Search Results (86)

Optimising the friction coefficient helps reduce friction losses and improve the efficiency of mechanical systems. The purpose of this study is to experimentally investigate the impact of roughness orientation on the friction coefficient in elastohydrodynamic (EHD) contact. Tests were carried out on a twin-disc machine. Three pairs of discs of identical material (nitrided steel) and geometry were tested: a smooth pair (the root mean square surface roughness Sq = 0.07 µm), a pair with transverse roughness and another with longitudinal roughness. The two rough pairs have similar roughness amplitudes (Sq = 0.5 µm). A comparison of the friction generated by these different pairs was carried out to highlight the effect of the roughness orientation under different operating conditions (oil injection temperature from 60 to 80 °C, Hertzian pressure from 1.2 to 1.5 GPa and mean rolling speed from 5 to 30 m/s). Throughout all the tests conducted in this study, longitudinal roughness resulted in higher friction than transverse, with an increase of up to 30%. Moreover, longitudinal roughness is more sensitive to variations in operating conditions. Finally, in all tests, the asperities of longitudinal roughness were found to influence the friction behaviour, unlike transverse roughness. Full article

This study proposes an intelligent prediction framework integrating native sparse attention (NSA) with the Chen-Guan (CHG) algorithm to optimize tunnel boring machine (TBM) operations in heterogeneous geological environments. The framework resolves critical limitations of conventional experience-driven approaches that inadequately address the nonlinear coupling between the spatial heterogeneity of rock mass parameters and mechanical system responses. Three principal innovations are introduced: (1) a hardware-compatible sparse attention architecture achieving O(n) computational complexity while preserving high-fidelity geological feature extraction capabilities; (2) an adaptive kernel function optimization mechanism that reduces confidence interval width by 41.3% through synergistic integration of boundary likelihood-driven kernel selection with Chebyshev inequality-based posterior estimation; and (3) a physics-enhanced modelling methodology combining non-Hertzian contact mechanics with eddy field evolution equations. Validation experiments employing field data from the Pujiang Town Plot 125-2 Tunnel Project demonstrated superior performance metrics, including 92.4% ± 1.8% warning accuracy for fractured zones, ≤28 ms optimization response time, and ≤4.7% relative error in energy dissipation analysis. Comparative analysis revealed a 32.7% reduction in root mean square error (p < 0.01) and 4.8-fold inference speed acceleration relative to conventional methods, establishing a novel data–physics fusion paradigm for TBM control with substantial implications for intelligent tunnelling in complex geological formations. Full article

The transmission accuracy and meshing performance of the gearbox is determined by the internal helical gears pair. Thermal deformation of internal helical gears pair is derived from sliding friction between the contacting teeth surface, resulting in shock, vibration, and misalignments. The purpose of this paper is to compare the influence of a modified gear and an unmodified gear on the temperature field and transmission characteristics of a planetary gear system under the same working conditions. This study presents an innovative temperature field model for gear pairs utilizing Surf152 elements, integrating Hertzian contact theory, tribological principles, and finite element analysis. For the first time, we quantitatively demonstrate the enhancement of thermo-mechanical performance through topological modification in helical gears. Under light-load conditions (200 rpm), the modified gear configuration exhibits a 6.38% reduction in tooth surface temperature and a 46.5% decrease in thermal deformation compared to conventional designs. Experimental validation confirms these improvements, showing an average 62.35% reduction in transmission error. These findings establish a novel methodology for high-precision gear design while providing critical theoretical foundations for planetary gear systems, ultimately leading to significant improvements in both transmission accuracy and operational lifespan. Full article

