Lagrangian Explicit Finite Element Modeling for Spin-Rolling Contact

2015 ◽  
Vol 137 (4) ◽  
Author(s):  
Xiangyun Deng ◽  
Zhiwei Qian ◽  
Rolf Dollevoet
Keyword(s):  
Finite Element ◽  
Material Properties ◽  
Fatigue Behavior ◽  
Rolling Contact ◽  
Material Behavior ◽  
Elastoplastic Material ◽  
Fe Model ◽  
New Approach ◽  
Explicit Finite Element ◽  
Deep Groove

Spin in frictional rolling contact can cause significant stress, which is the key to understanding and predicting the wear and fatigue behavior of contact components, such as wheels, rails, and rolling bearings. The lateral creep force arising from spin influences the kinematics of a wheelset and thus of vehicles. The solution that is currently employed in the field of elasticity and continuum statics was developed by Kalker and uses a boundary element method (BEM). In this paper, a new approach based on Lagrangian explicit finite element (FE) analysis is employed. This approach is able to consider arbitrary geometric profiles of rails and wheels, complex material behavior and dynamic effects, and some other factors. The new approach is demonstrated using a three-dimensional (3D) model of a wheel with a coned profile rolling along a quarter cylinder and can be easily adapted to apply to wheels and rails of arbitrary profiles. The 3D FE model is configured with elastic material properties and is used to obtain both normal and tangential solutions. The results are compared with those of the Hertz theory and the Kalker's model. The 3D FE model is then configured with elastoplastic material properties to study the spin-rolling contact with plasticity. The continuum dynamics phenomenon is captured by the FE model, which enhances the ability of the model to mimic reality. This improvement considerably extends the applicability of the FE model. The model can be applied to fatigue and wear analyses at gauge corners or rails as well as to deep groove bearings, where a large geometrical spin is present and plastic deformation may be of importance.

Applications for a New Production Technology: Analysis of Linear Flow-Split Linear Guides

2012 ◽  
Author(s):  
Ivan Karin ◽  
Nils Lommatzsch ◽  
Klaus Lipp ◽  
Volker Landersheim ◽  
Holger Hanselka ◽  
...  
Keyword(s):  
Finite Element ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Material Behavior ◽  
Research Centre ◽  
Fe Model ◽  
Linear Flow ◽  
Guidance Systems ◽  
Calculation Models

Within the collaborative research centre 666 “Integral Sheet Metal Design with Higher Order Bifurcations” the innovative manufacturing technologies linear flow-splitting and linear bend-splitting are researched that allow the continuous production of multi-chambered steel profiles in integral style. The massive forming processes create an ultra-fine grained microstructure in the forming area that is characterized by an increased hardness and lower surface roughness compared to as received material. These properties predestine the technology to be used in the production of linear guides. Additionally, the multi-chambered structure of the linear flow-split and -bend components can be used for function integration. To design and evaluate linear guides that use the whole technological potential, the research is focused on a macroscopic and a microscopic point of view. The macroscopic approach is targeting the development of linear flow-split linear guides with integrated functions to provide additional performance values to the established machine parts. Continuously produced guidance systems with innovative functionality can be introduced to a new market with the technology push approach. Preliminary designs of linear flow-split guidance systems and integrated functions are promising. Therefore, an approach to develop new functions for linear flow-split linear guides basing on calculation models and property networks is shown [1]. With this approach, optimized solutions can be created and possible design modifications can be derived. In this contribution, the development and integration of a clamping function for decelerating the slide is presented. Calculation models for analyzing the functionality are presented and validated by finite element models and experiments. The microscopic examination of the profiles aims to investigate the material behavior, particularly of the formed areas. Beside the conventional mechanical and fatigue properties of linear flow-split material ZStE500 [2], the present work focuses on the rolling contact fatigue. This is necessary to evaluate linear flow-split components regarding their eligibility with regard to the rolling contact fatigue behaviour. The Hertz theory for rolling contact fatigue is only valid for homogeneous materials [3]. The flow-split material ZStE500 shows a non-homogeneous behaviour and has to be analyzed with the Finite Element Method in order to determine stresses and strains. In comparison to simulation results with unformed and therefore homogeneous material, the effect of linear flow-split surfaces on the rolling contact behavior is demonstrated. Based on these results, it is possible to start experimental investigations on rolling contact fatigue of linear flow-split components to validate the FE model and determine the performance of linear flow-split flanges for rolling contact fatigue.

