Pub Date : 2023-01-10DOI: 10.3389/fmtec.2022.1029860
Xiaolin Liu, T. Long, Xinming Li, F. Guo
The roller end/rib contact of tapered roller bearings significantly affects lubricating condition and power loss. To improve the lubrication performance of the inner ring rib and the large end of the roller in tapered roller bearings used in railway coaches, based on the structural analysis of the inner rib and the large end of the roller and considering spin–slide effects between the rib and the large end of the roller, a thermal elastohydrodynamic lubrication model with a Carreau rheological model was established in a tapered roller bearing. Two kinds of rib structures were provided: the tapered rib and spherical rib. Under different conditions, variations in the friction coefficient versus the ratio of curvature radius of the large end of the roller to that of the rib were compared, and the film thickness and film temperature varied with the rotational speed and the effect of load was compared between the two rib structures. Results showed that spinning motion has little effect on the lubrication at the contact point between the inner ring rib and the large end of the tapered roller. There exists an optimal ratio of the curvature radius between the large end of the roller and the spherical or tapered rib; moreover, the friction coefficient corresponding to this optimal ratio value is the smallest. With the increase in the inner ring speed, both film thickness and temperature increase for the two rib structures. Different from the spherical rib, the difference between the minimum and the central film thickness is almost unchangeable, and the tapered rib shows a slight temperature rise. As the load increases, the difference between the minimum and the central film thickness becomes larger, and the temperature in the contact zone gradually increases for the two ribs. Different from the tapered rib, the lower frictional coefficient and lower minimum film thickness are generated for the spherical rib because of higher film temperature.
{"title":"Thermal EHL analysis of the inner ring rib and roller end in tapered roller bearings with the Carreau model","authors":"Xiaolin Liu, T. Long, Xinming Li, F. Guo","doi":"10.3389/fmtec.2022.1029860","DOIUrl":"https://doi.org/10.3389/fmtec.2022.1029860","url":null,"abstract":"The roller end/rib contact of tapered roller bearings significantly affects lubricating condition and power loss. To improve the lubrication performance of the inner ring rib and the large end of the roller in tapered roller bearings used in railway coaches, based on the structural analysis of the inner rib and the large end of the roller and considering spin–slide effects between the rib and the large end of the roller, a thermal elastohydrodynamic lubrication model with a Carreau rheological model was established in a tapered roller bearing. Two kinds of rib structures were provided: the tapered rib and spherical rib. Under different conditions, variations in the friction coefficient versus the ratio of curvature radius of the large end of the roller to that of the rib were compared, and the film thickness and film temperature varied with the rotational speed and the effect of load was compared between the two rib structures. Results showed that spinning motion has little effect on the lubrication at the contact point between the inner ring rib and the large end of the tapered roller. There exists an optimal ratio of the curvature radius between the large end of the roller and the spherical or tapered rib; moreover, the friction coefficient corresponding to this optimal ratio value is the smallest. With the increase in the inner ring speed, both film thickness and temperature increase for the two rib structures. Different from the spherical rib, the difference between the minimum and the central film thickness is almost unchangeable, and the tapered rib shows a slight temperature rise. As the load increases, the difference between the minimum and the central film thickness becomes larger, and the temperature in the contact zone gradually increases for the two ribs. Different from the tapered rib, the lower frictional coefficient and lower minimum film thickness are generated for the spherical rib because of higher film temperature.","PeriodicalId":330401,"journal":{"name":"Frontiers in Manufacturing Technology","volume":"3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133431243","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-12-19DOI: 10.3389/fmtec.2022.1021029
V. Rudel, Pascal Kienast, G. Vinogradov, P. Ganser, T. Bergs
In this publication, the application of an implemented Digital Twin (DT) framework is presented by orchestration of CAM-integrated and containerized technology models carrying out FEM-coupled simulations for the finishing process of a simplified blade integrated disk (blisk) demonstrator. As a case study, the continuous acquisition, processing and usage of virtual process planning and simulation data as well as real machine and sensor data along the value chain is presented. The use case demonstrates the successful application of the underlying DT framework implementation for the prediction of the continuously changing dynamic behavior of the workpiece and according stable spindle speeds in the process planning phase as well as their validation in the actual manufacturing phase.
