while a model involving two degrees of freedom, allowing for the traveling wave response of the shell, is adopted. The method of harmonic balance is applied to study the forced vibration responses of the two-degrees-of-freedom system. The stability of analytical steady-state solutions is analyzed. Results obtained with analytical method are compared with numerical simulation. The agreement between them bespeaks the validity of the method developed in this paper. The effects of rotating speed and some other parameters on the nonlinear dynamic response of the system are also investigated.     

车轮多边形激励下高速列车制动界面摩擦学行为分析

高速列车车轮多边形磨耗是一种沿车轮周向的不均匀磨耗,是列车服役过程中常见的车轮失效现象,其产生的剧烈轮轨激励严重威胁车辆系统服役可靠性.制动系统作为保障高速列车服役安全的核心部件,其界面摩擦学行为直接受到轮轨激励的影响.为探究车轮多边形激励下的制动界面摩擦学行为,建立了刚柔耦合车辆动力学模型和制动系统热机耦合有限元模型,并分别通过线路试验和台架试验验证了模型的正确性.然后,提出一种考虑车轮多边形激励的制动界面摩擦学行为分析方法,能够真实地反映服役过程中制动界面摩擦学行为.基于此,研究了不同车辆运行速度下车轮多边形激励对制动系统动态接触、温度以及振动特性的影响规律.结果表明：车轮多边形磨耗导致系统接触面积、摩擦热、接触应力和振动等摩擦学行为更为复杂且剧烈.此外,系统接触面积标准差和振动加速度均方根值随速度的增加而增大.因此,车轮多边形磨耗对制动界面摩擦学行为具有不可忽略的影响.该研究成果可为制动系统界面摩擦学行为研究及结构优化设计提供有效方法与工程指导.     

NONLINEAR THERMAL ANALYSIS FOR THE INTER-SHAFT BEARING UNDER THE DYNAMIC LOAD 1)

中介轴承作为双转子系统高低压转子重要的支承部件,其内圈和外圈均随着低压转子和高压转子高速旋转, 其传热问题更加突出.本文研究中介轴承在非线性动载荷作用下的非线性热行为.基于双转子系统动力学响应定义中介轴承动载荷,考虑中介轴承的径向游隙、分数指数非线性和参数激励等非线性因素,中介轴承动载荷会出现跳跃和双稳态等非线性行为. 考虑润滑剂的黏温关系,根据Palmgren经验公式建立动载荷作用下中介轴承的热传递模型,通过数值求解得到中介轴承稳态温度,发现动载荷的非线性行为导致中介轴承温度出现跳跃和双稳态等非线性热行为.分析转速比、偏心距、中介轴承径向游隙、Hertz接触刚度和滚子数目对中介轴承温度及非线性热行为的影响,表明偏心距、径向游隙和刚度只影响非线性热行为,而转速比和滚子数目对两者都有重要影响. 本文研究表明,动载荷相较于静载荷更适合描述中介轴承的实际载荷,由于双转子系统具有非线性振动特性, 中介轴承的热行为也表现出复杂的非线性行为.     

动载荷作用下中介轴承的非线性热行为研究

中介轴承作为双转子系统高低压转子重要的支承部件,其内圈和外圈均随着低压转子和高压转子高速旋转, 其传热问题更加突出.本文研究中介轴承在非线性动载荷作用下的非线性热行为.基于双转子系统动力学响应定义中介轴承动载荷,考虑中介轴承的径向游隙、分数指数非线性和参数激励等非线性因素,中介轴承动载荷会出现跳跃和双稳态等非线性行为. 考虑润滑剂的黏温关系,根据Palmgren经验公式建立动载荷作用下中介轴承的热传递模型,通过数值求解得到中介轴承稳态温度,发现动载荷的非线性行为导致中介轴承温度出现跳跃和双稳态等非线性热行为.分析转速比、偏心距、中介轴承径向游隙、Hertz接触刚度和滚子数目对中介轴承温度及非线性热行为的影响,表明偏心距、径向游隙和刚度只影响非线性热行为,而转速比和滚子数目对两者都有重要影响. 本文研究表明,动载荷相较于静载荷更适合描述中介轴承的实际载荷,由于双转子系统具有非线性振动特性, 中介轴承的热行为也表现出复杂的非线性行为.      

Nonlinear vibrations of blade with varying rotating speed

This paper investigates the nonlinear dynamic responses of the rotating blade with varying rotating speed under high-temperature supersonic gas flow. The varying rotating speed and centrifugal force are considered during the establishment of the analytical model of the rotating blade. The aerodynamic load is determined using first-order piston theory. The rotating blade is treated as a pretwist, presetting, thin-walled rotating cantilever beam. Using the isotropic constitutive law and Hamilton??s principle, the nonlinear partial differential governing equation of motion is derived for the pretwist, presetting, thin-walled rotating beam. Based on the obtained governing equation of motion, Galerkin??s approach is applied to obtain a two-degree-of-freedom nonlinear system. From the resulting ordinary equation, the method of multiple scales is exploited to derive the four-dimensional averaged equation for the case of 1:1 internal resonance and primary resonance. Numerical simulations are performed to study the nonlinear dynamic response of the rotating blade. In summary, numerical studies suggest that periodic motions and chaotic motions exist in the nonlinear vibrations of the rotating blade with varying speed.