Three-Dimensional Finite Element Elastic–Plastic Model for Subsurface Initiated Spalling in Rolling Contacts

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
John A. R. Bomidi ◽  
Farshid Sadeghi
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Fatigue Damage ◽  
Three Dimensional ◽  
Rolling Contact ◽  
Material Behavior ◽  
Lower Percentage ◽  
Fe Model ◽  
Plastic Model ◽  
Elastic Plastic

In this investigation, a three-dimensional (3D) finite element (FE) model was developed to study subsurface initiated spalling observed in rolling line contact of tribo components such as bearings. An elastic–kinematic hardening–plastic material model is employed to capture the material behavior of bearing steel and is coupled with the continuum damage mechanics (CDM) approach to capture the material degradation due to fatigue. The fatigue damage model employs both stress and accumulated plastic strain based damage evolution laws for fatigue failure initiation and propagation. Failure is modeled by mesh partitioning along unstructured, nonplanar, intergranular paths of the microstructure topology represented by randomly generated Voronoi tessellations. The elastic–plastic model coupled with CDM was used to predict both ratcheting behavior and fatigue damage in heavily loaded contacts. Fatigue damage induced due to the accumulated plastic strains around broken intergranular joints drive the majority of the crack propagation stage, resulting in a lower percentage of life spent in propagation. The 3D FE model was used to determine fatigue life at different contact pressures ranging from 2 to 4.5 GPa for 33 different randomly generated microstructure topology models. The effect of change in contact pressure due to subsurface damage and plastic strain accumulation was also captured by explicitly modeling the rolling contact geometry and the results were compared to those generated assuming a Hertzian pressure profile. The spall shape, fatigue lives, and their dispersion characterized by Weibull slopes obtained from the model correlate well with the previously published experimental results.

scholarly journals Investigation on Wheel-Rail Contact and Damage Behavior in a Flange Bearing Frog with Explicit Finite Element Method

2019 ◽  
Vol 2019 ◽  
pp. 1-17
Author(s):  
Yuan Gao ◽  
Ping Wang ◽  
Yibin Liu ◽  
Jingmang Xu ◽  
Zhiguo Dong ◽  
...  
Keyword(s):  
Finite Element ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Numerical Procedure ◽  
Contact Forces ◽  
Rolling Contact ◽  
Fe Model ◽  
Wheel Load ◽  
Explicit Finite Element ◽  
Contact Behavior

Flange bearing frogs are designed to provide continuous rolling surfaces for trains traveling on the through line, but the interaction between wheel and rail in a diverging line is more complex than that for a common crossing, especially including flange bearing mode and multipoint contact during the transition. The wheel load will be transited from tread to flange and back to tread, which will intensify the wheel-rail interaction. In this paper, a numerical procedure is presented for the analysis of wheel-rail rolling contact behavior and damage prediction for the flange bearing frog. The three-dimensional explicit finite element (FE) model of a wheel passing the flange bearing frog is established to obtain the dynamic wheel-rail interaction in both the facing and the trailing move. The evolution of contact forces, the distribution of adhesion-slip regions, and shear surface stress and microslip at the contact patch are revealed. Then, the competition relationship between RCF (rolling contact fatigue) and wear of a flange bearing frog is analyzed. The results of numerical simulations can contribute to an understanding of the mechanism of the transient rolling contact behavior and provide guidance in design optimization for flange bearing frogs.

Age Dependent and Anisotropic Material Properties of Immature Porcine Sclera

2013 ◽  
Author(s):  
Jami M. Saffioti ◽  
Brittany Coats
Keyword(s):  
Finite Element ◽  
Material Properties ◽  
Anisotropic Material ◽  
Computational Models ◽  
Fe Model ◽  
Ocular Tissues ◽  
Load Bearing ◽  
Anisotropic Properties ◽  
Age Dependent ◽  
Testing Protocols

Current finite element (FE) models of the pediatric eye are based on adult material properties [2,3]. To date, there are no data characterizing the age dependent material properties of ocular tissues. The sclera is a major load bearing tissue and an essential component to most computational models of the eye. In preparation for the development of a pediatric FE model, age-dependent and anisotropic properties of sclera were evaluated in newborn (3–5 days) and toddler (4 weeks) pigs. Data from this study will guide future testing protocols for human pediatric specimens.