Ultra-high-pressure hydrogen solenoid valves face a fundamental design challenge of operating across a wide pressure range from 2 MPa to 87.5 MPa. To address the conflicting requirements of effective sealing at low pressures and structural integrity at high pressures, this study proposes a novel concave contact geometry based on Hertzian contact theory. Finite element analysis examines the mechanical relationships between plunger curvature radius (R_ₚ), seat curvature radius (Rₛ), and eccentricity (e). Optimization utilizing Latin hypercube sampling and kriging metamodeling yields an optimal design (Rₚ = 5.73 mm, Rₛ = 4.68 mm, e = 0.95 mm) with an Rₚ/Rₛ ratio of 1.22. The optimized concave contact geometry achieves 23.7% higher contact pressure at 2.0 MPa and 42.7% lower maximum equivalent stress at 87.5 MPa compared to conventional rectangular geometry. Experimental validation confirms the concave contact geometry seals at 1.7 ± 0.2 MPa, below the AIS-195 standard requirement of 2.0 MPa and 69.6% lower than the rectangular design (5.6 ± 0.7 MPa). Structural analysis after 87.5 MPa high-pressure exposure reveals no measurable deformation in the concave design, while the rectangular design exhibits permanent deformation of 0.0580 ± 0.007 mm. This integrated methodology provides a framework for optimizing contact geometries in fluid control components operating under extreme pressure conditions, successfully reconciling contradictory requirements across the entire pressure range. Full article

The intelligent bearing with an embedded sensor is a key technology to realize the running state monitoring of railway locomotive axle box bearings at the source end. To investigate the mechanical properties of axle box bearings with embedded sensor slots, based on nonlinear Hertzian contact theory and the bearing fatigue life theory, a mechanical equivalent analysis model with a virtual mandrel is established for double-row tapered roller bearings used in axle boxes with sensor-embedded slots, which integrally considers the effects of external forces. After verifying the mesh independence before and after embedding the sensor slots, the contact load of tapered rollers calculated by the mechanical model is compared with the theoretical solution based on Hertz contact which verifies the validity of the model from the perspective of contact load. The results show that adjusting the grooving depth and axial position has a significant effect on the local stress peak, and an excessive grooving depth or inappropriate axial position will trigger fatigue damage. This study provides a theoretical basis for analyzing the mechanical characteristics of sensor-embedded slots used in railway locomotive axle box bearings. Full article

This study explores the in situ measurement of contact temperature in thermo-elastohydrodynamic lubrication (TEHL) within cylindrical roller thrust bearings (CRTBs) utilizing vapour-deposited resistive thin-film sensors. The sensors, optimized for compactness and high spatial resolution, were strategically embedded on the stationary bearing raceways near the outer, inner, and mean radius. This configuration enabled a precise measurement of temperature variations in both pure rolling and rolling–sliding regions of the CRTBs. The experimental results revealed a consistent decrease in temperature from the inner and outer radius zones towards the mean radius as the slip-to-roll ratio (SRR) decreased in these regions. Temperature profiles showed an early rise in the inlet zone attributed to thermal inlet shear. At higher speeds, a secondary temperature peak indicative of full-film lubrication was observed in the outlet zone immediately following the Hertzian contact. The study further shows the influence of surface pressure, shear rates, sliding friction, and circumferential speed on contact temperature dynamics, offering insights into their complex interplay. Additionally, viscosity variations due to different oil temperatures were found to critically affect the rate of temperature rise and the propensity for mixed friction phenomena. A higher viscosity resulted in an earlier onset of the temperature rise in the contact, while a lower viscosity and higher speeds promote mixed lubrication, leading to reduced contact film temperatures. These findings provide valuable insights into the behaviour of CRTB-lubricated contacts under various operating conditions and serve as crucial validation data for advanced TEHL computational models. Full article

