Search Results (6)

A transient multibody dynamics simulation of rolling-element bearings is the basis for the design of high-speed rotating machinery; however, the established solvers are proprietary, cannot be used with automatic differentiation, and offer no built-in measure of their own physical consistency. We present OpenBEARD, an open-source, fully differentiable transient dynamics solver for angular-contact ball bearings. The solver steps a $40+13Z$-component state (inner ring, cage, and Z balls with quaternion attitude, plus guide-patch, lumped-thermal, and energy-audit states) forward in time under coupled Hertzian contact, Hamrock–Dowson and full-multigrid elastohydrodynamic lubrication, thermal–elastohydrodynamic traction, and centrifugal/press-fit clearance models, using nondimensionalized implicit stiff time integration. A built-in metriplectic conservation audit checks energy closure, the second law per dissipation channel, and the gyroscopic-power identity at every output step. OpenBEARD is cross-verified against two published ADORE references of Gupta. For a high-speed NASA angular-contact ball bearing, the quasi-static contact loads, angles, stresses, and centrifugal force match the published values to within $0.3\%$, and the ball spin and orbital velocities and the spin-axis orientation to ≤0.1%. The inner-race spin-to-roll ratio—a slip-derived secondary quantity that is the most model-sensitive metric in this class of solvers—differs from the NASA quasi-static reference by $8.8\%$. In the separate caged BallBearingTestCase benchmark, the corresponding quasi-static difference is $3.2\%$, and the transient settled value is $\approx 16\%$ above the ADORE step-100 snapshot; these bounded offsets reflect different spin-moment constitutive models. The BallBearingTestCase comparison—a caged bearing under combined thrust and radial load—matches the per-ball contact angles and loads to within $0.23\%$ RMS, and a single published dynamic snapshot (step 100) agrees with the transient contact mechanics to within a few percent. The built-in energy-closure residual stays of order ${10}^{-5}$ with no second-law violations. In the fully transient regime, race control emerges as a dynamical attractor of the coupled traction balance—ball-spin states perturbed by $\pm 12\%$ converge to a single outer-race-control solution—rather than the kinematic hypothesis assumed by quasi-static theory. OpenBEARD is released under the MIT license. Full article

Magnetostrictive sensors based on the inverse magnetostrictive effect offer the advantages of wireless passive operation and structural simplicity; however, achieving both high sensitivity and superior linearity remains a persistent challenge. This study presents a magnetostrictive pressure sensor incorporating a tunable Poisson’s ratio (TPR) chiral auxetic honeycomb substructure, designed to linearize the stress response of the sensing material. A theoretical model linking substructure design parameters to sensor output linearity was derived and validated through finite element simulations. The fabricated substructure exhibited a stable negative Poisson’s ratio (−1.278 to −1.213) within its elastic regime and a highly linear axial-to-transverse strain relationship (x = 1.214y + 0.113). The sensor achieved a calibration linearity of R² = 0.99745, a continuous linear force response up to 118.7 N while the corresponding voltage variation reached 10.75 mV, and a maximum hysteresis error of 5.495% over eight loading cycles. Bearing press-fit force monitoring experiments confirmed practical viability under industrial conditions, with R² exceeding at least 0.995 for dry assembly between multiple bearing types and maintaining R² > 0.994 under lubricated conditions. The proposed TPR substructure approach establishes a reference framework for linearity enhancement in inverse magnetostrictive force sensors. Full article

This paper presents an experimental method for determining the suitable bore diameter of bearing housings made of polymer designated as PA6, which enables multiple bearing replacement processes. Preceded by analytical calculation, four distinct series of housing samples (each with varying production tolerances) were subjected to testing, where each series comprised three housing samples with identical tolerance specifications. The assembly and disassembly processes of press-fit joints were thoroughly monitored using a force sensor, complemented by equipment for measuring the roughness of contact surfaces. Based on the experimental findings, a recommendation is provided for an appropriate interference fit for the tested bearing housing, providing a suitable solution for multiple maintenance processes. As a summary, the idea of this research is to define the prototype solution for the interference fit of a rolling bearing installed in a PA6 housing. Methods used to examine the proposed solution were surface topography and roundness measuring of PA6 housings, while the press-fitting and dismantling tests of rolling bearings in/from PA6 housings were used to verify it. Full article

