Ruiting Tong

A Frictional Heat Model of Planetary Roller Screw Mechanism Considering Load Distribution

Planetary roller screw (PRS), with higher thrust, higher load capacity, and higher speed, is the best choice of the transmission component of the servo system. However, spinning sliding of rollers and support bearings can cause frictional moments and frictional heat, which is an undesirable phenomenon. Besides, frictional heat will further result in high temperature that causes deterioration of lubrication and eventually lead to destruction of the mechanism. Therefore, it is important to predict frictional moments which result in frictional heat. In order to predict the magnitude of frictional heat of PRS mechanism and study the influence of structural parameters of thread and operating conditions on frictional heat, first, a frictional moment model of bearings is built, and frictional moments models of PRS considering the elastic hysteresis of material, the spinning sliding of the rollers, the viscosity of lubricating oil and the differential sliding of thread raceways are established in this paper, respectively. Second, heat generation models of bearing and PRS are presented, respectively. Finally, relationships between frictional heat in terms of operating conditions of PRS, contact angle, and helix angle of roller thread are investigated. The achievements of this project will provide theoretical basis for the design of PRS with lower frictional moments and higher transmission efficiency.

Multiscale Analysis on Two Dimensional Nanoscale Sliding Contacts of Textured Surfaces

Nanoscale sliding contacts are the major factors that influence the friction and result in wear in micro/nanoelectromechanical systems. Many experimental studies indicated that some surface textures could help improve the contact characteristics and reduce friction forces. However, the experimental results may be biased, due to the contamination of the sample surface or substantial defects in the materials. Numerical methods, such as continuum mechanics, meet great challenges when they are applied at length of nanoscale, and the time cost of molecular dynamics (MD) simulation can be extremely high. Therefore, multiscale method, which can capture atomistic behaviors in the region underlying micro/nano physical processes by MD simulations and models other regions by continuum mechanics, offers a great promise. Coupling MD simulation and finite element method, the multiscale method is used to investigate two dimensional nanoscale sliding contacts between a rigid cylindrical tip and an elastic substrate with textured surface, in which adhesive effects are considered. Two series of nanoscale surface textures with different asperity shapes, different asperity heights, and different spacings between asperities are designed. For different heights of asperities or different spacings between asperities, average potential energy, normal forces, mean normal forces, friction forces, and mean friction forces are compared to observe how these parameters influence friction characteristics; then, the optimal asperity height or spacing is discovered. Through the average potential energy, normal forces, mean normal forces, friction forces, and mean friction forces comparisons between smooth surface and textured surfaces, a better shape is advised to indicate that asperity shape plays an important role in friction force reduction. The influences of the indentation depth and radius of the rigid cylindrical tip are analyzed to find out the sensitivity of surface textures to these two parameters. Effects of sliding speed on the characteristics of nanoscale sliding contacts are also discussed. The results show that, with proper asperity height and proper spacing between asperities, surface textures can reduce friction forces effectively. Coefficients of friction (COFs) of all the cases are calculated and compared. Some negative COFs caused by significant adhesive effects are discovered, which are different from traditional macroscopic phenomena.

A New Study on the Parameter Relationships of Planetary Roller Screws

As a more powerful transmission device, planetary roller screws (PRSs) recently have received more attention, compared to conventional ball screws. However, due to the complicated and unclear relationships among the PRS components’ parameters, it is difficult to design high-quality PRSs. To facilitate the PRS design, a new study on the parameter relationships of PRS is conducted in this work. New models of the axial stiffness and the frictional moment of PRS are developed, and the relationships of the axial stiffness and the frictional moment in terms of contact angle, helical angle, and tooth number of the roller thread are investigated. This study could contribute to the research of PRS to improve its transmission performance, especially to increase its positioning accuracy.

Load distribution of planetary roller screw mechanism and its improvement approach

A model of load distribution over threads of planetary roller screw mechanism (PRSM) is developed according to the relationships of deformation compatibility and force equilibrium. In order to make the applied load of PRSM uniformly distributed over threads, an improvement approach is proposed, in which the parameters of thread form of roller and nut are redesigned, and the contact conditions of roller with screw and nut are changed to compensate the axial accumulative deformation of shaft sections of screw and nut. A typical planetary roller screw mechanism is taken as example to analyze the load distribution, and the effects of installation configurations, load conditions and thread form parameters on load distribution are studied. Furthermore, the improvement approach is applied to the PRSM, and it is proved to be beneficial to reach uniform load distribution over threads.

Optimal Design and Contact Analysis for Planetary Roller Screw

Based on the meshing principle of Planetary Roller Screw (PRS), the meshing clearance of screw pair is minimized by taking the half of thread angle, and the pitch diameter tooth thickness, e, as the optimization variables. Optimal structural parameters are obtained by using optimization module of the software Matlab. The 3D model of PRS structures are established with Solidworks and the finite element contact analysis is carried out with Ansys. The contact deformation and stress distribution are calculated among screw, rollers and nut. The results can be used for PRS design.

