Orientador: Katia Lucchesi Cavalca Dedini / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-16T18:19:16Z (GMT). No. of bitstreams: 1 Carvalho_RafaelVischi_M.pdf: 7127919 bytes, checksum: 2c7a6895f35098e4e4f46ed38b158980 (MD5) Previous issue date: 2010 / Resumo: Rolamentos de esfera são elementos de máquinas de forma simples mas utilizados em aplicações envolvendo altas velocidades, altas temperaturas e diferentes carregamentos. O modelo para o carregamento é fundamental para análise dinâmica do mancal e por esse motivo é necessário definir com precisão o desempenho desses mecanismos usando métodos analíticos. O objetivo deste trabalho é analisar o rolamento de esferas baseando-se, em um primeiro momento, em referências bibliográficas de diversos autores para, em seguida, iniciar o equacionamento e simulação para analisar as influências do momento giroscópico, das velocidades geradas nos diversos componentes do rolamento e do carregamento nas esferas. A partir de um rolamento padrão, aplicou-se uma metodologia de testes por simulação numérica variando os principais fatores críticos de um rolamento do ponto de vista estático, cinemático e dinâmico. Conclui-se que a rotação e o ângulo de contato influem nas forças de atrito que resistem ao momento giroscópico e nas velocidades geradas na zona de contato entre esfera e pistas interna e externa. Em altas rotações, quanto maior os seus valores, maior a influência nos ângulos de precessão e de nutação, causando o efeito de escorregamento. Verificou-se, ainda, o valor do ângulo de nutação no qual a velocidade normal ao contato é nula, isto é, validou-se o efeito de outer raceway control. Assim, o modelo apresentou-se consistente com a aproximação para as velocidades e acelerações presentes no elemento rolante, fatores estes fortemente relacionados à condição de lubrificação de mancais de esferas / Abstract: Ball bearings are simple machine elements but largely used in several applications involving high velocities, high temperatures and different loads. The load model is fundamental for the ball bearing's dynamic and for this reason it is necessary to define with accuracy the mechanisms performance using analytical methods. The objective of this thesis is to analyze the ball bearings using, firstly, the most relevant books and papers from several authors as reference and then initiate the modeling and simulation to analyze the influences from the gyroscopic moment and from the velocities created due to the bearing's components and also to the load. Based on a basic bearing, a numeric simulation's test methodology was applied modifying the main critical factors from the bearing and considering the kinematical, dynamical and statical behaviors. The conclusion is that the rotation and the contact angle have influence at the friction forces that resist to the gyroscopic moment and to the velocities that are created at the contact zones between balls and inner and outer raceways. Under high rotations, as higher its value is, higher is the influence at the precession and nutation angles, causing sliding. It was also verified the nutation angle in which the normal velocity at contact is zero, validating the outer raceway control. The model presented itself very consistent with the approximation for the velocities and accelerations presented at rolling element, factors that are highly related to the lubrication condition from the ball bearings / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica

Orientador: Kátia Lucchesi Cavalca Dedini / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-22T11:25:08Z (GMT). No. of bitstreams: 1 Radaelli_GustavoZarpelon_M.pdf: 6785468 bytes, checksum: 07019edf34b966c552330056d686bd33 (MD5) Previous issue date: 2013 / Resumo: Os mancais possuem um papel expressivo dentre os componentes de um sistema rotativo, tendo o suporte de um elemento rotativo como sua principal função. Por trabalharem na interface entre elementos fixos e rotativos, os mancais constituem a origem de grande parcela das falhas ocorrentes em um sistema. Dentre estes, os mancais de rolamento de contato angular estão entre os mais utilizados, principalmente pela indústria automobilística. Apesar da ampla gama de aplicações, esses mancais usualmente estão sujeitos a falhas por fadiga de superfície, o que torna imprescindível um estudo aprofundado dos esforços e das velocidades aplicados às esferas e, consequentemente, às pistas interna e externa. A descrição dos esforços e das velocidades nas esferas é um desafio considerável, uma vez que as esferas estão sujeitas a uma lubrificação elastohidrodinâmica, que por sua vez, depende integralmente dos esforços e das velocidades das esferas para ser modelada, gerando assim um processo iterativo. O principal objetivo deste trabalho é analisar o rolamento de esferas de contato angular, com embasamento teórico na literatura clássica para, em seguida, iniciar o equacionamento do equilíbrio de forças nas esferas e no mancal, o qual por sua vez, resulta na força de contato associada à condição de lubrificação. Para tanto, um programa computacional para simulação numérica das análises cinemáticas e dinâmicas foi desenvolvido e seus resultados comparados com a literatura. Após realizar a validação inicial do modelo com a literatura, uma solução mais completa é proposta para reproduzir de uma forma mais detalhada o que se encontra em aplicações práticas. Os resultados encontrados pelas diversas simulações foram condizentes com os resultados encontrados na literatura clássica, atestando que o programa computacional desenvolvido é consistente / Abstract: The bearings are of great importance and its major function is to support a rotating element. Due to the mandatory role of these components in the interface between fixed and rotating elements, the bearings are the source of a great percentage of the possible faults on a system. The rolling bearings of angular contact are one of the most utilized, mainly by the automotive industry. In spite of the great applications field, these bearings are usually subject to damage by superficial fatigue, which makes of great significance the detailed study of the efforts and the velocities on the spheres and, consequently, on the external and internal railways. The description of the efforts and velocities acting on the spheres is a considerable challenge, once the spheres are subject to an elastohidrodynamic lubrication that fully depends on the efforts and velocities of the spheres, generating an iterative process. The main objective of this work is to analyze the rolling bearings of angular contact, under theoretical bases, in order to accomplish the forces balance for the balls and for the bearing, which in turn results in the contact forces associated to the lubrication condition. The analysis requires the development of a computational program to numerically simulate the kinematic and dynamic conditions and, then, some of the results can be compared with the literature. After the initial validation of the model with the literature, a more complete solution is proposed to make it closer to practical applications. Results obtained by several simulations are compatible with those found in theoretical bases, attesting that the computational program developed is consistent / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica

<p>Predmet ove doktorske disertacije je analiza dinamičkog ponašanja<br />kotrljajnih ležaja primenom veštačkih neuronskih mreža. Na bazi<br />rezultata eksperimentalnog ispitivanja obučene su veštačke<br />neuronske mreže koje su sposobne da predvide amplitude brzine<br />vibracija ležaja. Vibracije koje ležaj generiše zavise od niza<br />uticajnih parametara koji se mogu podeliti na konstrukcione,<br />tehnološke i eksploatacione. Modeli dobijeni primenom veštačkih<br />neuronskih mreža određuju zavisnosti između uticajnih parametara i<br />amplituda brzine vibracija koje ležaj generiše. Validacija<br />neuronskih modela izvršena je na osnovu eksperimentalnih rezultata.<br />Analiziran je uticaj svakog parametra ležaja na amplitude brzine<br />vibracija u karakterističnim područjima frekvencija. U radu su<br />prikazani i rezultati međusobnog uticaja više parametara. Modelima<br />su dobijene preporučene vrednosti uticajnih parametara ležaja. Pri<br />analizi tehnoloških parametara uvedeni su: parametar ekvivalentne<br />površinske hrapavosti, parametar ekvivalentne valovitosti i<br />parametar ekvivalentnog odstupanja od kružnosti staza kotrljanja.<br />Novouvedeni parametri omogućavaju bolje razumevanje uticaja na<br />dinamičko ponašanje. U radu je pokazano da su neuronski modeli<br />sposobni da na osnovu parametara ležaja predvide klasu kvaliteta<br />ležaja.</p> / <p>The subject of this doctoral dissertation is the analysis of the dynamic<br />behavior of ball bearings using artificial neural networks. Based on the<br />results of the experimental test, artificial neural networks were trained to be<br />able to predict the amplitudes of the bearing vibration velocity. The vibrations<br />generated by the bearing depend on a number of influential parameters that<br />can be divided into construction, technological and exploitation. Models<br />obtained by applying artificial neural networks determined the dependences<br />between the influencing parameters and the amplitudes of the vibration<br />velocity generated by the bearing. Validation of neural models was<br />performed based on experimental results. The influence of each parameter<br />on the vibration velocity amplitudes in the characteristic frequency ranges<br />was analyzed. The paper also presents the results of the mutual influence of<br />several parameters. The models obtained the recommended values of the<br />influential bearing parameters. In the analysis of technological parameters,<br />the following parameters were introduced: the parameter of equivalent<br />surface roughness, the parameter of equivalent waviness and the parameter<br />of equivalent roundness error of raceways. The newly introduced parameters<br />provide a better understanding of the impact on dynamic behavior. The paper<br />shows that neural models are able to predict the bearing quality class based<br />on bearing parameters.</p>

