Analysis of clearance fit pin joints

The analysis of clearance fit joints falls within the realm of mixed boundary problems with moving boundaries. In this paper, this problem is solved by a simple continuum method of analysis applying an inverse technique; the region of contact is specified and the corresponding causative load is evaluated. Illustrations are given for a rigid clearance fit pin in a large elastic plate with smooth zero-shear interface between pin and plate, under biaxial plate stress at infinity and due to load transfer through pin.     

Design considerations and experimental studies on semi-active smart pin joint

Hostile dynamic loadings such as severe wind storms, earthquakes, and sudden impacts can cause severe damage to many civil engineering structures. An intelligent structural system equipped with smart structural members that are controllable in real-time is an effective solution to structural damage and failure during such situations. Civil intelligent structures with controllable properties to adapt to any changes due to dynamic loadings can lead to effective protection of structures and their occupants. In this paper, design and testing of a semi-active magnetorheological (MR) pin joint, in which the moment resistance can be controlled in real-time by altering the magnetic field, is reported with the view of using it as a potential candidate for smart members in the development of intelligent structures. Design of prototype smart pin joints includes theoretical analysis related to the radius of the rotary plate, the property of MR fluids and the gap between the rotary plate and the casing based on the requirements of the dynamics of MR pin joints. FEM analysis was deployed to study the distribution of the magnetic field along the gap. It is found, from the theoretical analysis and experimental verification, that the MR pin joint with a diameter of 180 mm can produce a torque of up to 30 Nm, which meets requirements for semi-active members in a multi-storey prototype building model in the next stage of research and development.     

Design considerations and experimental studies on semi-active smart pin joint

Hostile dynamic loadings such as severe wind storms, earthquakes, and sudden impacts can cause severe damage to many civil engineering structures. An intelligent structural system equipped with smart structural members that are controllable in real-time is an effective solution to structural damage and failure during such situations. Civil intelligent structures with controllable properties to adapt to any changes due to dynamic loadings can lead to effective protection of structures and their occupants. In this paper, design and testing of a semi-active magnetorheological (MR) pin joint, in which the moment resistance can be controlled in real-time by altering the magnetic field, is reported with the view of using it as a potential candidate for smart members in the development of intelligent structures. Design of prototype smart pin joints includes theoretical analysis related to the radius of the rotary plate, the property of MR fluids and the gap between the rotary plate and the casing based on the requirements of the dynamics of MR pin joints. FEM analysis was deployed to study the distribution of the magnetic field along the gap. It is found, from the theoretical analysis and experimental verification, that the MR pin joint with a diameter of 180 mm can produce a torque of up to 30 Nm, which meets requirements for semi-active members in a multi-storey prototype building model in the next stage of research and development.     

Importance of pin geometry on pin-on-plate wear testing of hard-on-hard bearing materials for artificial hip joints

The contact mechanics between the pin and the plate used in simple wear screening tests were investigated in this study. Both soft-on-hard, such as ultra-high molecular weight polyethylene (UHMWPE)-on-metal or UHMWPE-on-ceramic, and hard-on-hard, such as metal-on-metal, bearing couples were considered. The effect of the pin geometry and the misalignment between the pin and the plate were investigated on the predicted contact pressure distribution at the bearing surfaces using the finite element method. It was demonstrated that in the case of soft-on-hard bearing couples, neither the geometrical discontinuity of the pin surface nor the misalignment could cause a significant increase in the contact stress. However, for hard-on-hard combinations, even with a very small misalignment of 0.5 degrees between the pin and the plate, the geometrical discontinuity could lead to a more than tenfold increase in the predicted contact stress. This elevated contact stress may lead to a large scatter in the wear data and, even more importantly, structural damage of the bearing surfaces.     

Load bearing capacity of tool pin during friction stir welding

Although friction stir welding (FSW) is now widely used for the welding of aluminum and other soft alloys, premature tool failure limits its application to hard alloys such as steels and titanium alloys. The tool pin, the weakest component of the tool, experiences severe stresses at high temperatures due to both bending moment and torsion. It is shown that the optimum tool pin geometry can be determined from its load bearing capacity for a given set of welding variables and tool and work-piece materials. The traverse force and torque during friction stir welding are computed using a three-dimensional heat transfer and viscoplastic material flow model considering temperature and strain rate-dependent flow stress of the work-piece material. These computed values are used to determine the maximum shear stress experienced by the tool pin due to bending moment and torsion for various welding variables and tool pin dimensions. It is shown that a tool pin with smaller length and larger diameter will be able to sustain more stress than a longer pin with smaller diameter. The proposed methodology is used to explain the failure and deformation of the tool pin in independent experiments for the welding of both L80 steel and AA7075 alloy. The results demonstrate that the short tool life in a typical FSW of steels is contributed by low values of factor of safety in an environment of high temperature and severe stress.     