{"title":"Cloud-based process design in a digital twin framework with integrated and coupled technology models for blisk milling","authors":"V. Rudel, Pascal Kienast, G. Vinogradov, P. Ganser, T. Bergs","doi":"10.3389/fmtec.2022.1021029","DOIUrl":"https://doi.org/10.3389/fmtec.2022.1021029","url":null,"abstract":"In this publication, the application of an implemented Digital Twin (DT) framework is presented by orchestration of CAM-integrated and containerized technology models carrying out FEM-coupled simulations for the finishing process of a simplified blade integrated disk (blisk) demonstrator. As a case study, the continuous acquisition, processing and usage of virtual process planning and simulation data as well as real machine and sensor data along the value chain is presented. The use case demonstrates the successful application of the underlying DT framework implementation for the prediction of the continuously changing dynamic behavior of the workpiece and according stable spindle speeds in the process planning phase as well as their validation in the actual manufacturing phase.","PeriodicalId":330401,"journal":{"name":"Frontiers in Manufacturing Technology","volume":"69 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-12-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125045133","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-12-12DOI: 10.3389/fmtec.2022.947474
João Sousa, A. Nazarenko, C. Grunewald, F. Psarommatis, F. Fraile, O. Meyer, J. Sarraipa
Zero-Defect Manufacturing (ZDM) is the next evolutionary step in quality management for manufacturing that makes use of Industry 4.0 technologies to support quality in manufacturing. These technologies help reduce the cost of inspection, allowing for more inspection points throughout the manufacturing process, reducing the size of quality feedback loops, and guaranteeing that no defective product is delivered to the customer. There are several ZDM-related initiatives, but still no harmonized terminology. This article describes the methodological approach to provide a common agreement on the ZDM concept and its associated terminology taking place within an open CEN-CENELEC Workshop. The methodology has the support of ISO standards for terminology work such as ISO 704, ISO 860, and ISO 10241–1/2. This work shows that the terminology for ZDM has a significant overlap with the terminology of quality management, metrology, dependability, statistics, non-destructive inspection, and condition monitoring. The proposed new terms and definitions can be used to further extend ISO’s and IEC’s already available terminologies and support present and future researchers in the field to conduct their research using a common vocabulary.
{"title":"Zero-defect manufacturing terminology standardization: Definition, improvement, and harmonization","authors":"João Sousa, A. Nazarenko, C. Grunewald, F. Psarommatis, F. Fraile, O. Meyer, J. Sarraipa","doi":"10.3389/fmtec.2022.947474","DOIUrl":"https://doi.org/10.3389/fmtec.2022.947474","url":null,"abstract":"Zero-Defect Manufacturing (ZDM) is the next evolutionary step in quality management for manufacturing that makes use of Industry 4.0 technologies to support quality in manufacturing. These technologies help reduce the cost of inspection, allowing for more inspection points throughout the manufacturing process, reducing the size of quality feedback loops, and guaranteeing that no defective product is delivered to the customer. There are several ZDM-related initiatives, but still no harmonized terminology. This article describes the methodological approach to provide a common agreement on the ZDM concept and its associated terminology taking place within an open CEN-CENELEC Workshop. The methodology has the support of ISO standards for terminology work such as ISO 704, ISO 860, and ISO 10241–1/2. This work shows that the terminology for ZDM has a significant overlap with the terminology of quality management, metrology, dependability, statistics, non-destructive inspection, and condition monitoring. The proposed new terms and definitions can be used to further extend ISO’s and IEC’s already available terminologies and support present and future researchers in the field to conduct their research using a common vocabulary.","PeriodicalId":330401,"journal":{"name":"Frontiers in Manufacturing Technology","volume":"57 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-12-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128591812","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-10-31DOI: 10.3389/fmtec.2022.951643
Shohin Aheleroff, Huiyue Huang, Xun Xu, R. Zhong
There is a recognized need for mass personalization for sustainability at scale. Mass personalization is becoming a leading research trend in the latest Industrial Revolution, whereas substantial research has been undertaken on the role of Industry 4.0 enabling technologies. The world is moving beyond mass customization, while manufacturing has led to mass personalization ahead of other industries. However, most studies have not treated human capabilities, machines, and technologies as sustainable collaboration. This research investigates mass personalization as a common goal under the latest Industrial revolutions. Also, it proposes a Reference Architecture Model for achieving mass personalization that contributes to understanding how Industry 5.0 enhances Industry 4.0 for higher resilience and sustainability through a human-centric approach. The study implies that Human Capital 5.0 leads collaboration with machines and technologies, bringing more value-added and sustainable products.
