Search Results (126)

Accurate remaining useful life (RUL) prediction of rolling bearings was essential for condition-based maintenance because bearing service degradation was primarily governed by progressive rolling-contact fatigue at the rollingelement–raceway interface, whereas vibration signals provided measurable responses to this degradation rather than being its physical cause. However, reliable RUL prediction remained challenging because vibration measurements were noisy, nonlinear, stage-dependent, and sensitive to operating-condition shifts. In this study, a health-indicator-guided temporal-attention framework was developed for bearing RUL prediction using public run-to-failure vibration datasets. The novelty of this work lay in integrating degradation-consistent health indicator construction, sliding-window life-cycle representation, and HI-guided temporal attention into a unified and interpretable prediction framework. First, degradation-sensitive vibration features were extracted and fused into a compact health indicator (HI) to represent the progressive deterioration trend. Then, sliding-window sequences were generated and processed by a Transformer-based temporal-attention network, through which long-range temporal dependencies were captured and higher weights were assigned to informative degradation segments near stage transitions and late-life acceleration. Experiments on the XJTU-SY and IMS datasets showed that the proposed method improved prediction stability, reduced late-life error amplification, and achieved better performance than baseline variants without HI or temporal attention. Ablation analysis confirmed that HI construction mitigated cross-stage drift, whereas temporal attention enhanced transition sensitivity during accelerated degradation. Robustness and cross-domain tests further indicated that the method maintained acceptable degradation-following behavior under noise perturbations and operating-condition changes, although explicit domain-adaptation mechanisms were still required for strongly shifted target domains. Full article

In hybrid rolling bearings operating under extreme high-temperature and high-load conditions, steel rolling elements are prone to early failure, which has accelerated the widespread adoption of ceramic materials. To address the limitations of conventional studies, which have focused mainly on macroscopic wear parameters while neglecting subsurface failure mechanisms and the relationship among sintering process, microstructure, and fatigue performance, this work systematically compares the tribological behavior of Si₃N₄ ceramic balls fabricated by high-pressure electric resistance hot-pressing (REHP) and B₄C ceramic balls prepared by conventional hot pressing (HP) against 52100 steel counterparts. The central innovation of this study lies in clarifying, based on Hertzian contact theory and Lundberg-Palmgren life theory, that subsurface orthogonal shear stress, rather than surface compressive stress, is the fundamental driving force for contact fatigue failure of ceramic balls. In addition, two distinct damage evolution modes are revealed: B₄C exhibits early-stage brittle fracture and large-scale spalling, whereas REHP-Si₃N₄ is characterized by microcrack initiation and slow crack propagation. Moreover, the intrinsic mechanism by which the REHP process significantly enhances the contact fatigue life of ceramics is elucidated; namely, it refines grain size, eliminates residual porosity, and increases densification. The results show that, under the same high-load conditions, the mass loss of REHP-Si₃N₄ ceramic balls is only 35.7% of that of HP-B₄C, while the service life is extended by 20%. This work provides a key theoretical basis for ceramic material selection and sintering process optimization in high-performance hybrid bearings. Full article

Wearable pressure-sensing orthoses are increasingly used in neurorehabilitation to support gait recovery, monitor plantar pressure distribution, and improve patient mobility during repetitive therapy sessions. The performance of these devices depends strongly on the materials used in the skin-contact layer, since material properties influence comfort, flexibility, durability, and force transmission during daily use. This study proposes a hybrid multi-criteria decision-making framework based on the Analytic Hierarchy Process (AHP) and the VIKOR method for material selection in sensor-integrated plantar orthoses. Five candidate materials, ethylene vinyl acetate (EVA), polyethylene (PE), polyurethane (PU), cobalt–chromium–molybdenum alloy (CoCrMo), and polypropylene (PP), were evaluated using five criteria: comfort and skin compatibility, elasticity, fatigue resistance, density, and energy dissipation. AHP was applied to determine the relative importance of the evaluation criteria using expert judgment, while VIKOR was used to rank the material alternatives and identify the compromise solution. The results showed that polyurethane achieved the best overall performance due to its balanced behavior in comfort, elasticity, and fatigue resistance, which are essential properties for long-term wearable neurorehabilitation devices. A sensitivity analysis confirmed that moderate variations in expert weighting did not modify the final ranking. Compared with conventional selection approaches based mainly on isolated material properties, the proposed framework offers a clear and reproducible method for integrating mechanical and user-related requirements into the material selection process for wearable orthoses. Full article

