A ball bearing is widely used in the precision machine, and the ball is its major component. The sphericity and the surface roughness of the ball significantly influence the bearing per-formance and reliability. First, this study considers the gyro-scopic effect and modifies the theoretical model of magnetic fluid grinding to analyze the kinematics characteristics of ball grinding process. According to the apparent changes in the spin angle and the shaft angular speed, the theoretical analysis qualitatively predicts the onset of skidding between contacts. Moreover, the gyroscopic effect is helpful to the randomizing for the ball motion. Second, the grinding trajectory on ball is theoretically analyzed for the new self-developed grinding machine to ob-tain the high efficiency and high precision grinding of balls. Results show that the grinding trajectory is uniform when the spin angle stably changes from 0 to 2p periodically.

Aero-engine assemblies are complex structures typically involving two or three nested rotors mounted within a flexible casing via squeeze-film damper (SFD) bearings. The deployment of SFDs into such structures is highly cost-effective but requires careful calculation since they can be highly nonlinear in their performance, particularly if they are unsupported (i.e. without a retainer spring). The direct study of whole-engine models with nonlinear bearings has been severely limited by the fact that current nonlinear computational techniques are not well-suited for complex large-order systems. The main contributions of this thesis are: • A procedure for unbalance response computation, suitable for generic whole-engine models with nonlinear bearings, which significantly extends the capability of current finite element packages. This comprises two novel nonlinear computational techniques: an implicit time domain integator referred to as the Impulsive Receptance Method (IRM) that enables rapid computation in the time domain; a whole-engine Receptance Harmonic Balance Method (RHBM) for rapid calculation of the periodic response in the frequency domain. Both methods use modal data calculated from a one-off analysis of the linear part of the engine at zero speed.• First-ever analyses on real twin-spool and three-spool engines. These studies illustrate the practical use of these solvers, provide an insight into the nonlinear dynamics of whole-engines and correlate with a limited amount of industrial experimental data. Both IRM and RHBM are directly formulated in terms of the relative response at the terminals of the nonlinear bearings. This makes them practically immune to the number of modes that need to be included, which runs into several hundreds for a typical engine. The two solvers are extensively tested on two/three-shaft engine models (with 5-6 SFDs) provided by a leading engine manufacturer using an SFD model that is used in industry. The tests show the IRM to be many times faster than an established robust conventional implicit integrator while achieving a similar level of accuracy. It is also shown to be more reliable than another popular implicit algorithm. The RHBM enables, for the first time, the frequency domain computation of the nonlinear response of whole-engine models. Its use is illustrated for both Single-Frequency Unbalance (SFU) excitation (unbalance confined to only one shaft) and Multi-Frequency Unbalance (MFU) excitation (unbalance located on two or more shafts, rotating at different speeds). Excellent correlation is demonstrated between RHBM and IRM.The parametric studies compare and contrast the frequency spectra for SFU and MFU cases. They also reveal the varying degree of lift at the unsupported SFDs. The sensitivity of the response to end-sealing and bearing housing alignment is also illustrated. It is demonstrated that the use of suitably preloaded vertically oriented “bump-springs” at the SFDs of heavy rotors produces a significant improvement in journal lift. It is also shown that the consideration of a slight amount of distributed damping in the structure significantly affects the predicted casing vibration levels, bringing them closer to measured levels, while having little effect on the SFD orbits.

