动态效应对管子与管板液压胀接接头接触压力的影响

常见的低碳钢换热管与低合金钢管板胀接为例,采用有限元法进行了管子与管板液压胀接的动态和静态分析,研究了材料应变率等动态效应对胀接接头接触压力的影响。计算结果表明将液压胀管过程简化为静态过程处理,能够节省大量计算时间,而且对结果影响甚微,因此,在换热器管子与管板液压胀接过程中,材料加工的动态效应不显著,将其简化为静态过程是合理的。计算结果为换热器管子与管板液压胀接的理论分析和数值模拟提供了参考。     

Effect of bipolar plate materials on the stress distribution and interfacial contact resistance in PEM fuel cell

In polymer electrolyte fuel cell (PEFC) system, ideal structural integrity design takes into account the end-to-end load transfer mechanism. Hence, structural durability of cell is dependent of individual layers response to the external clamp loading. Since failure modes of each layer differ from another, multidisciplinary approach is needed to innovative designs. Bipolar plate (BPP) of PEFC is multi-functional layer that has a significant potential for research to avoid its structural failure as well as neighboring layers. To this end, present work investigates the effect of BPP materials on the stress transfer as well as distribution in cell layers based on theoretical investigation for clamping load. Gas-diffusion layer (GDL) / BPP interface has drawn considerable interest among researchers due to its susceptibility for damage failure and other related losses. Hence, investigating the interfacial behavior and relating this to the electrical contact resistance is the key feature in proposed investigation.     

Simulation and experimentation on the contact width and pressure distribution of lip seals

The relative motion between two mated parts of machinery always generates heat from friction. The lubricant serves as a medium not only to reduce the friction but also to enhance heat dissipation. In order to contain the lubrication oil, lip seal is a most frequent sealing part used in these applications. This paper aims to study the contact width and contact pressure of the seal lip under the various interference fits between the shaft and seal. The contact force associated with the pressure was used to estimate the generated heat due to friction. Thereby, this frictional heat flux was employed to analyze the temperature distribution within the rubber seal. According to the temperature distribution, the thermal deformation of the seal and the concern of material ageing can be examined. Since the use of a seal with a shaft under allowable dimension tolerance is foreseeable, the fit with different degree of interference was investigated. On the other hand, a simple apparatus to measure the width and pressure on the contact lip zone under different diameters of shaft was designed and fabricated. The contact width and contact pressure were distilled from the press mark of a pressure-sensitive film. The measurements were used to demonstrate the feasibility and accuracy of the proposed set up.     

Effect of surface microgeometry on pressure distribution and film thickness profile in circular contact under impact loading

The transient contact between a steel ball and a metal plate is studied experimentally. The main aim of this research is to reveal the impact prints and the indentation profiles of the contacting surfaces for different conditions of thermal treatment, roughness and lubrication. The impact test rig and the measuring devices that have been used to carry out the study are presented. A ballistic pendulum with a steel ball as contacting part frontally impacts the steel sample. Using auxiliary devices, the force, acceleration and total impact duration are simultaneously recorded. When the impact velocity is increased, the force, acceleration and impression diameter increase in all cases. The recorded values of force, acceleration and contact pressure are higher in the lubricated condition than for dry impact for the annealed steel samples used, while the impression diameter is smaller. Copyright © 2006 John Wiley & Sons, Ltd.     