{"title":"Toward sustainability and resilience with Industry 4.0 and Industry 5.0","authors":"Shohin Aheleroff, Huiyue Huang, Xun Xu, R. Zhong","doi":"10.3389/fmtec.2022.951643","DOIUrl":"https://doi.org/10.3389/fmtec.2022.951643","url":null,"abstract":"There is a recognized need for mass personalization for sustainability at scale. Mass personalization is becoming a leading research trend in the latest Industrial Revolution, whereas substantial research has been undertaken on the role of Industry 4.0 enabling technologies. The world is moving beyond mass customization, while manufacturing has led to mass personalization ahead of other industries. However, most studies have not treated human capabilities, machines, and technologies as sustainable collaboration. This research investigates mass personalization as a common goal under the latest Industrial revolutions. Also, it proposes a Reference Architecture Model for achieving mass personalization that contributes to understanding how Industry 5.0 enhances Industry 4.0 for higher resilience and sustainability through a human-centric approach. The study implies that Human Capital 5.0 leads collaboration with machines and technologies, bringing more value-added and sustainable products.","PeriodicalId":330401,"journal":{"name":"Frontiers in Manufacturing Technology","volume":"41 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126954738","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-10-28DOI: 10.3389/fmtec.2022.972712
Konstantinos Papageorgiou, T. Theodosiou, A. Rapti, E. Papageorgiou, N. Dimitriou, D. Tzovaras, G. Margetis
The identification of defect causes plays a key role in smart manufacturing as it can reduce production risks, minimize the effects of unexpected downtimes, and optimize the production process. This paper implements a literature review protocol and reports the latest advances in Root Cause Analysis (RCA) toward Zero-Defect Manufacturing (ZDM). The most recent works are reported to demonstrate the use of machine learning methodologies for root cause analysis in the manufacturing domain. The popularity of these technologies is then summarized and presented in the form of visualizing graphs. This enables us to identify the most popular and prominent methods used in modern industry. Although artificial intelligence gains more and more attraction in smart manufacturing, machine learning methods for root cause analysis seem to be under-explored. The literature survey revealed that only limited reviews are available in the field of RCA towards zero-defect manufacturing using AI and machine learning; thus, it attempts to fill this gap. This work also presents a set of open challenges to determine future developments.
{"title":"A systematic review on machine learning methods for root cause analysis towards zero-defect manufacturing","authors":"Konstantinos Papageorgiou, T. Theodosiou, A. Rapti, E. Papageorgiou, N. Dimitriou, D. Tzovaras, G. Margetis","doi":"10.3389/fmtec.2022.972712","DOIUrl":"https://doi.org/10.3389/fmtec.2022.972712","url":null,"abstract":"The identification of defect causes plays a key role in smart manufacturing as it can reduce production risks, minimize the effects of unexpected downtimes, and optimize the production process. This paper implements a literature review protocol and reports the latest advances in Root Cause Analysis (RCA) toward Zero-Defect Manufacturing (ZDM). The most recent works are reported to demonstrate the use of machine learning methodologies for root cause analysis in the manufacturing domain. The popularity of these technologies is then summarized and presented in the form of visualizing graphs. This enables us to identify the most popular and prominent methods used in modern industry. Although artificial intelligence gains more and more attraction in smart manufacturing, machine learning methods for root cause analysis seem to be under-explored. The literature survey revealed that only limited reviews are available in the field of RCA towards zero-defect manufacturing using AI and machine learning; thus, it attempts to fill this gap. This work also presents a set of open challenges to determine future developments.","PeriodicalId":330401,"journal":{"name":"Frontiers in Manufacturing Technology","volume":"32 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124869058","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-10-20DOI: 10.3389/fmtec.2022.1012343
Joseph J. Kelley, G. Poll, F. Pape
The application of microdimple-textured surfaces for rolling bearings is not very common but can be beneficial for various usage scenarios. In contrast to the applications for plain bearings or cylinder running surfaces, however, surface patterns for rolling bearings only offer advantages under certain conditions. For example, for use with start-stop cycles, in mixed lubrication conditions, or under sliding conditions in a bearing as well as on a roller—bearing flange contact, friction can be reduced with the targeted use of microtextures. The geometry of the microtextures must be chosen so that individual dimples fit in the contact area between the ball or roll and the bearing surface in order to act as a reservoir for the lubricant. First applications for microtextured angular contact ball bearings under oscillating movement conditions proved friction reducing effects under reciprocating motion. In this case the microtextures served as lubricant reservoirs. The idea is transferred to the sliding contact for tapered roller bearings; it is investigated whether the measured reductions in friction are due to the microtextures serving as lubricant reservoirs or whether there is even a positive hydrodynamic effect caused by the microtextures. By means of a calculation approach as well as some exemplary test rig measurements, the behavior for microtextured tapered roller bearings is investigated.