Bending and extension of a multilayered plate with body forces and thermal loading

A multilayered plate composed of thin layers of isotropic materials is analyzed. The problem for the multilayered plate with body forces is formulated by using the lamination theory in which displacement fields are expressed in terms of in-plane displacements on a main plane and transverse displacement. Placing the main plane at an appropriate distance from the lower surface of the plate, a set of equilibrium equations is shown to be written in uncoupled forms, which are identical to those for an uncoupled plate such as a single layer plate. It is proved that the complete solutions of the multilayered plates subject to the specified in-plane resultant tractions or in-plane displacements on its whole boundary can be obtained from the sum of solutions for uncoupled plates. Closed form solutions are obtained for a circular laminate clamped or simply supported on its the boundary as well as for a rotating disk with a constant angular velocity. The calculations of thermoelastic stresses and displacements in multilayered plates are also discussed. Closed form solutions are obtained for a circular laminate with distributed temperature varying in the radial direction and through the thickness.     

新型阶梯圆柱销节流向心静压轴承特性研究

采用内部节流的静压轴承具有刚度高、不易堵塞等优点,但节流腔占据很大面积,造成轴承尺寸增大.文中将传统的节流腔改进为阶梯圆柱销式,最大限度地减少节流腔的面积,在不增加轴承尺寸的情况下提高了静压轴承的承载能力和刚度.该新型阶梯圆柱销节流器结构简单,工艺性良好,容易做成装配式结构.文中推导了该节流器的液阻及节流比,并通过计算比较了毛细管、小孔和阶梯圆柱销节流下向心静压轴承的无量纲承载能力和油膜刚度.     

Investigation on lubrication condition of piston pin in real engine block with ultrasonic technique

In situ observations of variations in the lubrication conditions between a piston pin and a pin boss in a real automotive engine block operating under low rotational speeds, such as during activation of the engine, were carried out by measuring the echo height detected by an ultrasonic probe installed into the cylindrical piston pin. It was possible to estimate the oil film thickness directly within an accuracy of 1 µm by the echo height ratio reflected from the piston pin surface. The amplitude of the reflected wave (echo height) under the condition including an air bubble was higher than that without an air bubble, and the phase of the wave approached that of the dry condition. It thus became possible to detect cavitation between the piston pin and the pin boss. In particular, cavitations were continuously observed at the anti‐thrust side in the upstroke under 300 rpm operation. However, it was at least clarified that the lubrication condition in the thrust side of the piston pin supporting a load under a stable condition was sufficient to maintain safe operation, since a continuous oil film without a cavity was formed at the thrust side even for a low rotational speed. Copyright © 2011 John Wiley & Sons, Ltd.     

On the influence of a pin type on the friction losses in pin bearings

The aim of this paper is to analyze lubricated revolute joints from the viewpoint of friction losses. The paper deals with the lubricated revolute joints composed of a pin and two more elements connected by means of the pin. It is considered here how different pin types affect friction losses in pin bearings. Three existing pin types are investigated: a pin press-fitted either in the first or in the second element or the one free to rotate in both elements. As a measure of friction losses, a dissipation function is determined in all three cases. Using the results obtained, the advantages of using the full-floating pin with respect to two other types are demonstrated by means of a numerical example.     

A new approach for bending analysis of thin circular plates with large deflection

This paper is concerned with bending analysis of an axisymmetric simply supported circular plate with large deflection. Based on the linear theory of thin plates, the incremental load technique is developed for solving the bending problem of a thin circular plate with large deflection. In the proposed method, the total applied load is divided into various small load steps. In each load step, the plate stress behavior is simplified to be linear. The incremental formulations are presented for the deflection and stresses of the plate when external loads increase. A numerical example is given to show simplicity and accuracy of the present method. It is found that the proposed method can be an alternative useful tool for engineering applications.     

Dynamic characteristics of a magnetorheological pin joint for civil structures

Magnetorheological (MR) pin joint is a novel device in which its joint moment resistance can be controlled in real-time by altering the applied magnetic field. The smart pin joint is intended to be used as a controllable connector between the columns and beams of a civil structure to instantaneously shift the structural natural frequencies in order to avoid resonance and therefore to reduce unwanted vibrations and hence prevent structural damage. As an intrinsically nonlinear device, modelling of this MR fluid based device is a challenging task and makes the design of a suitable control algorithm a cumbersome situation. Aimed at its application in civil structure, the main purpose of this paper is to test and characterise the hysteretic behaviour of MR pin joint. A test scheme is designed to obtain the dynamic performance of MR pin joint in the dominant earthquake frequency range. Some unique phenomena different from those of MR damper are observed through the experimental testing. A computationally-efficient model is proposed by introducing a hyperbolic element to accurately reproduce its dynamic behaviour and to further facilitate the design of a suitable control algorithm. Comprehensive investigations on the model accuracy and dependences of the proposed model on loading condition (frequency and amplitude) and input current level are reported in the last section of this paper.     