A Coupled Multibody Finite Element Model for Investigating Effects of Surface Defects on Rolling Contact Fatigue

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Zamzam Golmohammadi ◽  
Farshid Sadeghi
Keyword(s):  
Finite Element ◽  
Fatigue Life ◽  
Surface Defects ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Internal Stresses ◽  
Fe Model ◽  
Elastic Plastic ◽  
Pile Up

A coupled multibody elastic–plastic finite element (FE) model was developed to investigate the effects of surface defects, such as dents on rolling contact fatigue (RCF). The coupled Voronoi FE model was used to determine the contact pressure acting over the surface defect, internal stresses, damage, etc. In order to determine the shape of a dent and material pile up during the over rolling process, a rigid indenter was pressed against an elastic plastic semi-infinite domain. Continuum damage mechanics (CDM) was used to account for material degradation during RCF. Using CDM, spall initiation and propagation in a line contact was modeled and investigated. A parametric study using the model was performed to examine the effects of dent sharpness, pile up ratio, and applied load on the spall formation and fatigue life. The spall patterns were found to be consistent with experimental observations from the open literature. Moreover, the results demonstrated that the dent shape and sharpness had a significant effect on pressure and thus fatigue life. Higher dent sharpness ratios significantly reduced the fatigue life.

A New Approach for Fatigue Damage Modeling of Subsurface-Initiated Spalling in Large Rolling Contacts

2016 ◽  
Vol 139 (1) ◽  
Author(s):  
Aditya A. Walvekar ◽  
Neil Paulson ◽  
Farshid Sadeghi ◽  
Nick Weinzapfel ◽  
Martin Correns ◽  
...  
Keyword(s):  
Fatigue Damage ◽  
Damage Mechanics ◽  
Numerical Models ◽  
Rolling Contact ◽  
Fe Model ◽  
Triangle Mesh ◽  
Computationally Efficient ◽  
New Approach ◽  
Rolling Contacts ◽  
Delaunay Triangle

Large bearings employed in wind turbine applications have half-contact widths that are usually greater than 1 mm. Previous numerical models developed to investigate rolling contact fatigue (RCF) require significant computational effort to study large rolling contacts. This work presents a new computationally efficient approach to investigate RCF life scatter and spall formation in large bearings. The modeling approach incorporates damage mechanics constitutive relations in the finite element (FE) model to capture fatigue damage. It utilizes Voronoi tessellation to account for variability occurring due to the randomness in the material microstructure. However, to make the model computationally efficient, a Delaunay triangle mesh was used in the FE model to compute stresses during a rolling contact pass. The stresses were then mapped onto the Voronoi domain to evaluate the fatigue damage that leads to the formation of surface spall. The Delaunay triangle mesh was dynamically refined around the damaged elements to capture the stress concentration accurately. The new approach was validated against previous numerical model for small rolling contacts. The scatter in the RCF lives and the progression of fatigue spalling for large bearings obtained from the model show good agreement with experimental results available in the open literature. The ratio of L10 lives for different sized bearings computed from the model correlates well with the formula derived from the basic life rating for radial roller bearing as per ISO 281. The model was then extended to study the effect of initial internal voids on RCF life. It was found that for the same initial void density, the L10 life decreases with the increase in the bearing size.

Thermo-mechanical analysis of train wheel-rail contact using a novel finite-element model

2020 ◽  
Vol 72 (5) ◽  
pp. 687-693
Author(s):  
Liuqing Yang ◽  
Ming Hu ◽  
Deming Zhao ◽  
Jing Yang ◽  
Xun Zhou
Keyword(s):  
Finite Element ◽  
Peer Review ◽  
Frictional Heating ◽  
Element Model ◽  
Mechanical Analysis ◽  
Partial Slip ◽  
Computational Time ◽  
Fe Model ◽  
Content Type ◽  
Explicit Finite Element

Purpose The purpose of this paper is to develop a novel method for analyzing wheel-rail (W-R) contact using thermo-mechanical measurements and study the effects of heating on the characteristics of W-R contact under different creepages. Design/methodology/approach This study developed an implicit-explicit finite element (FE) model which could solve both partial slip and full sliding problems by setting different angular velocities on the wheels. Based on the model, four material types under six different creepages were simulated. Findings The results showed that frictional heating significantly affected the residual stress distribution under large creepage conditions. As creepage increased, the temperature of the wheel tread and rail head rose and the peak value was located at the trailing edge of the contact patch. Originality/value The proposed FE model could reduce computational time and thus cost to about one-third of the amount commonly found in previous literature. Compared to other studies, these results are in good agreement and offer a reasonable alternative method for analyzing W-R contact under various conditions. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2019-0298