{"title":"Investigation of the possible applications for microtextured rolling bearings","authors":"Joseph J. Kelley, G. Poll, F. Pape","doi":"10.3389/fmtec.2022.1012343","DOIUrl":"https://doi.org/10.3389/fmtec.2022.1012343","url":null,"abstract":"The application of microdimple-textured surfaces for rolling bearings is not very common but can be beneficial for various usage scenarios. In contrast to the applications for plain bearings or cylinder running surfaces, however, surface patterns for rolling bearings only offer advantages under certain conditions. For example, for use with start-stop cycles, in mixed lubrication conditions, or under sliding conditions in a bearing as well as on a roller—bearing flange contact, friction can be reduced with the targeted use of microtextures. The geometry of the microtextures must be chosen so that individual dimples fit in the contact area between the ball or roll and the bearing surface in order to act as a reservoir for the lubricant. First applications for microtextured angular contact ball bearings under oscillating movement conditions proved friction reducing effects under reciprocating motion. In this case the microtextures served as lubricant reservoirs. The idea is transferred to the sliding contact for tapered roller bearings; it is investigated whether the measured reductions in friction are due to the microtextures serving as lubricant reservoirs or whether there is even a positive hydrodynamic effect caused by the microtextures. By means of a calculation approach as well as some exemplary test rig measurements, the behavior for microtextured tapered roller bearings is investigated.","PeriodicalId":330401,"journal":{"name":"Frontiers in Manufacturing Technology","volume":"247 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121482700","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-10-20DOI: 10.3389/fmtec.2022.971410
C. Schimpf, M. Goldstein
The complexity of design problems compels the collection of rich process data to understand designers. While some methods exist for capturing detailed process data (e.g., protocol studies), design research focused on design activities still faces challenges, including the scalability of these methods and technology transformations in industry that require new training. This work proposes the Large Data for Design Research (LaDDR) framework, which seeks to integrate big data properties into platforms dedicated to studying design practice and design learning to offer a new approach for capturing process data. This technological framework has three design principles for transforming design platforms: broad simulation scope, unobtrusive logging and support for creation and analysis actions. The case is made that LaDDR platforms will lead to three affordances for research and education: capturing design activities, context setting and operationalization, and research design scalability. Big data and design expertise are reviewed to show how this approach builds on past work. Next, the framework and affordances are presented. Three previously published studies are presented as cases to illustrate the ways in which a LaDDR platform’s affordances manifest. The discussion covers how LaDDR platforms can address the aforementioned challenges, including advancing human-technology collaboration and how this approach can be extended to other design platforms.
{"title":"Large data for design research: An educational technology framework for studying design activity using a big data approach","authors":"C. Schimpf, M. Goldstein","doi":"10.3389/fmtec.2022.971410","DOIUrl":"https://doi.org/10.3389/fmtec.2022.971410","url":null,"abstract":"The complexity of design problems compels the collection of rich process data to understand designers. While some methods exist for capturing detailed process data (e.g., protocol studies), design research focused on design activities still faces challenges, including the scalability of these methods and technology transformations in industry that require new training. This work proposes the Large Data for Design Research (LaDDR) framework, which seeks to integrate big data properties into platforms dedicated to studying design practice and design learning to offer a new approach for capturing process data. This technological framework has three design principles for transforming design platforms: broad simulation scope, unobtrusive logging and support for creation and analysis actions. The case is made that LaDDR platforms will lead to three affordances for research and education: capturing design activities, context setting and operationalization, and research design scalability. Big data and design expertise are reviewed to show how this approach builds on past work. Next, the framework and affordances are presented. Three previously published studies are presented as cases to illustrate the ways in which a LaDDR platform’s affordances manifest. The discussion covers how LaDDR platforms can address the aforementioned challenges, including advancing human-technology collaboration and how this approach can be extended to other design platforms.","PeriodicalId":330401,"journal":{"name":"Frontiers in Manufacturing Technology","volume":"138 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116394278","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-10-17DOI: 10.3389/fmtec.2022.1008805
Xuequan Zhou, Yuqi Liu, G. Zacharewicz, Hua Zhang, David Chen
With the evolution of product service systems, as well as the proposal and wide application of cloud computing and big services, more and more manufacturing enterprises are turning from being product oriented to service oriented. A difficult aspect is that with the growth of customer scale and the personalization of customer service needs, service providers cannot rely on their own resources to fulfill services. Moreover, meeting the needs of customers often requires a complete and complex service. Therefore, the service provider has to provide cross-enterprise collaborative services and coordinate the resources of all participants in the product service system to complete the services together. This research proposes a novel resource allocation method for product service systems that adopt the bilateral resource integration service mode and considers the service process life cycle. Based on the process mining techniques, this method extracts knowledge from the execution event log of the service process stored in the enterprise information system, constructs the resource allocation problem model, and gives the process mining-based resource allocation algorithm (PMRA). We use an air conditioner repair service as a case to verify the method proposed in this study. The contribution of this study is to propose a new method of resource allocation for cross-enterprise product−service processes based on process mining techniques, which takes into account empirical knowledge from historical data and can provide a new idea for service optimization of product service systems.