Le bruit de roulement contribue fortement au bruit perçu à l'intérieur de l'habitacle des automobiles. Ce bruit a pour origine le contact du pneumatique sur une chaussée rugueuse. En basses fréquences (0-400 Hz), il est transmis dans l'habitacle du véhicule essentiellement par la voie solidienne. La méthode actuelle de prévision de ce bruit chez PSA Peugeot Citroën repose sur une approche mixte calcul-mesure longue, coûteuse et pas suffisamment prédictive. Pour contourner ces limitations, une filière purement numérique est envisagée. Elle demande de modéliser le comportement vibro-acoustique du pneumatique en prenant en compte les effets liés à la rotation et de résoudre le problème de contact avec une chaussée rugueuse. Concernant la modélisation d'un pneumatique en rotation, des formulations des effets tournants d'un solide déformable sont établies en utilisant une approche Arbitrairement Lagrangienne Eulérienne (ALE). Ces formulations sont validées par une application sur un nouveau modèle simplifié du pneumatique. Il s'agit d'un modèle d'anneau circulaire incluant les effets de cisaillement soumis localement à une charge représentative de la masse du véhicule. Un modèle plus complexe d'ensemble monté pneu/roue/cavité intégrant l'ensemble des effets liés à la rotation est également validé par une comparaison avec des essais. Ensuite, le contact avec une chaussée réelle est formulé par différentes approches permettant de réduire le temps de calcul pour une utilisation industrielle. En particulier, le calcul du contact est décomposé en un calcul statique non linéaire suivi d'un calcul dynamique linéaire. La validation du modèle de contact est réalisée par une comparaison calcul/essai. Les résultats sont très satisfaisants / The rolling noise contributes significantly to the noise inside cars. This noise comes from the tire/road contact. In low frequencies (0-400 Hz), it is mainly transmitted into the cabin through structural vibration. The current method used at PSA Peugeot Citroen to predict this noise, is a mixed simulation/experimental approach which is long, expensive and not sufficiently predictive. In order to overcome these difficult, a full numerical approach is considered. It requires modeling the tire vibration by taking into account the rotating effects and the contact with the rough surface. Concerning the model of rotating tire, a formulation of a deformable solid is constructed by using an Arbitrary Lagrangian Eulerian approach (ALE). This formulation is validated by an application on a new simplified tire model which is a circular ring including the shear stresses and the non linear effects due to the vehicle weight. A more complex model composed of tire/wheel/cavity including all the rotating effects is also validated by comparison with experiments. Then the contact with a real road is calculated by different approaches to get the acceptable computing time for industrial uses. In particular, the calculation of the contact is divided into a non-linear static analysis followed by a linear dynamic calculation. The validation of this model is successfully achieved by comparison test results

[pt] Neste trabalho um modelo dinâmico para um rotor vertical em balanço, considerando o fenômeno de contato com a sua guarda, é analisado. A conjunto é modelado como um sistema eixo-rotor-estator com contato. A análise do contato é particularmente complexa pela não linearidade nas equações de movimento. O impacto com o estator é levado em conta através do modelo de contato tipo Kelvin-Vôigt, e, as equações de movimento, do rotor, são deduzidas através da formulação Lagrangeana; estas equações podem capturar os fenômenos devido à vibração lateral, como: precessão direta, precessão retrograda, rolamento e escorregamento. Pela existência de diferentes parâmetros combinados e devido à não linearidade da equação de movimento, a resposta dinâmica não é simples de ser obtida apriori. Portanto, métodos numéricos são empregados para a solução, especificamente emprega-se o método de Runge-Kutta Fehlberg de passo variável. Os resultados da simulação mostram que para certas condições, o rotor pode mudar de orbita devido aos impactos com o estator, podendo chegar a realizar precessão retrograda. Este tipo de fenômeno é considerado como o mais violento e perigoso nas maquinas rotativas. Com o fim de estudar a dinâmica lateral do sistema, um rotor vertical em balanço com guarda anular é investigado. A passagem dela através de sua velocidade critica, quando conduzida por um motor elétrico, é analisada (e também quando o sistema opera em velocidades constantes). Além disso, neste trabalho, os resultados experimentais obtidos da bancada de experimentação são usados para estudar o fenômeno da precessão. / [en] In this work a dynamic model for the overhung rotor, considering the contact phenomenon between the rotor and the stator is analyzed. It is modeled as a shaft-rotor- stator system with contact. The analysis of contact is particularly complex, due to the high nonlinearity of motion equations. Impact with the stator is accounted by a consistent contact model, as Kelvin-Vôigt model, and, rotor`s motion equation is encountered employing Lagrangean`s method; this equations are capable of capturing the phenomenon due to lateral vibration, as: forward whirl, backward whirl, rolling or sliding along the stator. Due to the combined parameters and the effect of nonlinearity in motion equations, the dynamical response is not simple or easily predictable. Numerical simulation is the preferred method of analysis, exactly is used the Runge-Kutta Fehlberg method with variable step. Simulation results show that under certain conditions, a rotor changes its orbit due the impacts with the stator and after that, it executes backward whirl motion. It is a kind of phenomenon, which is considered as the most violent and dangerous in rotating machines. To this end, the analysis of a vertical overhung shaft-disc system with annular guard is investigated. The passing through its critical speed is analyzed when driven by an electric motor (also when the system operates under a constant rotational velocity). In addition, in this work the results obtained with an experimental test rig are used to investigate the whirl phenomenon.