The elasto-plastic contact models of cylinder-based and sphere-based fractal rough surfaces are developed. In the two models, the critical contact areas of a single asperity are scale-dependent. With an increase in the contact load and contact area, a transition from elastic, elasto-plastic to full plastic deformation takes place in this order. The truncated asperity size distribution functions of different frequency indexes in different contact zones are deduced. The relations between the total real contact area and total contact load for cylinder-based and sphere-based fractal rough surfaces are obtained. The pressure distributions in the contact zone are obtained. The results of elasto-plastic contact models show that the mechanical property of cylinder-based and sphere-based fractal rough surfaces depends on the range of the frequency index of asperities. When the first six frequency indexes are smaller than the elastic critical frequency index, the cylinder-based and sphere-based fractal rough surfaces approximately appear to have an elastic property in the complete contact process. When the minimum frequency index is greater than the elastic critical frequency index, elastic deformation first takes place in the rough surfaces. Then, elasto-plastic deformation takes place with an increase in the total contact load. In elastic deformation, the ratios of the peak pressures of present fractal models to those of Hertzian models are constant for a given range of frequency indexes. In inelastic deformation, the ratios of the peak pressures are inversely proportional to the total contact load. Full article

When testing soft biological samples using the Atomic Force Microscopy (AFM) nanoindentation method, data processing is typically based on equations derived from Hertzian mechanics. To account for the finite thickness of the samples, precise extensions of Hertzian equations have been developed for both conical and parabolic indenters. However, these equations are often avoided due to the complexity of the fitting process. In this paper, the determination of Young’s modulus is significantly simplified when testing soft, thin samples on rigid substrates. Using the weighted mean value theorem for integrals, an ‘average value’ of the correction function (symbolized as g(c)) due to the substrate effect for a specific indentation depth is derived. These values (g(c)) are presented for both conical and parabolic indentations in the domain 0 < r/H ≤ 1, where r is the contact radius between the indenter and the sample, and H is the sample’s thickness. The major advantage of this approach is that it can be applied using only the area under the force–indentation curve (which represents the work performed by the indenter) and the correction factor g(c). Examples from indentation experiments on fibroblasts, along with simulated data processed using the method presented in this paper, are also included. Full article

Severe changes in the profiles of the crossing nose are caused by large dynamic contact forces. To predict these forces as well as the profile evolution, the Whole System Model (WSM) was developed. However, it uses computationally expensive FE simulations. As a replacement, the semi-physical plasticity and wear model (SPPW) has been developed, thus majorly enhancing the overall performance of the WSM. The SPPW considers the influence of wear, plasticity, and wheel-profile-related effects. Its results have shown an overall good correlation with FE results, laboratory data for different materials, and field data from a real crossing. Due to the semi-physical nature of the model, the required computational time for the predictions was significantly reduced compared to FE simulations: minutes instead of weeks. The SPPW will be useful for time-efficient rail damage prediction, like wear and plastic deformation, and, as part of the WSM, contribute to a fast holistic track damage prognosis. Full article

In this research, the adhesive contact between a hard steel and a soft elastomer cylinder was experimentally studied. In the experiment, the hard cylinder was indented into the soft one, after which the two cylinders were separated. The contact area between the cylinders was elliptical in shape, and the eccentricity of this increased as the angle between the axes of the contacting cylinders decreased. Additionally, the adhesive pull-off force and the contact area increased with a decrease in the angle between the cylinders. The use of a transparent elastomer allowed for observation of the shape of the contact in real time, which facilitated the creation of videos demonstrating the complete process of contact failure and the evolution of the ellipse shape, depending on the distance between the cylinders and normal force. These findings contribute to a better understanding of adhesive interactions in elliptical contacts between cylinders and can be applied to fields such as soft robotics, material design, and bioengineering, where precise control over adhesion and contact mechanics is crucial. Full article