液压胀管工艺残余接触压力分析

通过对AP1000型管子-管板的液压胀接过程进行分析,充分利用ANSYS软件的面-面接触单元,研究管子-管板材料、管子-管板尺寸、管孔排列方式、胀管压力、保压时间等因素与残余接触压力之间的关系,从而为管子-管板胀接工艺参数的确定提供理论依据。最后应用AP1000型管子进行胀管实验,证明了理论计算的准确性。     

Effect of microseparation on contact mechanics in ceramic-on-ceramic hip joint replacements

The contact mechanics in ceramic-on-ceramic hip implants are investigated in this study under the microseparation condition where the edge contact occurs between the superolateral rim of the acetabular cup and the femoral head. A three-dimensional finite element model is developed to examine the effect of the microseparation distance between the femoral head and the acetabular cup on the contact area and contact stresses between the bearing surfaces. It is shown that microseparation leads to edge contact and elevated contact stresses, and these are mainly dependent on the magnitude of separation, the radial clearance between the femoral head and the acetabular cup, and the cup inclination angle. For a small microseparation distance (less than the diametrical clearance), the contact occurs within the acetabular cup, and consequently an excellent agreement of the predicted contact pressure distribution is obtained between the present three-dimensional anatomical model and a simple two-dimensional axisymmetric model adopted in a previous study [5]. However, as microsegregation is increased further, edge contact between the superolateral rim and the femoral head occurs. Consequently, the predicted contact pressure is significantly increased. The corresponding contact area resembles closely the stripe wear pattern observed on both clinically retrieved and simulator-tested ceramic femoral heads [8, 9, 11]. Furthermore, introducing a fillet radius of 2.5 mm at the mouth of the acetabular cup is shown to reduce the contact stress due to edge contact, but only under relatively large microseparation distances.     

The contact pressure distribution during plastic compression of lead spheres

Pressure-sensitive film has been used to examine the form of the contact pressure distribution for lead spheres plastically compressed between hard steel platens. The mean contact pressure attained a maximum value of 0.6–0.7 times the Vickers hardness of the undeformed sphere when the sphere had been deformed to , where a is the contact radius and R is the radius of the undeformed sphere. The form of the pressure distribution changed markedly as the contact area increased in size, with an increasingly larger proportion of the load being supported towards the contact perimeter. The results are compared with theoretical pressure distributions proposed by Matthews [Acta Metall.28, 311–318 (1980)] for contact between spheres. Fair agreement is obtained if the sphere is assumed to deform by power-law creep, which is thought to reflect the observed time-dependent plastic deformation of the lead.     

The contact pressure distribution in the friction region of miniature journal bearings

The contact pressure distribution in miniature journal bearings is theoretically studied taking into consideration the friction between the contacting surfaces of the journal and the bearing bush. The experimentally confirmed formulae for the contact pressure distribution, the angle of contact and the ratio of the maximum contact pressure to the bearing contact pressure are derived. The contact pressure distribution may be described with a parabolic function.     

The influence of surface roughness and the contact pressure distribution on friction in rolling/sliding contacts

A numerical contact model is used to study the influence of surface roughness and the pressure distribution on the frictional behaviour in rolling/sliding contacts. Double-crowned roller surfaces are measured and used as input for the contact analysis. The contact pressure distribution is calculated for dry static contacts and the results are compared with friction measurements in a lubricated rolling/sliding contact made with a rough friction test rig. The mean pressure is suggested as a parameter that can be used to predict the influence of surface roughness on the friction coefficient in such contacts. The results show two important properties of the friction coefficient for the friction regime studied in this paper: (1) there is a linear decrease in friction coefficient as a function of the slide-to-roll ratio, and (2) the friction coefficient increases linearly with increasing mean contact pressure up to a maximum limit above which the friction coefficient is constant. The absolute deviation of experimental results from the derived theory is for most cases within 0.005.     

Effect of contact pressure on fretting fatigue of austenitic stainless steel

The effect of contact pressure on fretting fatigue in solution-treated austenitic stainless steel was studied. With an increase in contact pressure, fretting fatigue life was almost unchanged at low contact pressures, however it decreased drastically at high contact pressures. At low contact pressures, stress concentration due to fretting damage occurred at the middle portion of the fretted area and the main crack responsible for failure was initiated there. At high contact pressures, concavity was formed at the fretted area without accompanying heavy wear. The main crack was initiated at the outer edge corner of the concavity which probably acted as a notch. Plain fatigue prior to the fretting fatigue test increased the fretting fatigue life at high contact pressures since the concavity formation was suppressed by the cyclic strain hardening.     