The main purpose of this thesis work was to halve the cycle time of a grinding process of the groove of carbonitrided ball bearings rings. The study was conducted as a Six Sigma project at SKF in Bari, Italy. Reaching the goal was important for the company as it meant avoiding the purchase of another grinding machine. The groove grinding process on carbonitrided rings features double the cycle time than the same process on through hardened rings and halving it was required to fulfill the volumes demanded. The Six Sigma methodology was applied through the implementation of DMAIC. The analysis of the problems and identification of areas for improvement were carried out deploying different tools such as an Ishikawa diagram, Hypothesis Testing and Statistical Process Control. The outcome of this was the need to optimize the carbonitriding process minimizing the depth of the layer without enlarged carbides in order to render the design of the part easier to machine and subsequently find the process parameters for the groove grinding yielding a cycle time of six seconds. Many trials were conducted with the supplier of carbonitriding, until the carbon and ammonia potentials were set at levels resulting in a depth of the layer allowing the change of the design. An optimizing DOE was instead performed for the grinding process which highlighted the parameters settings yielding the target cycle time. Finally actions and controls to perform in order to maintain the gains were defined.

Thesis (M.App.Sc.) - Carleton University, 2007. / Includes bibliographical references (p. 123-128). Also available in electronic format on the Internet.

Orientador: Robson Pederiva / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-04T03:26:01Z (GMT). No. of bitstreams: 1 Bezerra_RobertodeAraujo_D.pdf: 3842898 bytes, checksum: 23a6bdd65c87be47fe4cfa856795bab0 (MD5) Previous issue date: 2004 / Resumo: Neste trabalho, é feito um estudo comparativo entre diversas técnicas de detecção de falhas em rolamentos por análise de vibração. Inicialmente, as técnicas foram aplicadas a modelos matemáticos de falhas nas pistas interna, externa e nas esferas dos rolamentos; sendo, em seguida, feito um estudo comparativo entre as técnicas. As técnicas foram aplicadas também a rolamentos com falhas induzidas nas pistas e esfera com diferentes tamanhos de falhas e submetidos a diferentes velocidades, para uma melhor compreensão das técnicas. Finalmente, as técnicas foram usadas para o monitoramento da evolução das falhas em um conjunto de doze rolamentos que foram submetidos a condições próximas as de trabalho, o que possibilitou um estudo mais detalhado do processo de evolução dessas falhas. Os resultados obtidos mostraram que, de todas as técnicas utilizadas, o envelope com filtro adaptativo foi a mais eficiente, sendo capaz de detectar pequenos amassamentos e o surgimento de falhas na gaiola. O estudo em condições próximas a realidade possibilitou uma melhor compreensão do processo de evolução das falhas em rolamentos / Abstract: In this thesis, it is made a comparative study among several vibration analysis techniques of fault detection. Initially, the techniques were applied to inner and outer race and rolling element mathematical models of faults, and so, it was possible to compare the techniques. It was used the same techniques on the races and rolling elements with different size of induced faults, submitting to different speeds. With those studies it was possible to understand how to use the technique in a better way. Finally, we monitored a group of twelve bearings to analyse the evolution of faults, close to real conditions. The results showed that the most efficient techniques is the envelope with adaptive filter, it detects small dentings and the begging of cage failure. It was possible to get a better understanding of the failure evolution process in bearings, studying it in close conditions to the reality / Doutorado / Mecanica dos Sólidos e Projeto Mecanico / Doutor em Engenharia Mecânica