Driver drowsiness detection has become an important application of sensor-based monitoring systems aimed at improving road safety. This review focuses on sensing technologies and physiological parameters used for real-time drowsiness detection in drivers. The surveyed approaches are categorized into physiological sensing methods, including electroencephalography (EEG), electrocardiography (ECG), galvanic skin response (GSR), and photoplethysmography (PPG), and mechanical sensing methods, including respiration rate, eye blinking, head movement, yawning, and steering wheel gripping force. Each method is analyzed from a sensor system perspective, considering signal acquisition principles, measurement location, and practical deployment constraints. In addition, the reviewed techniques are evaluated based on real-time capability, level of sensor attachment, cost, restriction of user movement, and suitability for standalone operation. The comparison highlights that mechanical sensing approaches provide non-invasive and cost-effective solutions; however, they are sensitive to environmental noise and behavioral variability. In contrast, physiological sensing methods offer more direct and earlier indicators of fatigue-related changes in biosignals, although they typically require wearable or contact-based sensors and more complex acquisition systems. The review further indicates that multimodal sensor fusion is increasingly being adopted to improve robustness and reliability in real-world driving conditions. Overall, this work provides a structured overview of sensing modalities and highlights key considerations for designing efficient, real-time driver monitoring systems. Full article

With continued expansion of offshore oil and gas development, the number of high-inclination wells has increased rapidly. During drilling of such wells, vibration transmission from the bottom drillstring to the wellhead is significantly attenuated. Therefore, even when severe vibration occurs at the bit, surface monitoring may not accurately reflect downhole conditions. To analyze axial and lateral vibration behavior, this study considers drillstring–wellbore contact and bit–formation interaction. Based on the Lagrange equation and the S–N fatigue curve, a dynamic model of the drillstring in offshore high-inclination wells is developed using the beam element method. A dynamic safety evaluation model is then constructed using the calculated dynamic characteristics, forming a mechanical analysis and optimization approach for drillstrings in these wells. The technique was applied in a branch well in the Bohai Oilfield. Drillstring vibration under different wellbore trajectories and drilling parameters was examined, and limit drilling parameters were selected through fatigue life analysis. The recommended configuration includes 24 drill collars, a weight on bit of 100 kN, and a rotation speed of 60 r/min. These optimization guidelines support improved drilling efficiency and help ensure drillstring safety in offshore high-inclination well applications. Full article

Structural health monitoring (SHM) of composite structures using surface strain fields measured by digital image correlation (DIC) has been widely demonstrated; however, accurate damage quantification remains challenging. This study proposes a hybrid framework integrating finite element (FE) modeling, machine learning (ML), and peridynamics (PD). A CFRP specimen with a notch was subjected to cyclic loading, and damage evolution was monitored using DIC and validated by ultrasound measurements. A validated FE model generated synthetic strain-field datasets for ML training, enabling defect detection and quantitative characterization directly from surface strains. The trained models achieved high accuracy, including perfect notch detection and low prediction errors. A calibrated PD model captured internal damage evolution and fatigue behavior. The combined DIC–ML–PD approach enables accurate, non-contact damage identification and prognosis, supporting physics-informed digital twins for composite structures. Full article

This study prepares three types of Si₃N₄ ceramic bearing balls with distinct microstructures by regulating the content of Al₂O₃-Y₂O₃ sintering aids, and systematically investigates the influence mechanisms of microstructure, grain boundary phase distribution and grain aspect ratio on the rolling contact fatigue (RCF) failure behavior. The experimental results show that a low content of sintering aids leads to insufficient liquid phase formation, hindered densification and porous defects inside the material, with spalling as the dominant RCF failure mode and the Weibull modulus being only 1.877. With the increase in sintering aid content, the liquid phase promotes densification and the growth of elongated β-Si₃N₄ grains; when the average grain aspect ratio reaches 4.47, the grain toughening mechanism significantly improves the RCF life, with the characteristic life attaining 1.035 × 10⁷ cycles. However, an excessive content of sintering aids induces the steric hindrance effect, which inhibits grain growth and increases the content of soft grain boundary phases, thus leading to the transition of the failure mode to wear and a subsequent decrease in service life. This study demonstrates that an appropriate liquid phase content is crucial for balancing the densification degree, grain morphology and RCF performance of Si₃N₄ ceramic bearing balls. Full article

To address the problems of insufficient precision reserve, limited rotational speed, and excessive temperature rise in high-speed ultra-precision machine tool spindle bearings, the influence of frictional power loss on the thermo-mechanical behavior of the bearing system was investigated. Firstly, based on the analysis of the heat source of the bearing, the friction power consumption model of the bearing assembly is established, and the analysis of the bearing temperature field is realized by studying the heat energy transfer. Secondly, the test bench is built for experimental verification. Finally, through the study of thermal-mechanical coupling performance, the influence of different rotational speeds on bearing stress and life is analyzed. The results show that the friction power consumption generated by the spin sliding of the bearing rolling element accounts for the largest proportion, accounting for 31% of the total friction power consumption; the increase in bearing speed will increase the bearing temperature. At 55,000 r/min, the highest temperature at the rolling element is close to 75 °C, followed by the inner ring up to 68 °C, and the lowest outer ring temperature is 57 °C. The temperature has a great influence on the bearing performance. Under the same working conditions, the equivalent stress is increased by 21%, the contact pressure is increased by 25%, and the fatigue life of the bearing is reduced by 5.6%. Bearing performance is significantly affected by thermodynamic behavior. Full article