The simple spring structure, with detachable electrical contacts, is a very suitable solution for many applications, such as electromechanical relays and connectors. However, they are prone to exhibit instantaneous interruption faults under mechanical vibration environments. In this paper, the governing equations of the modal analysis of a beam with cantilever-Hertzian contact boundary conditions are presented. Then, the time domain analysis method and frequency domain analysis method for solving the forced vibration response are described explicitly. Next, the effect of the axial force on the modal frequency of a detailed model sourced from the practical relay is investigated by using commercial ANSYS Workbench 2021R1 software. Afterward, the harmonic response of the beam is numerically solved individually by using the transient analysis model and the harmonic analysis model in ANSYS Workbench 2021R1 software. Then, the influences of the damping coefficient and excited frequency on the contact force response are investigated. The experimental results of transient displacement and contact resistance of the beam structure agree well with the simulation outcomes. It is proven that there is a linear relationship between the stiffness coefficient and the mass coefficient, which are used for characterizing the damping of the structures in the time domain method and frequency domain methods. Full article

A novel piezoresistive cantilever microprobe (PCM) with an integrated electrothermal or piezoelectric actuator has been designed to replace current commercial PCMs, which require external actuators to perform contact-resonance imaging (CRI) of workpieces and avoid unwanted “forest of peaks” observed at large travel speed in the millimeter-per-second range. Initially, a PCM with integrated resistors for electrothermal actuation (ETA) was designed, built, and tested. Here, the ETA can be performed with a piezoresistive Wheatstone bridge, which converts mechanical strain into electrical signals by boron diffusion in order to simplify the production process. Moreover, a new substrate contact has been added in the new design for an AC voltage supply for the Wheatstone bridge to reduce parasitic signal influence via the EAM (Electromechanical Amplitude Modulation) in our homemade CRI system. Measurements on a bulk Al sample show the expected force dependence of the CR frequency. Meanwhile, fitting of the measured contact-resonance spectra was applied based on a Fano-type line shape to reveal the material-specific signature of a single harmonic resonator. However, noise is greatly increased with the bending mode and contact force increasing on viscoelastic samples. Then, to avoid unspecific peaks remaining in the spectra of soft samples, cantilevers with integrated piezoelectric actuators (PEAs) were designed. The numbers and positions of the actuators were optimized for specific CR vibration modes using analytical modeling of the cantilever bending based on the transfer-matrix method and Hertzian contact mechanics. To confirm the design of the PCM with a PEA, finite element analysis (FEA) of CR probing of a sample with a Young’s modulus of 10 GPa was performed. Close agreement was achieved by Fano-type line shape fitting of amplitude and phase of the first four vertical bending modes of the cantilever. As an important structure of the PCM with a PEA, the piezoresistive Wheatstone bridge had to have suitable doping parameters adapted to the boundary conditions of the manufacturing process of the newly designed PCM. Full article

We investigate the effect of three different harmonically varying loads as a function of the friction coefficient on energy loss in a three-dimensional discrete uncoupled frictional contact problem. Three loading cases include (1) a normal force is constant and a tangential force varies, (2) normal and tangential forces both vary, but the loading and unloading curves are identical, and (3) normal and tangential forces both vary, but the loading and unloading curves are different. For a higher coefficient of friction, three loading cases show different characteristics. If a normal force is constant and a tangential force varies, there is always some slip, but dissipation tends asymptotically to zero at large coefficient of friction. If normal and tangential forces both vary, but the loading and unloading curves are identical, there is no slip and no dissipation above a critical coefficient of friction. If the loading and unloading curves are different, dissipation occurs for all values of the coefficient of friction, and we expect that the dissipation is asymptotic to the relaxation damping value as the coefficient of friction approaches infinity. For lowering coefficient of friction, the three loading cases show similar behavior. Dissipation increases and reaches a maximum just before a state where gross slip is possible. Full article

