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)