GOALI/Collaborative Research: Reliable Prediction of Endurance Life of Ultra-High-Strength Aerospace Rolling-Element Bearings

GOALI/合作研究：超高强度航空航天滚动轴承耐久性寿命的可靠预测

• 批准号: 1434834
• 负责人: Qian Wang
• 金额: $ 20万
• 依托单位: Northwestern University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2014
• 资助国家: 美国
• 起止时间: 2014-08-01 至 2019-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1434834&HistoricalAwards=false
• 关键词: GOALI; Collaborative; Research; Reliable; Prediction

Rolling-element bearings are key precision components used for rotor support in nearly all machinery. The annual revenue associated with bearings is a substantial $50.5 billion worldwide. Future demands on high performance rotor support for advanced aircraft engines, wind turbines and high-speed rail require bearings to survive thousands of hours and consequently billions of Rolling Contact Fatigue (RCF) cycles under severe operating conditions. A new generation of high strength bearing steels with graded material properties has been designed to meet these challenges. Existing life prediction methodologies rely on empirical models dating back to the 1940s, resulting in a large discrepancy between observed and predicted life, for the new generation of materials. This Grant Opportunity for Academic Liaison with Industry (GOALI) collaborative researh project aims to predict reliable service life and structural integrity of new generation bearing materials based on novel experimental and computational procedures for understanding material degradation due to RCF at the micro and nanometer scale. The results will translate to the design of other components with large economic impact such as transmission gears, cams, railway wheels and tracks, and manufacturing tooling. This research is an effort to bring back an academic focus to manufacturing-related research to campuses and to better assist US industries. The project will contribute to the education and training of future manufacturing research workforce and leaders.This collaborative GOALI project involves developing a novel physics-based material-specific life prediction model rooted in fundamental understanding of local material properties of as-manufactured and RCF-affected materials from sub-micrometer/nanometer to macroscopic length scales. The project will develop: 1) quantifiable measures for subsurface graded material response as a function of load, temperature and RCF cycles; 2) computational approaches for understanding the influence of microstructural features on the material cyclic response, resultant stress and strain fields, and fatigue damage; and 3) a material-specific RCF life prediction methodology based on enhancements to the existing Lundberg-Palmgren empirical approach by the evolving elastic-plastic subsurface stress and strain fields. Methodologies for tracking RCF material damage in the giga-cycle regime will become available for reliable life prediction, which are of considerable importance with applications to broader areas of tribology and heterogeneous materials for future component design. Intellectual significance of the project comprises of two novel contributions: 1) it will aid development of a new material-specific RCF life prediction model, particularly beneficial to accelerated design of new bearing materials, and 2) it will result in a methodology to model cycle-specific material property evolution in rolling contacts, with direct relevance to design of gears, cams, railway wheels and tooling.

滚动元件轴承是几乎所有机械中用于转子支撑的关键精度组件。与轴承相关的年收入是全球500亿美元。对高级飞机发动机，风力涡轮机和高铁的高性转子支持的未来需求需要轴承才能在严重的操作条件下生存数千小时，从而使数十亿个小时的滚动接触疲劳（RCF）周期。具有分级材料特性的新一代高强度轴承钢旨在应对这些挑战。现有的生活预测方法依赖于1940年代的经验模型，从而导致观察到的生活和预测寿命之间存在很大的差异。这种与行业联络的赠款机会（Goali）协作研究项目旨在根据新一代轴承材料的可靠服务寿命和结构完整性，该轴承材料基于新颖的实验和计算程序，以理解在微观和纳米尺度上因RCF而导致的材料退化。结果将转化为具有巨大经济影响的其他组件的设计，例如变速箱，凸轮，铁路车轮和轨道以及制造工具。这项研究是为了将与制造有关的研究重新引入校园并更好地协助美国行业。该项目将有助于对未来的制造研究劳动力和领导者的教育和培训。该协作目标项目涉及开发一种基于物理学的新型材料特异性生活预测模型，该模型植根于对来自亚液压计/纳米的AS型和RCF影响的材料的局部材料特性的基本理解，从而扎根于元素和RCF影响的材料。该项目将开发：1）可量化材料响应的量化度量，该材料响应是负载，温度和RCF周期的函数； 2）理解微结构特征对材料循环响应，导致应力和应变场以及疲劳损伤的影响的计算方法； 3）一种基于对现有的lundberg-palmgren经验方法的增强的材料特异性RCF寿命预测方法，该方法通过不断发展的弹性 - 塑性地下应力和应变场。追踪RCF物质损害的方法论将用于可靠的生活预测，这对于对更广泛的摩擦学和异质材料的应用非常重要，用于未来的组件设计。该项目的智力意义包括两个新颖的贡献：1）它将有助于开发一种新的特定于材料的RCF生活预测模型，特别有益于加速新轴承材料的设计，而2）2）它将导致一种方法论，它可以使模型周期的材料属性发展在滚动接触中的特定材料属性演化，并与齿轮，摄像头，火车，铁路，铁路，工具厂和工具的设计直接相关。