Kinematics of Planetary Roller Screw Mechanism considering Helical Directions of Screw and Roller Threads

Based on the differential principle of thread transmission, an analytical model considering helical directions between screw and roller threads in planetary roller screw mechanism (PRSM) is presented in this work. The model is critical for the design of PRSM with a smaller lead and a bigger pitch to realize a higher transmission accuracy. The kinematic principle of planetary transmission is employed to analyze the PRSM with different screw thread and roller thread directions. In order to investigate the differences with different screw thread and roller thread directions, the numerical model is developed by using the software Adams to validate the analytical solutions calculated by the presented model. The results indicate, when the helical direction of screw thread is identical with the direction of roller thread, that the lead of PRSM is unaffected regardless of whether sliding between screw and rollers occurs or not. Only when the direction of screw thread is reverse to the direction of roller thread, the design of PRSM with a smaller lead can be realized under a bigger pitch. The presented models and numerical simulation method can be used to research the transmission accuracy of PRSM.

Study on Axial Contact Deformation of Planetary Roller Screw

Based on the current study of planetary roller screw(PRS), a summary of how to match the main parameters of the PRS is obtained. A mathematic model for contact analysis is developed, where series of equivalent balls are used to replace the rounded profile of the roller. At the same time, the formula of axial contact deformation of the PRS is derived. Then a simplified finite element model of the PRS is established and the contact analysis is conducted by FEA. The FEA results and the theoretical ones agree well with each other, so the accuracy of the calculation method and the validity of the equivalent method are verified.

Two Dimensional Nanoscale Reciprocating Sliding Contacts of Textured Surfaces

Detailed behaviors of nanoscale textured surfaces during the reciprocating sliding contacts are still unknown although they are widely used in mechanical components to improve tribological characteristics. The current research of sliding contacts of textured surfaces mainly focuses on the experimental studies, while the cost is too high. Molecular dynamics(MD) simulation is widely used in the studies of nanoscale single-pass sliding contacts, but the CPU cost of MD simulation is also too high to simulate the reciprocating sliding contacts. In this paper, employing multiscale method which couples molecular dynamics simulation and finite element method, two dimensional nanoscale reciprocating sliding contacts of textured surfaces are investigated. Four textured surfaces with different texture shapes are designed, and a rigid cylindrical tip is used to slide on these textured surfaces. For different textured surfaces, average potential energies and average friction forces of the corresponding sliding processes are analyzed. The analyzing results show that “running-in” stages are different for each texture, and steady friction processes are discovered for textured surfaces II, III and IV. Texture shape and sliding direction play important roles in reciprocating sliding contacts, which influence average friction forces greatly. This research can help to design textured surfaces to improve tribological behaviors in nanoscale reciprocating sliding contacts.

Adaptive multiscale method for two-dimensional nanoscale adhesive contacts

There are two separate traditional approaches to model contact problems: continuum and atomistic theory. Continuum theory is successfully used in many domains, but when the scale of the model comes to nanometer, continuum approximation meets challenges. Atomistic theory can catch the detailed behaviors of an individual atom by using molecular dynamics (MD) or quantum mechanics, although accurately, it is usually time-consuming. A multiscale method coupled MD and finite element (FE) is presented. To mesh the FE region automatically, an adaptive method based on the strain energy gradient is introduced to the multiscale method to constitute an adaptive multiscale method. Utilizing the proposed method, adhesive contacts between a rigid cylinder and an elastic substrate are studied, and the results are compared with full MD simulations. The process of FE meshes refinement shows that adaptive multiscale method can make FE mesh generation more flexible. Comparison of the displacements of boundary atoms in the overlap region with the results from full MD simulations indicates that adaptive multiscale method can transfer displacements effectively. Displacements of atoms and FE nodes on the center line of the multiscale model agree well with that of atoms in full MD simulations, which shows the continuity in the overlap region. Furthermore, the Von Mises stress contours and contact force distributions in the contact region are almost same as full MD simulations. The method presented combines multiscale method and adaptive technique, and can provide a more effective way to multiscale method and to the investigation on nanoscale contact problems.

Friction characteristics of nanoscale sliding contacts between multi-asperity tips and textured surfaces

Nanoscale sliding contacts of smooth surfaces or between a single asperity and a smooth surface have been widely investigated by molecular dynamics simulations, while there are few studies on the sliding contacts between two rough surfaces. Actually, the friction of two rough surfaces considering interactions between more asperities should be more realistic. By using multiscale method, friction characteristics of two dimensional nanoscale sliding contacts between rigid multi-asperity tips and elastic textured surfaces are investigated. Four nanoscale textured surfaces with different texture shapes are designed, and six multi-asperity tips composed of cylindrical asperities with different radii are used to slide on the textured surfaces. Friction forces are compared for different tips, and effects of the asperity radii on the friction characteristics are investigated. Average friction forces for all the cases are listed and compared, and effects of texture shapes of the textured surfaces are discussed. The results show that textured surface II has a better structure to reduce friction forces. The multi-asperity tips composed of asperities with R=20r0 (r0=0.227 7 nm) or R=30r0 get higher friction forces compared with other cases, and more atoms of the textured surfaces are taken away by these two tips, which are harmful to reduce friction or wear. For the case of R=10r0, friction forces are also high due to large contact areas, but the sliding processes are stable and few atoms are taken away by the tip. The proposed research considers interactions between more asperities to make the model approach to the real sliding contact problems. The results will help to vary or even control friction characteristics by textured surfaces, or provide references to the design of textured surfaces.