Fracture Analysis and Working Stress Calculation of Bearing Cage Used in Charging Pump in a Nuclear Power Plant
Abstract
:1. Introduction
2. Investigative and Analysis Methods
2.1. Failure Investigation Process
- (1)
- Investigation of the bearing procurement channel and confirmation with SKF to ensure the authenticity of the bearing.
- (2)
- Collection of detailed information regarding the pump failure process, historical operational data, maintenance records, and experiences with similar equipment failures.
- (3)
- List and analysis of possible failure modes for the bearing failure, as depicted in Figure 2.
- (4)
- Designing protocols for metallurgical experimental studies based on the identified failure modes.
- (5)
- Perform analysis work on the fractured bearing cage sample and summarize and analyze all the obtained data.
- (6)
- Analyze the operating conditions of the bearing, establish boundary conditions, and utilize finite element calculation and analysis software to assess the forces acting on the bearing cage.
- (7)
- Explore corrective action plans aimed at preventing the recurrence of bearing failures.
2.2. Metallological Analysis Process
2.3. Calculation Condition of Working Stress of Bearing Cage
3. Results and Discussion
3.1. Fracture Morphologies Analysis of Bearing Cage
3.2. Chemical Composition Analysis of Bearing Cage
3.3. Observation of Metallographic Structure of Bearing Cage
3.4. Hardness Test of The Bearing Cage and Roller
3.5. Residual Stress Test at Stamping Position of Bearing Cage
3.6. Calculation Results of Working Stress of Bearing Cage
3.7. Discussion on Corrective Measures
4. Conclusions
- (1)
- The material of the bearing cage was carbon structural steel with the proper chemical composition, microstructure, and hardness.
- (2)
- The fracture of the bearing cage was located at the stamping depression position, which showed fatigue fracture mode.
- (3)
- The bearing cage had large residual stress at some stamping positions of up to 142 MPa. When the bearing was running, the working stress reached the maximum while the bearing roller entered and exited the working area. The direction of the residual stress was the same as that of the working stress, both of which were tensile stresses perpendicular to the fracture direction. The superposition of the two stresses exceeded the material fatigue limit.
- (4)
- The new structure could reduce the stress concentration of the steel cage, thus improving its reliability.
- (5)
- The nylon cage had the lowest stress concentration (without residual stress) and a good lubrication function, which further improved its reliability.
- (6)
- Both materials and structures should be considered simultaneously in the future design of bearing cages.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Load | Speed | Friction Coefficient | ||
---|---|---|---|---|
Between Roller and Inner and Outer Rings | Between Roller and Outer Ring Edge | Between Roller and Cage | ||
725 N | 4657 r/min | 0.02 | 0.05 | 0.1 |
Subject | C | Mn | Si | Cr | Ni | Cu | P | S | Fe | |
---|---|---|---|---|---|---|---|---|---|---|
Sample | 0.044 | 0.22 | <0.03 | <0.03 | <0.03 | <0.03 | 0.010 | <0.001 | Bal. | |
DIN EN 10111: 2008 | DD11 | ≤0.12 | ≤0.6 | - | - | - | - | ≤0.045 | ≤0.045 | Bal. |
DD12 | ≤0.1 | ≤0.45 | - | - | - | - | ≤0.035 | ≤0.035 | Bal. | |
DD13 | ≤0.08 | ≤0.4 | - | - | - | - | ≤0.030 | ≤0.030 | Bal. | |
DD14 | ≤0.08 | ≤0.35 | - | - | - | - | ≤0.025 | ≤0.025 | Bal. |
Sample | 1 | 2 | 3 | 4 | Average |
---|---|---|---|---|---|
Roller | 481 | 469 | 479 | 483 | 478 |
Cage | 160 | 168 | 164 | 164 | 164 |
Sample | 1 | 2 | 3 | 4 | Average |
---|---|---|---|---|---|
Cage | 53 | 7 | 142 | 60 | 66 |
No. | Load | Speed | Friction Coefficient | ||
---|---|---|---|---|---|
Between Roller and Inner and Outer Rings | Between Roller and Outer Ring Edge | Between Roller and Cage | |||
1 | 725 N | 4657 r/min | 0.02 | 0.05 | 0.1 |
2 | 0.05 | 0.08 | 0.12 |
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Chen, Q.; Jiang, S.; Duan, D. Fracture Analysis and Working Stress Calculation of Bearing Cage Used in Charging Pump in a Nuclear Power Plant. Metals 2023, 13, 1380. https://doi.org/10.3390/met13081380
Chen Q, Jiang S, Duan D. Fracture Analysis and Working Stress Calculation of Bearing Cage Used in Charging Pump in a Nuclear Power Plant. Metals. 2023; 13(8):1380. https://doi.org/10.3390/met13081380
Chicago/Turabian StyleChen, Qiang, Shengli Jiang, and Deli Duan. 2023. "Fracture Analysis and Working Stress Calculation of Bearing Cage Used in Charging Pump in a Nuclear Power Plant" Metals 13, no. 8: 1380. https://doi.org/10.3390/met13081380
APA StyleChen, Q., Jiang, S., & Duan, D. (2023). Fracture Analysis and Working Stress Calculation of Bearing Cage Used in Charging Pump in a Nuclear Power Plant. Metals, 13(8), 1380. https://doi.org/10.3390/met13081380