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Research Papers: Contact Mechanics

Numerical Running-In Method for Modifying Cylindrical Roller Profile Under Mixed Lubrication of Finite Line Contacts

[+] Author and Article Information
Yazhao Zhang

State Key Laboratory of Tribology,
Tsinghua University,
Beijing 100084, China
e-mail: zhang-yz14@mails.tsinghua.edu.cn

Hui Cao

State Key Laboratory of Tribology,
Tsinghua University,
Beijing 100084, China
e-mail: caoh15@mails.tsinghua.edu.cn

Alexander Kovalev

State Key Laboratory of Tribology,
Tsinghua University,
Beijing 100084, China
e-mail: akovalev@tsinghua.edu.cn

Yonggang Meng

State Key Laboratory of Tribology,
Tsinghua University,
Beijing 100084, China
e-mail: mengyg@tsinghua.edu.cn

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received May 1, 2018; final manuscript received November 21, 2018; published online January 16, 2019. Assoc. Editor: Wang-Long Li.

J. Tribol 141(4), 041401 (Jan 16, 2019) (9 pages) Paper No: TRIB-18-1172; doi: 10.1115/1.4042099 History: Received May 01, 2018; Revised November 21, 2018

A numerical method for modifying cylindrical roller profile was proposed to smooth axial pressure distributions of finite line contacts under the mixed lubrication regime. The mixed lubrication model, in which the Reynolds equation modified by Patir and Cheng has been solved with implementing the rough surface contact model of Kogut and Etsion for the stochastic solution of hydrodynamic pressure and asperity-contact pressure, was established and it is validated by the comparison between simulation results and experiments. Some common roller profiles were carried into the mixed lubrication model and obvious increment of pressure appears near the roller ends or at the central contact area. A numerical running-in method was developed to smooth pressure shapes and the crown drop of roller profile was modified gradually implementing Archard's wear law, where a higher asperity-contact pressure leads to a larger crown drop on a roller profile. The results of the numerical running-in method indicated that pressure distributions of finite line contacts are uniform if the optimized roller profile is employed.

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References

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Figures

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Fig. 1

The roller crown drop along the axial direction

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Fig. 2

The flowchart for the mixed lubrication and roller profile optimization

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Fig. 3

Comparison of friction coefficient between simulations and measurements: (a) W¯=4×10−5, U¯=1×10−11, σ¯=2.1×10−5 and (b) W¯=1×10−4, U¯=1×10−11, σ¯=2.1×10−5

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Fig. 4

Pressure distributions and oil film thickness for the roller with chamfered corners: (a) diagram for roller profile with rounded corners contact, (b) axial direction, and (c) rolling direction

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Fig. 5

Pressure distributions and oil film thickness for the roller with rounded corners: (a) diagram for rounded roller profile, (b) axial direction, and (c) rolling direction

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Fig. 6

Pressure distributions and oil film thickness for the crowned roller: (a) diagram for crowned roller profile, (b) axial direction, and (c) rolling direction

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Fig. 7

Pressure distributions and oil film thickness for the crowned roller with rounded corners: (a) diagram for the profile of crowned roller with rounded corners, (b) axial direction, and (c) rolling direction

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Fig. 8

Pressure distributions and oil film thickness for the logarithmic profile roller: (a) diagram for logarithmic roller profile, (b) axial direction, and (c) rolling direction

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Fig. 9

Pressure distributions and oil film thickness for the optimized roller: (a) diagram for optimized roller profile, (b) axial direction, and (c) rolling direction

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Fig. 10

Comparison of axial roller profiles in the previous section

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Fig. 11

The comparison of wear crown profiles with different loads and entraining velocities: (a) with the same applied load of 3000 N but different entraining velocities and (b) with the same entraining velocity of 0.25 m/s but different applied loads

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