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提高轴承寿命的计算检测方法Improving Bearing Life With Computational Testing用 DigitalClone 技术提高轴承寿命DigitalClone Technology to Improve Bearing Life
资产管理和可靠性Asset Management and Reliability
了解整体机组的保修状况Understand Fleet LevelWarranty Exposure
- 供应链的选择如何影响资产寿命How do I understand how my supply
chain choices will affect my asset life?- 使用和保养如何延长轴承的实际使用寿命
How can my operating conditions and maintenance decisions extend the life of bearings in the field?
新产品引入市场New Product Introduction
新产品测试More Testing for New Products
- 改变现有产品的设计如何影响市场占有或价格How would design changes to my current product lines improve market share or price premium?
- 如何降低新产品进入市场的时间和成本How do I decrease go-to- market time and cost for new products?
表面强化和摩擦学Surface Enhancement and Tribology
快速证明性能的方法Rapid Solutions to Prove Performance
- 怎么最快让客户认可轴承的性能How do I accelerate customer confidence in my bearing performance?
- 怎么突出轴承的竞争优势How can I highlight my bearing or
enhancement’s competitive advantage?
当前市场的挑战?What Business Challenges Exists?
概念设计Conceptual
Design
具体设计Detailed Design
原型生产Prototype
物理测试Physical Testing
投入生产Launch
客户在实际情况下测试产品Customer Tests Product in the Field
失败Failure
怎么改进?Could this perform better?
计算测试 – 在原型生产前先做几百次的计算测试Computational Testing – Perform 100’s of tests before prototyping
计算测试技术Computational Testing Technical
Approach
4 个主要特性
纵向应用 在线帮助
客户库
在线帮助
DigitalClone 技术DigitalClone Technical Approach
1) DigitalClone 系统模型DigitalClone System™ Loads & Requirements & System Life
6) DigitalClone 寿命模型DigitalClone Live™ Output Predict-Acquire-Confirm- Control
2) DigitalClone 材料模型DigitalClone Material™ Characterize & Create Microstructure Model
3) DigitalClone 部件模型DigitalClone Component™ Friction, & Lubrication Surface
Treatments
5) 预测部件的故障模式和寿命Predict Component Failure Mode/Failure Life
4) 计算微观应力 - 预测断裂的产生和扩展Simulate Stress in Microstructure – Predict Crack Initiation & Propagation
Superfinish
Ground Finish
现有的断裂模型Failure Modes Ready for Implementation
• 微点蚀疲劳Micropitting Fatigue
• 弯曲疲劳Bending Fatigue
• 剥落疲劳Spalling Fatigue
• 微动疲劳Fretting Fatigue
Gear Pitting Bearing Spalling
Bending FatigueSpline Fretting
正在研发中的断裂模型Failure Modes in R&D Released 2014
• 白蚀White Etching
• 金属磨损Metal Wear
(Abrasion, Adhesion, Scuffing)• 腐蚀疲劳
Corrosion Fatigue• 合成材料分层
Composite Delamination• 涂层老化
Coating Degradation
Corrosion Fatigue and Wear Metal Wear
Composite Laminate White Layer Etching
计算测试的应用Computational Testing Applications
部件寿命预测Component LifecyclePrediction材料 Materials
系统寿命预测Assembly/System
Lifecycle Prediction
整体检测,监控,报告Fleet Analysis,
Monitoring, & Reporting
Man
aged
Ser
vice
sS
aaS
/ A
aaS
需求Requirements
产品寿命周期 Product Lifecycle
设计和测试Design&Tests
生产和保修Manufacture&Warranty
使用和维护Operate&Maintain
再利用 / 退役Reuse/Retire
计算测试应用的实例Computational Testing Applications
and Research
旋翼机齿轮箱轴承Rotorcraft Gearbox Bearing
L10 Life (Million Revolutions)
S-N plot for off-shelve (AISI-52100) and aerospace-quality (SAE-4620) TGB taper roller bearings
60
70
90
80
100
120
110
130
150
140
160
1 10 100 1000 10000
% o
f Des
ign
Load
CLP CLP TIMKEN
75%75% 100% 108% 115% 125% 140% 150%
100%
125%
150%
Axi
al
Load
Radial load
Failure probability for 4620 taper roller bearing under different load combinations
DC AISI-52100 DC SAE-4620 OEM 52100
0-0.2 0.2-0.4 0.4-0.6 0.6-0.8
旋翼机齿轮箱轴承Rotorcraft Gearbox Bearing
Surface crack
22
Some RCF spalls/radial cracks in aerospace-quality bearing (clean steel):
Some RCF spalls/radial cracks in off-shelve bearings (steel with inclusions):
Subsurface cracks initiated at inclusions
Radial cracksRCF spalls
23Sentient Confidential
300.00
350.00
Forc
e (N
)
450.001500.00
400.00
500.00
550.00
650.001800.00
600.00
700.00
0 10000 20000 30000 40000 50000 60000 70000Shaft speed (rpm)
1300.00
1400.00
1600.00
1700.00
1900.00
0 10000 20000 30000 40000 50000 60000Shaft speed (rpm)
70000
Pres
sure
(MPa
)
涡轮增压器混合轴承Turbocharger Hybrid Bearing
Inner race Outer race Inner race Outer race
0.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
3500.00
4000.00
0 10000 20000
30000 40000 50000 60000
70000
L10
(Mill
ion
shaf
t rev
olut
ions
)
涡轮增压器混合轴承Turbocharger Hybrid Bearing
0.00
24Sentient Confidential
Shaft speed (rpm) Shaft speed (rpm)
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
0 10000 20000 30000 40000 50000 60000 70000
Failu
re ra
te (%
)
总体趋势General trends seem logical
涡轮增压器混合轴承Turbocharger Hybrid Bearing
Miner’s rule:
• 假设 Assuming:• n: 根据指定的占空比所需的失败总轴旋转数 total number of shaft
revolutions required for failure under the specified duty cycle• FS ( 安全参数 safety factor) = 1
n = 2579.43 million shaft revolutions3.88E-4 n = 1
Dutycycle
25
风能电机齿轮箱的轴承系统Gearbox Bearing System
• 问题:风能电机齿轮箱轴承过早断裂Motivation/Problem: Premature cracking on wind turbine gearbox bearings
(NU232, NU2326, NU2334, NU2336)
• Sentient 的研发目标:− 模拟径向断裂和早期故障
Simulate radial cracking and early failure
– 确定问题和最佳解决方案 Determine problem areas and best fix
风能电机齿轮箱的轴承系统Gearbox Bearing System
Case 1: nom
inal loading condition with no hoop stress
额定负载Nominal Loading
高负载High Loading
无环向应力No Hoop Stress
情况 1 – 无断裂Case 1 – No Failures
情况 2 – 剥落 / 点蚀 , 无径向裂纹Case 2 – Spalling/Pitting, No Radial Cracking
有环向应力With HoopStress
情况 3 – 有径向裂纹 , 以及剥落 / 点蚀Case 3 – Radial Cracks andPitting/Spalling
情况 4 – 剥落 / 点蚀 , 部分亚表面损伤Case 4 – Spalling/Pitting,Little Subsurface Damage
风能电机齿轮箱的轴承系统Gearbox Bearing System
#4
#3
#2
#1
过早断裂:环向应力Premature failure: including hoop stress
环向应力Hoop stress
effect
额定负载Nominal
load
高负载Higher load
Exp. Data (Harris & Barnsby) Jalalahmadi-Sadeghi Lundberg-Palmgren Theory Raje-Sadeghi
S-N data for 52100 cylindrical roller bearing (CRB)