Avec l’apparition de moteur électrique dans le secteur automobile, les réducteurs mécaniques fonctionnent à des vitesses de rotation de plus en plus élevées. Pour ce type de réducteur, les pertes de puissance au niveau des paliers à roulements peuvent être prédominantes pour des vitesses de rotation élevées. Ces pertes sont fortement dépendantes du comportement thermique du palier à roulement. D’où l’intérêt de développer des outils numériques permettant d’estimer les puissances générées au sein d’un palier à roulement. Cette estimation permettra en phase de pré-étude de développer un dispositif de refroidissement adapté afin d’éviter tout risque de dégradation du palier à roulement. Cette thèse présente une nouvelle approche permettant d’étudier le comportement thermomécanique de palier à roulement. Cette approche intermédiaire requiert un minimum de paramètres d’entrée (géométrie externe du palier à roulement et condition de fonctionnement). Elle utilise la méthode dite « des réseaux thermiques » pour obtenir une interconnexion entre les pertes de puissance et le comportement thermique du palier à roulement. Enfin cette approche permet de calculer la puissance dissipée au sein d’un roulement et les températures des bagues et du lubrifiant principalement pour une application hautes vitesses. Cette approche est développée pour des roulements à billes à gorge profonde et contact oblique. Des valeurs expérimentales sont nécessaires pour valider cette nouvelle approche. C’est pourquoi, un nouveau banc d’essai modulaire dédié à l’étude du comportement thermomécanique de palier à roulement a été développé. Sur ce nouveau moyen d’essai, une grande variété de paliers à roulements peut être testée pour différentes conditions de fonctionnement. Pour les premiers essais, un roulement à billes à gorge profonde lubrifié par injection est testé pour un fonctionnement hautes vitesses (produit (n×D_m) supérieur au million). / Rolling Element Bearing (REB) is an essential component in mechanical transmission to reduce friction between rotating parts. Now, with the development of electrical motor in mechanical industry, REBs may work at very high rotation speed. It leads to an increase of REB power losses and temperatures. Theses power losses are strongly coupled with the REB thermal behaviour. The oil temperature has a significant impact on the kinematic viscosity which in turn affects the REB power losses. Based on thermal network approach, an intermediate model is developed in this study. This new model allows obtaining lumped information (temperature of rings) with a minimum of input data (REB external geometry and operating condition only) and by using global power loss models. This intermediate model is developed for angular contact ball bearing and deep groove ball bearing under oil jet lubrication for high speed application. Experimental data are required to validate this new approach. That why, a modular test rig is designed to obtain information on the REB thermomechanical behaviour. The new test rig developed in this study is dedicated to a wide range of REB dimensions and for different operating conditions. For the first test, a deep groove ball bearing under oil jet lubrication is studied for high speed application ((N.dm) product is higher than one million.)

The choice of the topic addressed in this thesis aims to improve the service and maintenance on ceramic ball bearings in a specific test dynamometer and through an engineering approach develop tools for condition monitoring. The company connected to this thesis, AVL, is the world's largest privately owned company for development, simulation and testing technology of powertrains for passenger cars, trucks and large engines. Engine testing is a critical part of the business at AVL Sweden and unexpected bearing failure can result in long repair times and great economic losses due to loss of the testing time. In short terms, the methodological approach followed the following steps; first a thorough information retrieval regarding bearings and analysis was conducted. The search was deepened around areas such as hybrid ball bearings, bearing failure mechanisms, bearing defect frequencies, signal analysis and condition monitoring. After this a table for bearing damage detection was developed and a “step by step” guidance for condition monitoring. The tools where afterwards verified by simple testing to detect complications within the chosen system. The existing condition monitoring system that is used today revealed weaknesses as it lacked the feature of taking preventive measures. The system that is based on temperature measurements isn’t satisfactory enough, especially when it’s missing visual clarity. Service and maintenance according to specifications from the manufacturer should be scheduled to ensure operational and guarantees. Currently mounted accelerometers on the housing of the Dynas3 engine should be connected for collecting data and the total sum of energy should be calculated for simple monitoring of historical progression. This should be done by following the guidance in order to ensure proper data acquisition. The best way to implement condition monitoring showed to be by performing multi-parameter monitoring. The design of the condition monitoring system is highly connected to what to monitor and at what stage. One main consideration to keep in mind is that it’s very rare that manufacturing defects are the reason for bearing failure. Instead it derives from improper storage, transport, handling or dimensional errors and even in some cases by improperly implemented force analysis prior to bearing selection. / Huvudämnet som behandlas i detta examensarbete syftar till att förbättra service och underhåll på keramiska kullager i en viss testdynamometer och genom ett ingenjörsmässigt tillvägagångsätt utveckla verktyg för tillståndsövervakning. Företaget som är ansluten till detta examensarbete är AVL som är världens största privatägda företag för utveckling, simulering och testteknik för drivlinor för personbilar, lastbilar och stora motorer. Motorprovning är en viktig del av verksamheten vid AVL Sverige, och ett oväntat lagerhaveri kan leda till långa reparationstider och stora ekonomiska förluster på grund av utebliven test tid. I korta termer följde den metod som använts följande steg, först genomfördes en grundlig informationssökning om lager och tillhörande analyser. Efter det fördjupades sökande kring områden som hybrida kullager, lagerskademekanismer, frekvenser kopplade till lagerskador, signalanalys och tillståndsövervakning. Efter detta framställdes en tabell för detektering av lagerskador, samt en ”steg för steg” guide för tillståndsövervakning. Verktygen för tillståndsövervakning kontrolleras efteråt, genom att enkla tester genomfördes för att upptäcka komplikationer inom det valda systemet. Det övervakningssystem som används idag avslöjade svagheter genom att sakna funktionen att vidta förebyggande åtgärder. System som är baserat på temperaturmätningar är inte tillräckligt tillfredsställande, speciellt när det saknar en visuell tydlighet. Den service och underhåll som enligt tillverkarens föreskrifter påvisas bör planeras för att säkerställa drift och garantier. Nuvarande monterade accelerometrar fästa vid motorhöljet bör anslutas för att insamla data, och den totala summan av energin bör beräknas för en enkel övervakning av det historiska utvecklingsförloppet. Detta bör göras genom att följa de riktlinjer som framställts för att säkerställa korrekt datainsamling. Det bäst passande sättet att genomföra tillståndsövervakning på i detta fall visade sig vara att utföra multiparameterövervakning. Framställningen av tillståndsövervakningssystemet är starkt förknippat med vad som skall övervakas och i vilket skede. En huvudsaklig bidragande faktor att komma ihåg är att det är mycket ovanligt att fabrikationsfel är orsaken till lagerhaveri. Istället härstammar haveriet från felaktig förvaring, transportering, hantering eller dimensioneringsfel och i vissa fall av felaktigt genomförd kraftanalys inför lagerval.