An implicit, elastoplastic, finite element method (FEM) with multi-body treatment function was applied to accurately analyze the real-world shaft clinching of a duplex-pair tapered roller (DPTR) wheel-bearing unit (WBU) under minimal assumptions during modeling. The inner races were viewed as elastoplastically deformable and were fitted to the hub shaft before clinching by imposing a thermal load reflecting the mechanical load of press-fitting. The forming roller (i.e., the power source) was considered to be force-prescribed, similar to the approach on real shop floors. The predictions focused on the homogenizing stage, during which the two inner races bear the preload. At this time, local plastic deformation occurred at the end of the hub shaft and in the armpit area and the cavity was either maintained or enlarged. The predicted cavity size in case of force-prescribed forming roller increased, compared with the velocity-prescribed forming roller. The residual stress became axisymmetric and was divided into two parts by the cavity. These findings allow engineers to control the pre-stresses imparted to the inner races of tapered roller bearing assemblies. Full article

An improved approach is presented to model the product particle size distribution resulting from grinding in high-pressure roll crusher with the aim to be used in standard high-pressure grinding rolls (HPGR). This approach uses different breakage distribution function parameter values for a single particle compression condition and a bed compression condition. Two materials were used for the experiments; altered Ta-bearing granite and a calc-silicate tungsten ore. A set of experiments was performed with constant operative conditions, while varying a selected condition to study the influence of the equipment set-up on the model. The material was comminuted using a previously determined specific pressing force, varying the feed particle size, roll speed and the static gap. A fourth group of experiments were performed varying the specific pressing force. Experimental results show the high performance of the comminution in a high-pressure environment. The static gap was the key in order to control the product particle size. A mathematical approach to predict the product particle size distribution is presented and it showed a good fit when compared to experimental data. This is the case when a narrow particle size fraction feed is used, but the fit became remarkably good with a multi-size feed distribution. However, when varying the specific pressing force in the case of the calc-silicate material, the results were not completely accurate. The hypothesis of simultaneous single particle compression and bed compression for different size ranges and with different parameters of the distribution function was probed and reinforced by various simulations that exchanged bed compression parameters over the single particle compression distribution function, and vice versa. Full article

Background: Nowadays, hip cups are being used in a wide range of design versions and in an increasing number of units. Their development is progressing steadily. In contrast to conventional methods of manufacturing acetabular cups, additive methods play an increasingly central role in the development progress. Method: A series of eight modified cups were developed on the basis of a standard press-fit cup with a pole flattening and in a reduced version. The surface structures consist of repetitive open-pore load-bearing textural elements aligned right-angled to the cup surface. We used three different types of unit cells (twisted, combined and combined open structures) for constructing of the surface structure. All cups were manufactured using selective laser melting (SLM) of titanium powder (Ti6Al4V). To evaluate the primary stability of the press fit cups in the artificial bone cavity, pull-out and lever-out tests were conducted. All tests were carried out under exact fit conditions. The closed-cell polyurethane (PU) foam, which was used as an artificial bone cavity, was characterized mechanically in order to preempt any potential impact on the test results. Results and conclusions: The pull-out forces as well as the lever moments of the examined cups differ significantly depending on the elementary cells used. The best results in pull-out forces and lever-out moments are shown by the press-fit cups with a combined structure. The results for the assessment of primary stability are related to the geometry used (unit cell), the dimensions of the unit cell, and the volume and porosity responsible for the press fit. Corresponding functional relationships could be identified. The findings show that the implementation of reduced cups in a press-fit design makes sense as part of the development work. Full article