An experimental study of contact pressure distribution in panel stamping operations

This paper presents an analysis of the dynamic contact pressure distribution at the sheet metal-tooling interface in normal and defective panel stamping operations. Specifically, the stamping of a 1.27?×?20?×?15?cm rectangular aluminum alloy panel has been simulated using finite-element modeling methods. The modeling results are leveraged to determine the forces acting on sensors embedded in the die structure. Based on these results, a customized stamping test bed has been designed, which incorporates an array of force sensors embedded into the stamping die to enable online measurement of the forces in the die. The force measurements are processed by the thin plate spline numeric surface interpolation method to evaluate a continuous contact pressure distribution map of the die cavity. The pressure distribution in the die cavity in normal and defective scenarios has been presented along with a suggested volume thresholding method for automated defect detection. By leveraging the numeric surface generation method to analyze experimental data, the present study establishes the basis for intelligent tooling and in-process monitoring for improved observability in sheet metal stamping.     

Effect of downward depth and inflation pressure on contact force of gasbag polishing

Gasbag polishing is a kind of ultra-precision machining technology by means of flexible contact, while how to control the polishing contact force online is one of the key issues. In this paper, by analyzing the effect of downward depth and inflation pressure on the contact force experimentally, and then the coupling contact force model is developed. Thus, the predictions of polishing contact force and inflation pressure in terms of the nonlinear composite material of rubber gasbag can be obtained, which can be used to get the optional combination and controllable range of polishing contact force, and to construct the control system of coupling contact force as well. Experimental study shows that applying coupling contact force model to the control system of gasbag polishing contact force with BP neural network PID control strategy is a proper method, which realizes the polishing contact force controllable online and uniform surface quality of mold.     

Influence of testing method on the contact pressure distribution and its effect on coefficient of friction in polymeric bearings

Influence of contact pressure distribution on the coefficient of friction was investigated for some polymeric bearings in dry and lubricated conditions. Reciprocal pin on plate sliding test and Soda pendulum type sliding tests were carried out. It was found that the contact pressure distribution had a significant effect on the coefficient of friction in lubricated condition. The coefficient of friction became smaller when the pin was sliding with the lower contact pressure side ahead. The coefficient of friction in dry condition does not depend on sliding direction regardless of contact pressure distribution. Furthermore a parametric equation was derived to calculate contact pressure in polymeric journal bearings. The accuracy of the equation was confirmed by Finite Element Method (FEM).     

Effect of fastening method on the vibration energy flow through bolted structural joints

Vibrational energy transmission through the bolt-nut system joining two elastic structures is important as it is one of the widely used fastening methods. In this work, the effects of fastening torque and washers are studied as major factors influencing the vibrational power transmission. An experimental method using the structural intensity technique is employed to investigate the characteristics of the power flow through the joint. It is found that the energy dissipation decreases with the increase of fastening torque until reaching the nominal one in the elastic range. Also, the test result reveals that increasing the number of washers is effective in attenuating the vibration energy transmission through the joint, but it is found that using more than 3 washers is not efficient in reducing the vibration transmission.     

Effect of slip-flow on pressure distribution in narrow porous bearings

The experimental work of Beavers et al. established that velocity slip takes place over a permeable boundary. The presence of slip-flow is taken into account while deriving the appropriate modified Reynolds equation that governs the flow of lubricant in a finite porous bearing. The expression for pressure distribution is obtained in a closed form making use of the narrow bearing approximation.It is found that slip-flow reduces the pressure over the whole circumference. Also, this effect is prominent when the bearing operates at a lower eccentricity ratio and/or the bearing matrix has a low permeability.     