Wind turbine blades are subjected to complex environmental conditions during long-term operation, which may lead to structural degradation and performance loss. To ensure structural integrity, fatigue testing prior to deployment is essential. This paper proposes a vision-based method for measuring the full-cycle breathing deformation of wind turbine blades during fatigue testing. The method captures dynamic image sequences of the blade’s hotspot cross-section using industrial cameras and employs a feature-based template matching approach to reconstruct the three-dimensional coordinates of target points. Through coordinate transformation, the deformation trajectories are obtained, enabling quantitative analysis of the blade’s dynamic responses in both flapwise and edgewise directions. A dedicated hardware–software system was developed and validated through full-scale fatigue experiments. Quantitative comparison with strain gage measurements shows that the proposed method achieves mean absolute deviations of 0.84 mm and 0.93 mm in two independent experiments, respectively, with closely matched deformation trends under typical loading conditions. These results demonstrate that the proposed method can reliably capture the global deformation behavior of the blade with millimeter-level accuracy, while significantly reducing instrumentation complexity compared to conventional contact-based approaches. The proposed method provides an effective and practical solution for full-field dynamic deformation measurement in blade fatigue testing, offering strong potential for structural health monitoring and early damage detection in wind turbine systems. Full article

RV reducers are vital components in industrial robots and precision equipment, where the fatigue life of the crank arm and support bearings critically influences the overall system longevity. This study presents a comprehensive performance evaluation, with a specific focus on contact mechanics and wear analysis of these critical bearings. A theoretical mathematical model for force analysis is established based on static mechanics, which is further extended to incorporate wear depth prediction based on contact pressure and sliding velocity. To validate this model and investigate bearing behavior in detail, a high-fidelity parametric simulation model is developed using MASTA software. The simulation results, encompassing contact stress, shear stress, and wear patterns, demonstrate good correlation with the predictions from the theoretical mathematical model, effectively verifying its accuracy for performance and life assessment. The systematic analysis confirms that both the investigated tapered roller and needle roller bearings meet the design requirements. This integrated approach of theoretical modeling, which includes wear analysis, and software simulation provides a reliable methodology for assessing bearing performance and fatigue life, offering significant value for the design optimization and reliability enhancement of RV reducers. Full article

To investigate the influence of asymmetric support clearances (caused by manufacturing and assembly tolerances in practical engineering) on the fretting wear behavior of steam generator heat exchange tubes, this study focuses on 2.25Cr-1Mo alloy heat exchange tubes and 405 stainless steel anti-vibration bars. A high-precision impact wear test platform with adjustable bilateral clearances was designed, and its dynamic reliability was verified by theoretical calculations, finite element simulations and modal tests. An experimental model with asymmetric clearances (0.15 mm and 0.20 mm) was established to study the nonlinear contact force response and wear evolution under excitation frequencies of 60 Hz, 65 Hz and 70 Hz. The results show that asymmetric clearances induce two contact modes: high-frequency “quasi-static friction” on the small-clearance side and intermittent “collision-rebound-flight” impacts on the large-clearance side. The system exhibits a clear excitation instability threshold that shifts backward with increasing excitation frequency. The 0.20 mm side triggers dynamic instability, with wear volume and rate increasing explosively (106.2% and 41.36% at 65 Hz) beyond the threshold. Microscopic analysis reveals that the wear mechanism on the large-clearance side transitions from mild abrasive wear to severe fatigue delamination when crossing the threshold, with surface morphology deteriorating sharply from faint contact spots to extensive spalling craters. This study clarifies the energy distribution mechanism and identifies the large-clearance side as the core “trigger” for system instability and catastrophic failure, providing a theoretical basis for nuclear heat exchange tube monitoring and anti-vibration design. Full article

In view of the potential fretting wear issues of Laser Metal Deposition (LMD) In718 in engineering applications, this paper investigates the fretting wear behavior of LMD In718 alloy subjected to two different heat treatment processes: homogenized Solution-Treated and Aged (STA) and direct-aged only. This was conducted utilizing a newly designed fretting wear apparatus to enable real-time dynamic monitoring of the contact interface and maintain uniform normal force distribution. Furthermore, to provide a more comprehensive understanding of how different heat treatments influence the fretting wear performance of LMD In718, this study systematically evaluates their distinct tribological responses and underlying wear mechanisms. The wear resistance of the material was predicted by analyzing the proportion of the main strengthening phase γ″ in samples with different heat treatments using microstructural characterization methods. Wear resistance tests were conducted under ambient conditions. The results show that the homogenized STA sample has a specific wear rate of 1.375 × 10⁻⁷ mm³/(N∙m), while the direct-aged sample has a wear rate of 1.550 × 10⁻⁷ mm³/(N∙m). The direct-aged sample exhibited severe fatigue spalling accompanied by adhesive and abrasive wear, with numerous subsurface cracks. The homogenized STA sample demonstrated a combined mechanism of oxidative wear and localized abrasive wear. Full article