A new method of machining ultrasonic cavitation abrasive flow based on phase control technology was proposed for improving the machining efficiency of the inner wall of TC4 (Ti-6Al-4V) titanium alloy tubes. According to ultrasonic phase control theory and Hertzian contact theory, a model of ultrasonic abrasive material removal rate under phase control technology was established. Using COMSOL Multiphysics 6.1 software, the phase control deflection effect, acoustic field distribution, and the size of the phase control cavitation domain on the inner wall surface were examined at different transducer frequencies and transducer spacings. The results show that the inner wall polishing has the most excellent effect at a transducer frequency of 21 kHz and spacing of 100 mm. In addition, the phased deflection limit was explored under the optimal parameters, and predictive analyses were performed for voltage control under uniform inner wall polishing. Finally, the effect of processing time on polishing was experimented with, and the results showed that the polishing efficiency was highest from 0 to 30 min and stabilized after 60 min. In addition, the change in surface roughness and material removal of the workpiece were analyzed under the control of the voltage applied, and the experimental results corresponded to the voltage prediction analysis results of the simulation, which proved the viability of phase control abrasive flow polishing for the uniformity of material removal of the inner wall of the tube. Full article

Peeling wheat yields higher-quality flour. During processing in a flaking machine, wheat kernels undergo continuous compression within the machine’s chamber. As this compression persists, damage to the kernels intensifies and accumulates, eventually leading to kernel breakage. To study the damage characteristics of wheat kernels during peeling, this study established a continuous damage model based on Hertzian contact theory and continuous damage theory. The model’s accuracy was validated through experiments, culminating in the calculation of critical parameters for wheat peeling. This study focused on different wheat varieties (Ningmai 22 and Jichun 1) and kernel sizes (the thicknesses of the small, medium, and large kernels were standardized as follows: Ningmai 22—2.67 ± 0.07 mm, 2.81 ± 0.07 mm, and 2.95 ± 0.07 mm; Jichun 1—2.98 ± 0.11 mm, 3.20 ± 0.11 mm, and 3.42 ± 0.11 mm). Continuous compression tests were conducted using a mass spectrometer, and critical damage parameters were analyzed and calculated by integrating the theoretical model with experimental data. The test results showed that the average maximum crushing force (F_c) for small, medium, and large-sized kernels of Ningmai 22 was 96.71 ± 2.27 N, 110.17 ± 2.68 N, and 128.41 ± 2.85 N, respectively. The average maximum crushing deformation (α_c) was 0.65 ± 0.08 mm, 0.68 ± 0.13 mm, and 0.77 ± 0.17 mm, respectively. The average elastic–plastic critical pressure (F_s) was 50.21 N, 60.13 N, and 59.08 N, respectively, and the average critical values of elastic–plastic deformation (α_s) were 0.37 mm, 0.38 mm, and 0.39 mm, respectively. For Jichun 1, the average maximum crushing force (F_c) for small-, medium-, and large-sized kernels was 113.34 ± 3.15 N, 125.28 ± 3.64 N, and 136.15 ± 3.29 N, respectively. The average maximum crushing deformation (α_c) was 0.75 ± 0.11 mm, 0.83 ± 0.15 mm, and 0.88 ± 0.18 mm, respectively. The average elastic–plastic critical pressure (F_s) was 58.11 N, 64.17 N, and 85.05 N, respectively, and the average critical values of elastic–plastic deformation (α_s) were 0.45 mm, 0.47 mm, and 0.52 mm, respectively. The test results indicated that during mechanical compression, if the deformation is less than α_s, the continued application of the compression load will not result in kernel crushing. However, if the deformation exceeds α_s, continued compression will lead to kernel crushing, with the required number of compressions decreasing as the deformation increases. If the deformation surpasses α_c, a single compression load is sufficient to cause kernel crushing. Since smaller wheat kernels are more susceptible to breakage during processing, the peeling pressure (F) within the chamber should be controlled to remain below the average elastic–plastic critical pressure (F_s) of small-sized wheat kernels. Additionally, the kernel deformation (α) induced by the flow rate and loading in the chamber should be kept below the average elastic–plastic critical deformation (α_s) of small-sized wheat kernels. This paper provides a theoretical foundation for the structural design and optimization of processing parameters for wheat peeling machines. Full article