Structural Modeling of Crossed Roller Wire Race Bearings: An Analytical Submodel for Efficient Finite Element Analysis

Core Concepts

This research paper presents a novel analytical submodel for simulating the structural behavior of crossed roller wire race bearings, aiming to reduce the computational cost of traditional Finite Element Analysis (FEA) while maintaining accuracy in predicting bearing stiffness and contact mechanics.

Abstract

• Bibliographic Information: Martín, I., Heras, I., Coria, I., Abasolo, M., & Aguirrebeitia, J. (2020). Structural modeling of crossed roller wire race bearings: Analytical submodel for the roller-wire-ring set. Tribology International, 151, 106420. https://doi.org/10.1016/j.triboint.2020.106420

• Research Objective: The study aims to develop an efficient analytical submodel that accurately represents the structural behavior of the roller-wire-ring set within crossed roller wire race bearings, addressing the computational challenges posed by traditional FEA for these complex systems.

• Methodology: The researchers developed a geometrical interference model as the analytical submodel, considering contact interferences and deformations under axial, radial, and tilting loads. This model was then integrated into a simulation algorithm to predict the overall bearing stiffness and contact mechanics. To validate the analytical model, detailed FE models were created, simulating pure axial, radial, and tilting load cases up to the static load-carrying capacity. The results from the analytical model and FE simulations were then compared to assess the accuracy and efficiency of the proposed approach.

• Key Findings: The analytical submodel demonstrated excellent agreement with the FE simulations in predicting bearing stiffness under axial, radial, and tilting loads. The model accurately captured the wire rotation phenomenon and provided precise estimations of contact forces and angles.

• Main Conclusions: The proposed analytical submodel offers a computationally efficient alternative to traditional FEA for analyzing crossed roller wire race bearings. Its accuracy in predicting stiffness and contact mechanics makes it a valuable tool for bearing design and optimization.

• Significance: This research contributes significantly to the field of bearing analysis by providing a simplified yet accurate method for simulating the complex behavior of crossed roller wire race bearings. The developed submodel can be integrated into global FE models, enabling more efficient analysis and design optimization of these bearings for various applications.

• Limitations and Future Research: The current research focuses on static load cases. Future work could explore the application of the analytical submodel to dynamic loading scenarios. Additionally, further investigation into the influence of different materials and geometrical parameters on the submodel's accuracy would be beneficial.

Stats

Weight savings up to 65% can be achieved in wire bearings compared to conventional bearings when using aluminum rings instead of steel.
The analytical model assumes a "stick" contact state for the roller-wire interface and a "slip" contact state for the wire-ring interface.
The static load-carrying capacity is determined as the load causing a roller-wire contact pressure of 4000 MPa.
The FE models used a friction coefficient of 0.1 for both roller-wire and wire-ring contacts.
The analyzed bearing had a pitch diameter of 420 mm, a wire diameter of 14 mm, and 94 rollers.

Quotes

"This manuscript develops an analytical submodel that represents the structural behaviour of the roller-wire-ring set, in order to include it later in a global FE model to account for ring flexibility and boundary conditions."
"This way, the computationally intensive FE modelling of these complex zones can be substituted by the analytical model developed in this work, and a much manageable global FE model can be used to predict the structural response of the bearing."

Key Insights Distilled From

Structural modeling of crossed roller wire race bearings: analytical submodel for the roller-wire-ring set

by Inigo Martin... at arxiv.org 11-06-2024

https://arxiv.org/pdf/2411.02906.pdf