This paper investigates deflection deformation and premature bearing failure in deep-hole machining spindles with high length-to-diameter ratios under eccentric loading. A contact stiffness model for angular contact ball bearings was developed based on Hertz contact theory. Combined with the finite element method (FEM), a comprehensive mechanical analysis model of the spindle was established. The results show that spindles with high length-to-diameter ratios exhibit significant cantilever behavior, leading to considerable front-end deflection under eccentric loading. This deflection causes the inner and outer rings to incline, resulting in localized stress concentrations, which are the primary contributors to spindle fatigue failure. To improve the spindle’s stress distribution and dynamic performance, an optimized design replacing the metal housing with carbon fiber composite material is proposed. Static and modal analyses were performed using Abaqus and Romax. The analysis results demonstrate that the carbon fiber shell reduces self-weight deformation by 35.8%, decreases coupled deformation under self-weight and grinding loads by 28.6%, and increases modal fundamental frequencies by 20.88% to 47.41%. These improvements significantly enhance structural stiffness and dynamic stability. Experimental vibration monitoring during machine testing validated the accuracy of the modeling and simulation. Full article

This study presents a novel numerical framework that elucidates the critical, yet previously underexplored, role of Marangoni vortex dynamics in determining the final surface quality during the laser polishing of Ti6Al4V (TC4). TC4 titanium alloy is widely used in aerospace, biomedicine, and other high-precision applications due to its excellent specific strength, corrosion resistance, and biocompatibility. However, its surface quality directly affects the fatigue life and service performance of parts, and traditional polishing methods suffer from low efficiency and high pollution. As a non-contact, controllable surface treatment technology, nanosecond laser polishing has demonstrated unique advantages in balancing processing efficiency and surface quality. This study systematically discussed the influence of key process parameters (spot overlap rate, laser power, and scanning times) on the nanosecond laser polishing of TC4 titanium alloy. It revealed the internal physical mechanism by analyzing the temperature and velocity fields and vortex dynamics during molten-pool evolution. It is found that the polishing effect is determined by the process parameters, which adjust the thermal–fluid coupling physical field (temperature distribution, melt flow, and vortex structure) in the molten pool. There is an optimal combination of parameters (spot overlap rate of 79%, laser power of 0.8 W, scanning speed of 5 m/min, scanning 3 times) that can place the molten pool in an optimal dynamic balance state and achieve effective flatness. The experimental results show that, under this parameter, the surface roughness of the specimen with an initial roughness of 1.223 μm is reduced by about 32%. The research further clarified the mechanism by which the initial roughness of the base metal influences the molten pool: the greater the initial roughness, the more pronounced the “peak shaving and valley filling” effect. Under the same parameters, the improvement rate of the specimen with the initial roughness of 1.623 μm could reach about 40%. This study not only establishes the optimized process window but also reveals the essential relationship between “process parameters–bath behavior–surface quality” from the level of the physical field of the molten pool. The findings provide a practical guideline for parameter optimization, directly applicable to the high-precision laser finishing of critical titanium components in the aerospace and biomedical industries. Full article

To investigate the effect of surface roughness on the fretting wear behavior of the Inconel 718 alloy, specimens fabricated by selective laser melting (SLM) were polished using SiC abrasive papers to obtain different surface roughness levels. Ball-on-flat tangential fretting tests were conducted under a normal load of 50 N, displacement amplitudes of 50 and 100 µm, and a total of 10⁴ cycles. The results reveal that all test conditions fall within the gross slip regime (GSR). The coefficient of friction was not significantly affected by surface roughness, while the energy dissipation per cycle exhibited a decreasing trend with decreasing roughness. The high-roughness surface (R_a = 0.80 µm) exhibited severe stress concentration, leading to asperity fracture and fatigue delamination. The medium-roughness specimen (R_a = 0.43 µm) developed a dense third-body layer, showing a synergistic mechanism of abrasive and fatigue wear. The low-roughness specimen (R_a = 0.07 µm) maintained a stable contact interface with sufficient debris evacuation, dominated by adhesive and abrasive wear. At a displacement amplitude of D = 100 µm, the wear depth reached −6 µm, indicating the largest material removal and the most severe damage. Full article