An Experimental and Numerical Study to Analysis and Design of Sheet Hydroforming Process for an Automobile Fender Shell

2006 ◽  
Author(s):  
Mohammad Habibi Parsa ◽  
Payam Darbandi
Keyword(s):  
Finite Element ◽  
Numerical Study ◽  
Fluid Pressure ◽  
Finite Element Program ◽  
New Approach ◽  
Explicit Finite Element ◽  
Sheet Hydroforming ◽  
Analysis And Design ◽  
Hydroforming Process ◽  
Element Program

A new approach for manufacturing of shell fender is proposed and has been examined numerically and experimentally. The new suggested method is based on sheet hydroforming process, which has a lot of advantages over conventional deep drawing process. After defining the shape of initial blank using an inverse finite element program, numerical evaluation of the proposed sheet hydroforming process for production of shell fender has been carried out using an explicit finite element code considering fluid pressure, boundary conditions and tools. Then experimental evaluation has been carried out using down sized specimen and the results have been compared with results of previous simulations. It has been shown that there are similar trends between finite element and experimental results.

Explicit Finite Element Analyses of Drop Tests With Thin-Walled Steel Sheet Containers for the Konrad Repository

2015 ◽  
Author(s):  
Christian Protz ◽  
Uwe Zencker ◽  
Robert Liebich
Keyword(s):  
Finite Element ◽  
Numerical Simulations ◽  
Damage Mechanics ◽  
Steel Sheet ◽  
Assessment Procedure ◽  
Fe Model ◽  
Explicit Finite Element ◽  
Safety Margins ◽  
Drop Tests ◽  
Thin Walled

Alternatively to experimental drop tests, the mechanical safety analyses of containers for final disposal of radioactive waste with negligible heat generation in the German Konrad repository may be carried out by numerical simulations within the safety assessment procedure. In the past, safety assessments for thin-walled steel sheet containers have been done exclusively by prototype tests and unfavorable drop scenarios were determined by engineering judgment. So far, reliable numerical simulations do not exist. Therefore, a research project was started to develop numerical simulation approaches for drop test analyses and to determine existing safety margins. Comparisons of experimental and numerical results confirm that the Finite Element (FE) model represents the general mechanical behavior of the steel sheet container sufficiently. Simulations have been used to determine an unfavorable drop scenario resulting in large deformation and damage. This paper presents the investigations carried out as well as the further development of the FE model in terms of damage mechanics.

FEM-Based Simulation of Temperature in Speed Stroke Grinding with 3D Transient Moving Heat Sources

2011 ◽  
Vol 223 ◽  
pp. 733-742 ◽  
Author(s):  
Barbara Linke ◽  
Michael Duscha ◽  
Anh Tuan Vu ◽  
Fritz Klocke
Keyword(s):  
Finite Element ◽  
Material Properties ◽  
Material Removal ◽  
Structural Changes ◽  
Numerical Technique ◽  
Temperature Fields ◽  
Fe Model ◽  
Measured Temperature ◽  
Temperature Dependent ◽  
Removal Rates

The grinding process is one of the most important finishing processes to obtain high surface quality. Nowadays, grinding is also considered as a high performance process with high material removal rates. Nevertheless, to avoid thermally-induced structural changes poses a major challenge for this manufacturing technology. Until now, the Finite Element Method (FEM) has been widely applied as a proper numerical technique to predict workpiece properties in machining processes. However, actual models in grinding are limited to conventional grinding processes with simple workpiece profiles and low table speeds. In this paper, finite element simulations are expanded to 3-dimensional (3D) models with temperature-dependent material properties and heat source profiles derived from experimental results, i.e. tangential forces. Both temperature simulation and measurement were conducted for deep grinding, pendulum grinding and speed stroke grinding in the table speed range of vw= 12 m/min to 180 m/min and specific material removal rates of Q’w= 40 mm³/mms. Overall, the simulation results show a good agreement with the measured temperature and surface integrity after grinding. This research indicates that a 3D FE model with temperature dependent material properties can predict realistic temperature fields in speed stroke grinding. Therefore, the experiment and measurement costs and time can be reduced by FEM simulation.

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