{"title":"A resource allocation method of the product−service process based on process mining","authors":"Xuequan Zhou, Yuqi Liu, G. Zacharewicz, Hua Zhang, David Chen","doi":"10.3389/fmtec.2022.1008805","DOIUrl":"https://doi.org/10.3389/fmtec.2022.1008805","url":null,"abstract":"With the evolution of product service systems, as well as the proposal and wide application of cloud computing and big services, more and more manufacturing enterprises are turning from being product oriented to service oriented. A difficult aspect is that with the growth of customer scale and the personalization of customer service needs, service providers cannot rely on their own resources to fulfill services. Moreover, meeting the needs of customers often requires a complete and complex service. Therefore, the service provider has to provide cross-enterprise collaborative services and coordinate the resources of all participants in the product service system to complete the services together. This research proposes a novel resource allocation method for product service systems that adopt the bilateral resource integration service mode and considers the service process life cycle. Based on the process mining techniques, this method extracts knowledge from the execution event log of the service process stored in the enterprise information system, constructs the resource allocation problem model, and gives the process mining-based resource allocation algorithm (PMRA). We use an air conditioner repair service as a case to verify the method proposed in this study. The contribution of this study is to propose a new method of resource allocation for cross-enterprise product−service processes based on process mining techniques, which takes into account empirical knowledge from historical data and can provide a new idea for service optimization of product service systems.","PeriodicalId":330401,"journal":{"name":"Frontiers in Manufacturing Technology","volume":"179 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115867989","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-10-07DOI: 10.3389/fmtec.2022.1010759
Jae-il Hwang, G. Poll
Today, the service life calculation of rolling bearings is standardized in ISO 281, based on the theory of Lundberg and Palmgren. In the standard calculation method, material properties such as fatigue limit stress were taken into account by introducing the fatigue limit stress proposed by Ioannides and Harris. This standard calculation method provides a reasonable range of fatigue life in good agreement with experimental results under ideal test conditions such as constant external load. However, complex operating conditions of bearings such as varying loads and oscillating motion are not considered. Therefore, there is a need for a new analytical calculation model that can predict the fatigue life of rolling bearings operating under these complex conditions. This makes it possible to advance the application of rolling bearings and optimize their use in machines such as wind turbines. In the proposed approach, the fatigue life is determined based on the Palmgren-Miner linear damage rule, evaluating the subsurface stresses below the rolling contact using the S-N curve according to the fatigue criterion proposed by Lundberg and Palmgren. All rolling contacts that occur in an internal stress cycle due to the internal dynamic behavior during rotating operations are evaluated individually and referred to as partial damage risks. The partial damage risks are accumulated linearly according to the Palmgren-Miner theory to obtain the load cycle to failure. At this time, the loaded volume is assessed along the depth from the contact area to the core of the bearing ring, which makes it possible to indicate the depth position of fatigue occurrence in terms of crack initiation. The material properties such as the fatigue limit stress and the probability of failure are taken from the S-N curve itself. To consider the residual stress, a simple link concept is suggested by using the ratio of the maximum contact pressure to the yield criteria. The proposed approach can be extended to calculate oscillating fatigue life regarding the number of rolling contacts at a given oscillation amplitude. In this study, it can be confirmed that the analytically determined fatigue lifetime according to ISO 281 is still close to the bearing life test result. In addition, it shows that the results obtained using the proposed approach agree well with the calculation results obtained using ISO 281.
