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Optimal Bearing Housing Designing Using Topology Optimization

[+] Author and Article Information
Simon Kabus

 Vestas Turbines Research and Development, Motion Systems,Vestas Wind Systems, 8200 Aarhus, DenmarkSIKAB@Vestas.com

Claus B. W. Pedersen

 FE-Design, 22765 Hamburg, Germanyclaus.pedersen@FE-design.com

J. Tribol 134(2), 021102 (Apr 12, 2012) (9 pages) doi:10.1115/1.4005951 History: Received October 28, 2011; Revised January 27, 2012; Published April 11, 2012; Online April 12, 2012

The internal load distribution in rolling bearings has a high impact on the bearing fatigue life. This study presents a method to optimize roller bearing housing design in order to maximize the bearing fatigue life by ensuring an optimal internal load distribution. An FE-model of a cylindrical roller bearing utilizing nonlinear springs in the roller modeling is presented, which is capable of simulating the bearing load distribution efficiently. The optimal load distribution is achieved by specifying the desired internal load distribution as design constraints in a topology optimization of the bearing housing design. The superiority of the method is clearly demonstrated through case studies involving a cylindrical roller bearing, where it is shown that the fatigue life is increased and the bearing housing mass and roller contact misalignment is reduced.

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Copyright © 2012 by American Society of Mechanical Engineers
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Figures

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Figure 1

Optimal and rigidly supported load distributions

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Figure 2

Modeling roller j using three springs

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Figure 3

Convergence study using different number of springs

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Figure 4

Schematic overview of topology optimization workflow

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Figure 5

Topological iterative design process in a present CAE and CAD workflow using TOSCA [16]

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Figure 6

Initial V1 design with general model descriptions

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Figure 7

Load distribution evaluation

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Figure 8

Considered bearing housings in aligned study

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Figure 9

V5 bearing housing for misaligned study

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Figure 10

Optimization convergence and evaluation of load distributions and misalignments

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Figure 11

Deflection sum comparison of V4 and V5 bearing cross sections at × 300 magnification with misalignment indications at bottom roller position. Scale in mm

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Figure 12

Evaluation of non-Hertzian contact pressures for misaligned contact study

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