A combined contact elasticity and finite element-based model for contact load and pressure distribution calculation in a frictional workpiece-fixture system

Contact forces between workpiece and fixture define fixture stability during clamping and influence workpiece accuracy during machining. In particular, forces acting in the contact region are important for understanding deformation of the workpiece at the contact region. This paper presents a model that combines contact elasticity with finite element methods to predict the contact load and pressure distribution at the contact region in a workpiece-fixture system. The objective is to determine how much clamp forces can be applied to generate adequate contact forces to keep the workpiece in position during machining. The model is able to predict the normal and tangential contact forces as well as the pressure distribution at each workpiece-fixture contact in the fixturing system. Model prediction is shown to be in good agreement with known industry practice on clamp force determination. The presented method has no limits on the types of materials that can be analyzed.     

化学机械抛光过程中护环对硅片表面接触压强分布和宏观轮廓的影响

为了获得单晶硅片化学机械抛光过程中护环对接触压强分布的影响规律,根据有护环化学机械抛光实际出发,建立了抛光过程的接触力学模型和边界条件,利用有限元的方法对有护环抛光接触状态接触压强分布进行了计算和分析,并利用抛光实验对计算获得结果进行了验证;获得了硅片与抛光垫间的接触表面压强分布形态,以及护环几何参数对压强分布的影响规律;结果表明护环抛光接触压强的分布也存在不均匀性,而且在硅片外径邻域内接触压强最大,这些也能导致被加工硅片产生平面度误差和塌边,选择合理地护环几何参量和负载比,可以改善接触压强场分布的均匀性。     

The interfacial transfer of aluminium to steels and ceramic materials under loaded contact at high temperatures I: Large temperature difference between the two surfaces in contact

The interactions under pressure between hot aluminium and a selection of different high temperature materials were studied with rolling contact experiments using aluminium strips and small cylindrical rods of the other materials. Rolls of Pyrex glass and a glass ceramic failed under the rolling pressures used. The only change for the other materials was a build-up of a coating on the contact surfaces. The surface structures, roughnesses and compositions of these coatings were examined.The roll coatings were mainly aluminium metal. They were relatively thick and continuous for steel rolls, thick but discontinuous for WC and SiC roll materials and thin and discontinuous for Si₃N₄ and Cr₂O₃ roll materials. A discontinuous coating was also obtained on Al₂O₃ rolls. The smallest amounts of transferred aluminium were obtained for those roll materials which are not wetted by aluminium.     

Influence of the varus-valgus instability on the contact of the femoro-tibial joint

The varus-valgus instability of the knee joint is mainly due to ruptured or lax collateral ligaments. The purpose of this investigation was to study the influence of the varus-valgus instability on the contact pressures of the femoro-tibial joint. Six fresh knee specimens of human cadavers were tested to measure the contact pressure on the tibia plateau of the knee joint at varus or valgus alignment under various loads and at full extension. Pressure transducers and Bourdon tube pressure gauges were used simultaneously for recording pressure. At neutral alignment of the knee with the menisci intact, the peak pressure increased linearly with forces up to 4 MPa. With increasing varus alignment, the peak contact pressure on the medial plateau not covered by the menisci increased up to a maximum of 7.3 MPa at 5 degrees varus, and at 5 degrees valgus, the peak pressure on the lateral plateau was 7.8 MPa. After total meniscectomy, the contact pressure increased up to a maximum of 7.4 MPa at a force of 2700 N. With increasing varus alignment, the contact pressure on the medial plateau increased to 8.1 MPa at 5 degrees varus and on the lateral plateau 9.2 MPa at 5 degrees valgus.     

Effect of cyclic internal pressure on the temperature distribution in a viscoelastic cylinder

A modified numerical method is introduced to study the interaction between the heat and dynamic response of viscoelastic bodies with temperature-dependent properties. The method is applied to calculate the stress and temperature distributions in a viscoelastic cylinder subjected to cyclic internal pressures. It is found that a large temperature rise may occur due to the interaction, where the value depends upon the thermal and mechanical properties of the material, cylinder size and the frequency of the applied pressure.