<p>The objectives of this investigation were to experimentally and numerically assess the performance of a ball bearing supported turbocharger (TC). Turbochargers are mechanical devices used to improve the efficiency of modern engines. Using ball bearings improves the TC efficiency, and represents one of many evolving high-speed applications for ball bearings.</p> <p>The experimental objectives of this investigation were to design and develop a turbocharger test rig (TTR) to measure the shaft whirl of the rotating assembly and the axial and frictional loads experienced by the bearing cartridge. The TTR contains a ball bearing TC which was instrumented and operated under a variety of test conditions including rotational speeds up to 55,000 rpm. In order to measure the axial loads on the compressor and turbine sides, customized sensors were designed, fabricated and integrated into the TC housing. The anti-rotation (AR) pin, which normally prevents the bearing cartridge from rotating, was replaced with a custom-made sensor to measure frictional losses in the bearing cartridge.  These sensors were designed to minimally affect the operation of the TC. Proximity probes were initially installed on the compressor side and later on the turbine side to monitor shaft whirl using targets attached to the ends of the impellers. An assembly to record axial shaft motion with a proximity probe was also developed. Axial load and motion results indicated that the compressor side bears most of the axial load. As the backpressure or the speed of the TC increased the axial load also increased. Frictional measurements from the AR pin sensor demonstrated low power losses in the ball bearing cartridge. For certain shaft speed ranges, the data from the sensors illustrated periodic trends in response to subsynchronous whirl of the shaft.</p> <p>The numerical modeling objectives of this investigation were to characterize the dynamics of the ball bearing supported TC. In this TC, the compressor, turbine and shaft are supported by a bearing cartridge composed of back-to-back angular contact ball bearings. The cartridge is supported by squeeze film dampers (SFDs) and is prevented from rotation by the AR pin. To achieve the objectives, first an equivalent bearing model was developed to investigate the bearing dynamics and whirl of the TC rotating assembly. The TC bearing cartridge was modeled with a single deep groove ball bearing (DGBB) using the discrete element method. The SFD which supports the bearing was modeled with a bilinear spring and damper. A DGBB was used because it can support axial load in both directions. This model was then extended to include a flexible shaft represented by tetrahedral finite elements and supported by an ACBB cartridge. After this model was used to reproduce the whirl from the test rig, the bearing internal geometry and SFD properties were adjusted to determine their effect on shaft whirl. Wear and damage criteria were also developed to evaluate the simulation results. The best simulation result was obtained with a small clearance in the bearing and with a stiffer SFD. The clearance was necessary as the shaft and bearing deform at high speeds, preloading the bearing.</p> <p>The best simulation result was found to have reduced sliding and limited variation in contact force, which should lead to reduced friction and improved overall life. This study demonstrates the importance of taking the bearing system into account while designing a TC or other high speed mechanical system, as the bearing and SFD properties can have a significant impact on the system performance.</p>

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