A scanning electron microscope study of attrition wear in tungsten carbide taper pin reamers

The wear of tungsten carbide taper pin reamers used to ream holes in a composite structure of aluminium alloy plate overlaying a plate of ultra-high strength steel was examined under the scanning electron microscope. The predominant process of wear was by attrition, which involved the mechanical detachment of individual or groups of tungsten carbide grains from the reamers by both the swarf and workpiece material.This process of attrition wear was initiated by the removal of the cobalt binder phase, resulting in the undermining and subsequent removal of tungsten carbide grains. A mechanism is described for explaining how the cobalt binder phase is initially removed, and the means by which tungsten carbide grains are then removed are discussed. Consequent on the removal of tungsten carbide grains some cobalt binder phase attached to these grains is also removed, and this subsequently becomes an important mechanism of cobalt binder phase removal.     

Improving joint features and tensile shear properties of friction stir lap welded joint by an optimized bottom-half-threaded pin tool

To increase the lap shear failure load of friction stir lap welding (FSLW) joint, a tool with a bottom-half-threaded pin was designed in the present study. Using 7N01-T4 aluminum alloy as the research object, tools with the bottom-half-threaded pin and the traditional full-threaded pin were used to fabricate lap joints. Results showed that the thread end position on the pin greatly influenced the material flow behavior. The material concentrated zone using the bottom-half-threaded pin mainly located above the lap interface, which is beneficial to suppress the hook and cold lap. The lap shear failure load of the FSLW joint using the bottom-half-threaded pin was 17,644.7 N, which is equal to 122.8 % of the joint using the full-threaded pin.     

圆柱销强度的有限元分析

本文建立了圆柱销强度分析的有限元模型,采用了三维块体单元用ＡＬＧＯＲ有限元分析通用软件对圆柱销进行受力分析,结果表明,在同样的工况下,两只销串联使用与只采用一只长销相比,销的寿命和机构的可靠程度都得到明显提高。本文的计算结果对解决斯太尔重型汽车变速箱换档轴与拨爪的定位销的断裂问题有重要的理论指导作用,也可用于指导同类产品的改型设计。     

活塞销疲劳寿命预测的研究

疲劳破坏是活塞销的主要失效形式。对活塞销进行了载荷分析、利用APDL语言建立了有限元分析模型。理论计算了活塞销的疲劳安全系数。基于有限元结果结合Goodman单轴、Sinse多轴修正的名义应力算法,计算预测了活塞销的疲劳寿命。进一步利用FE-SEFE软件进行了单轴、多轴两种方法的疲劳寿命预测,验证该活塞销满足疲劳设计要求,理论验证了FE-SEFE软件在预测高周疲劳寿命的可行性。     

Lower-bound shakedown analysis of a simply supported plate carrying a uniformly distributed load and subjected to cyclic thermal loading

A lower-bound analysis is used to obtain the shakedown boundary for a simply supported circular plate carrying a uniformly distributed load subjected to cyclic thermal loading. Situations where the yield stress is constant and a function of position in the plate are examined. For low levels of thermal loading the results are in agreement with the upper-bound calculations of Ponter.     

Lowering friction coefficient under low loads by minimizing effects of adhesion force and viscous resistance

Conditions (normal load, sliding speed, ambient conditions, and material) to obtain the lower friction coefficient were studied by measuring the friction and pull-off forces between a metal pin (copper or gold) and a plate (steel or single crystal silicon). First, a pin was rubbed against a plate under a normal load between −12 and 870 μN at a sliding speed between 0.012 and 9.6 μm/s. The friction force was measured during reciprocating sliding motion. The pull-off force was measured before and after each friction force measurement. All the force measurements were taken in high vacuum at 10⁻⁵ Pa, dry argon at 1 atm, and ambient humid air of 38 and 60% relative humidity. Then, the friction coefficient was calculated by dividing friction force by the sum of normal load and pull-off force. In high vacuum, when a copper pin was rubbed against either a silicon or steel plate, the friction coefficient decreased to less than 0.05 with decreasing sliding speed. The effect of sliding speed on the friction coefficient suggests that under a low normal load the viscous resistance of liquid contributed to the friction force. When a gold pin was rubbed against a silicon plate, the friction coefficient was not affected by sliding speed.     

Robust pin layout design for sheet-panel locating

Sheet panels, represented as freeform surfaces in a CAD system, are widely used in manufacturing processes. Locating blocks and pins, collectively known as locators, are the most common fixtures for the joining and assembly of sheet panels. In this paper, a robust design approach is utilized to optimize the pin layout so that the sheet panel variations, expressed as translational and orientational variations at certain key product/process characteristic points (KPCs), are minimized. The advantage of this approach is that the locating variations at any given point on the panel can be obtained quantitatively, and hence, the optimal pin design can be selected from among an infinite set of feasible designs. Based on the analyses, some useful pin design guidelines will also be proposed.     

A new design for the pin and V-blocks tribometer

A compact and vacuum compatible design for the generally used pin and V-blocks tribometer is presented. The device has two built-in transducers for measurement of the applied load and friction torque, from which the coefficient of friction is determined. The design, construction and calibration of the transducers are described in detail. The use of the test rig is illustrated by tribotests in air and in high vacuum environments for the study of the tribological behaviour of a bonded solid lubricant film on various substrate materials.