{"title":"A new approach for the prediction of fatigue life in rolling bearings based on damage accumulation theory considering residual stresses","authors":"Jae-il Hwang, G. Poll","doi":"10.3389/fmtec.2022.1010759","DOIUrl":"https://doi.org/10.3389/fmtec.2022.1010759","url":null,"abstract":"Today, the service life calculation of rolling bearings is standardized in ISO 281, based on the theory of Lundberg and Palmgren. In the standard calculation method, material properties such as fatigue limit stress were taken into account by introducing the fatigue limit stress proposed by Ioannides and Harris. This standard calculation method provides a reasonable range of fatigue life in good agreement with experimental results under ideal test conditions such as constant external load. However, complex operating conditions of bearings such as varying loads and oscillating motion are not considered. Therefore, there is a need for a new analytical calculation model that can predict the fatigue life of rolling bearings operating under these complex conditions. This makes it possible to advance the application of rolling bearings and optimize their use in machines such as wind turbines. In the proposed approach, the fatigue life is determined based on the Palmgren-Miner linear damage rule, evaluating the subsurface stresses below the rolling contact using the S-N curve according to the fatigue criterion proposed by Lundberg and Palmgren. All rolling contacts that occur in an internal stress cycle due to the internal dynamic behavior during rotating operations are evaluated individually and referred to as partial damage risks. The partial damage risks are accumulated linearly according to the Palmgren-Miner theory to obtain the load cycle to failure. At this time, the loaded volume is assessed along the depth from the contact area to the core of the bearing ring, which makes it possible to indicate the depth position of fatigue occurrence in terms of crack initiation. The material properties such as the fatigue limit stress and the probability of failure are taken from the S-N curve itself. To consider the residual stress, a simple link concept is suggested by using the ratio of the maximum contact pressure to the yield criteria. The proposed approach can be extended to calculate oscillating fatigue life regarding the number of rolling contacts at a given oscillation amplitude. In this study, it can be confirmed that the analytically determined fatigue lifetime according to ISO 281 is still close to the bearing life test result. In addition, it shows that the results obtained using the proposed approach agree well with the calculation results obtained using ISO 281.","PeriodicalId":330401,"journal":{"name":"Frontiers in Manufacturing Technology","volume":"58 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131123558","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-09-23DOI: 10.3389/fmtec.2022.1008987
Amit Jain, Sandeep Kumar, Shubham Tayal
In today’s sustainability debate, industries are working to modernise their life cycle engineering strategies. Identifying a sustainable competitive edge in the era of Industry 4.0 is the most critical problem. Consequently, researchers and industry experts worldwide have optimised product life cycle by integrating machine learning, modern computing technologies, information management, and other multifaceted technologies, viz., semantic interoperability. Nevertheless, there are gaps between life cycle engineering and evolving Industry 4.0 technologies. Therefore, it is crucial to optimise the product life cycle via. digitalisation, innovation, resilience, and sustainability. This will allow for more value throughout the whole product’s life cycle design and resource planning to environmentally friendly production, unrestricted operational availability, and full recycling or reusability. In light of this, this Research Topic aims to assemble articles highlighting innovations in life cycle engineering motivated by Industry 4.0. Three research articles and one review article are among the papers on this Research Topic that have been published. A sound maintenance plan is crucial for optimising life cycle engineering. The research work by Alamri and Mo used the failure mode and consequences analysis to build novel preventive maintenance (PM) schedule for a complex system. Their methodology mainly relies on mean-time-to-failure (MTTF) information derived from Industry 4.0 system feedback data. If new MTTF data becomes available, the technique makes it simple to change the PM schedule. The case study findings show that over 90% system reliability has been reached while ensuring that related costs are kept to a minimum. The technical, environmental, and economic effects of maintenance choices throughout the product life cycle are considered in this approach. Information management has pushed digital manufacturing to discover more effective ways to link and share data throughout different system stages. One of the cornerstones of Industry 4.0 is the horizontal and vertical integration of intelligent and self-adaptive systems. To develop an intelligent manufacturing system, Pereira et al. tackled the problem of semantic interoperability. This study provided a conceptual OPEN ACCESS
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