Iztok Potrč

Numerical procedure for predicting the rolling contact fatigue crack initiation

Abstract A computational numerical model for contact fatigue damage analysis of mechanical elements is presented in this paper. The computational approach is based on continuum mechanics, where a homogenous and elastic material model is assumed in the framework of the finite element method analysis. Cyclic contact loading conditions are simulated with moving Hertzian contact pressure. The time-depending loading cycles are defined for each observed material point on and under the contact area. Furthermore, the influence of friction upon rolling–sliding contact loading cycles is analysed in detail, using Coulomb’s friction law. The model for prediction of the number of loading cycles, required for initial fatigue damages to appear, is based on Coffin–Manson relations between deformations and loading cycles, and includes characteristic material fatigue parameters. As a general example, the model is used to analyse a fundamental contact problem of a cylinder and flat surface, which is usually a substitutional model for analysing real mechanical problems. However, the results concerning the identification of critical material points and the number of loading cycles, required for initial fatigue damages to appear at those points, are the main purpose of the presented study.

Travel time models for automated warehouses with aisle transferring storage and retrieval machine

This paper presents analytical travel time models for the computation of travel time for automated warehouses with the aisle transferring S/R machine (in continuation multi-aisle AS/RS). These models consider the operating characteristics of the storage and retrieval machine such as acceleration and deceleration and the maximum velocity. Assuming uniform distributed storage rack locations and pick aisles and using the probability theory, the expressions of the cumulative distribution functions with which the mean travel time is calculated, have been determined. The computational models enable the calculation of the mean travel time for the single and dual command cycles, from which the performance of multi-aisle AS/RS can be evaluated. A simulation model of multi-aisle AS/RS has been developed to compare the performances of the proposed analytical travel time models. The analyses show that regarding all examined types of multi-aisle AS/RS, the results of proposed analytical travel time models correlate with the results of simulation models of multi-aisle AS/RS.

Numerical calculation of bending fatigue life of thin-rim spur gears

Abstract Mechanical elements subjected to cyclic loading have to be designed against fatigue. The aim of this paper is to examine the bending fatigue life of thin-rim spur gears of truck gearboxes. The gear service life is divided into the initiation phase of the damage accumulation and the crack growth, respectively. The analysis of thin-rim gear fatigue life has been performed using the finite element method and the boundary element method. The continuum mechanics based approach is used for the prediction of the fatigue process initiation phase, where the basic fatigue parameters of the materials are taken into account. The remaining life of gear with an initial crack is evaluated using the linear-elastic fracture mechanics.

Travel time models for double-deep automated storage and retrieval systems

In this paper new analytical travel time models for the computation of cycle times for unit-load double-deep automated storage and retrieval systems (in continuation double-deep AS/RS) are presented. The proposed models consider the real operating characteristics of the storage and retrieval machine and the condition of rearranging blocking loads to the nearest free storage location during the retrieval process. With the assumption of the uniform distributed storage rack positions and the probability theory, the expressions of the single and modified dual command cycle have been determined. The proposed models enable the calculation of the mean cycle time for single and dual command cycles, from which the performance of the double-deep AS/RS can be evaluated. A simulation model of the selected double-deep AS/RS has been developed to compare the performances of the proposed analytical travel time models. The numerical analyses show that with regard to the examined type of double-deep AS/RS with a different fill-grade factor, the results of the proposed analytical travel time models correlate with the results of simulation models of double-deep AS/RS.

Critical plane modelling of fatigue initiation under rolling and sliding contact

Contact fatigue is a phenomenon of important practical significance for engineering applications involving localized contacts, such as gears, rail-wheel system and rolling bearings. The service lifetime of such components is related to damage, which results from the contact fatigue. The process in the material structure that causes this kind of failure is quite complicated. The aim of the present paper is to describe a contact fatigue initiation criterion, based on the critical plane approach for the general contact problem. On the basis of contact stress analysis with modified Hertzian boundary conditions, the loading cycle of characteristic material points in the contact area is determined. The Dang Van damage initiation criterion is based on the critical plane approach, which combines the largest allowable shearing and hydrostatic stresses (tensile and compressive), with an assumed elastic shakedown behaviour and it is used in this work. The material point of initial fatigue damage is then determined at the transition of the loading cycle stresses over the critical plane. The model assumed a homogeneous and elastic material model, without any imperfections or residual stresses, and elastic shakedown is considered. A proper determination of loading cycles and their characteristic values is of significance for contact fatigue initiation analysis. Finally, determination of the most critical material point on or under the contact surface and related number of loading cycles required for fatigue damage initiation is calculated with the strain-life (ε—N) method.