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Raceway curvature ratio is a very important parameter, because its values influence the performance characteristics of rolling-element bearings, their durability and the level of generated vibrations. However, the level of generated vibrations is one of the most important operating parameters of the rolling-element bearings. Excessive vibrations generated by rolling-element bearings affect the operation of the whole mechanism. The article presents experimental studies aimed at evaluation of influence of the inner and outer raceway curvature ratios of 6304-type rolling-element bearings on generated vibrations values. The raceway curvature ratio was determined based on results of metrological measurements. For this purpose, the radii of the inner and outer raceways as well as the diameters of the balls were measured. Design and principle of operation of an innovative system for analysis of the raceway geometry of the rolling bearing rings was presented. The vibration analysis was carried out in three frequency ranges, i.e. low (50-300 Hz), medium (300-1,800 Hz) and high (1,800-10,000 Hz). Values of measured vibrations were expressed in Anderon units. The test results showed that increase in the raceway curvature ratio causes a moderate decrease in the value of the generated vibrations. The research results presented in this article will serve as a guidance to designers and manufacturers of the rolling-element bearings on how to modify the geometry of raceways and balls to obtain bearings that generate low vibration values. That is very important in car transportation.

Raceway curvature ratio is a very important parameter, because its values influence the performance characteristics of rolling-element bearings, their durability and the level of generated vibrations. However, the level of generated vibrations is one of the most important operating parameters of the rolling-element bearings. Excessive vibrations generated by rolling-element bearings affect the operation of the whole mechanism. The article presents experimental studies aimed at evaluation of influence of the inner and outer raceway curvature ratios of 6304-type rolling-element bearings on generated vibrations values. The raceway curvature ratio was determined based on results of metrological measurements. For this purpose, the radii of the inner and outer raceways as well as the diameters of the balls were measured. Design and principle of operation of an innovative system for analysis of the raceway geometry of the rolling bearing rings was presented. The vibration analysis was carried out in three frequency ranges, i.e. low (50-300 Hz), medium (300-1,800 Hz) and high (1,800-10,000 Hz). Values of measured vibrations were expressed in Anderon units. The test results showed that increase in the raceway curvature ratio causes a moderate decrease in the value of the generated vibrations. The research results presented in this article will serve as a guidance to designers and manufacturers of the rolling-element bearings on how to modify the geometry of raceways and balls to obtain bearings that generate low vibration values. That is very important in car transportation. [ABSTRACT FROM AUTHOR]

High-speed jet engine ball bearings operate under challenging operating conditions, such as high speeds, loads, and temperatures. In addition, they have to meet the highest reliability standards. Thus, they require advanced materials, designs, and cooling systems. Though new materials, heat treatments, and component designs have been developed to meet these challenging requirements, the design of the raceway curvature ratio mainly follows the classical rolling bearing life theory, which is based on subsurface fatigue. But the frictional heating in the contact zone due to the phenomenon of microsliding is not considered in the design of high-speed ball bearings. This article presents the results obtained from rig testing with a state-of-the-art high-speed jet engine ball bearing with various curvature ratios on the inner and outer races. The influence of the curvature ratio on the bearing ring temperatures and the bearing power loss is demonstrated. [ABSTRACT FROM AUTHOR]

Based on the mechanical model, the friction loss between the ball and the raceway along the major axis of the contact ellipse is analyzed. The result shows that this part of the loss accounts for about 13.67% of the overall loss, which is mainly determined by the ball sliding length and cannot be ignored. The effects of the radial force, torque, rotational speed and groove curvature ratio on the sliding are all studied. Compared with other factors, radial force has the greatest influence on the sliding loss. As bearing speed gradually grows, the sliding on the inner raceway gradually increases while it gradually decreases on the outer raceway. Compared to the outer raceway curvature ratio, the sliding length is less sensitive to changes in the curvature ratio of the inner raceway. The paper provides theoretical guidance for the design and application of low-friction bearings. [ABSTRACT FROM AUTHOR]

The raceway profile greatly influences the performance of a ball screw. Although the traditional circular raceway profile is simple in structure, it can be a limitation to the load carrying capacity of ball screws. In this paper, a novel type of ball screw raceway profile is proposed based on geometrical close contact theory. Firstly, the second-order approximation curve of the ball is derived using the McLaughlin formula in the normal plane of the raceway helix, which serves as the basis for constructing the close raceway profile. The mathematical expression of the contact stress distribution of the close raceway is then obtained using Chebyshev polynomials. A comparison and analysis of the contact stress distribution between the close raceway and the conventional raceway is carried out. Furthermore, simulation models of ball screws with the close raceway profile are established and the contact behavior of the ball with both types of raceways is statically simulated using ANSYS software. The dynamic performance of both ball screws is compared and analyzed using ADAMS software. The analysis results show that compared with the conventional raceway ball screw, the close raceway ball screw has lower stress, strain, and friction torque under the same load conditions. These research results have significant implications for the structural optimization of ball screws. [ABSTRACT FROM AUTHOR]

Despite enormous research, material, and manufacturing advancements in bearings, these continue to fail in critical aerospace applications. Material and processing aspects of bearing, which are often secondary, then become the central theme of investigation in place of a systemic and holistic view. Therefore, unlike conventional failure analysis, the present review critically examines potential issues in functionality, operation, unusual assembly configurations resulting in opposing inputs to the rolling elements, high DN (diameter × rpm) situations, distress due to slip, skid, and fatigue. Contra-rotating bearing can alleviate the effect of opposing inputs in aeroengine bearings where both the races rotate. It covers both state-of-the-art and conventional concepts. A brief on bearing materials, both conventional and unconventional, is also presented. Various techniques for monitoring bearing health and fault diagnosis are outlined. Life testing of bearing is mandatory to improve the design, material selection, manufacturing, and analysis. While prediction of the B10 life of bearings using Weibull analysis is more prevalent among industries, aerospace industry prefers B1.0 life. A brief on future possibilities is also presented. The present review aims to bring an application perspective on aerospace bearings to prevent their failures and enhance life. [ABSTRACT FROM AUTHOR]

A ball screw (BS) is a key functional component for precision machining equipment, medical instruments, and intelligent manufacturing production lines. The accuracy reliability of a ball screw plays a key role in the functioning of all such equipment. Since the operating conditions have time-dependent characteristics, the non-constant operating conditions affect the BS accuracy decay. In this paper, the numerical modeling and analysis of the BS accuracy decay are considered under non-constant operating conditions. The BS accuracy reliability under single and multiple non-constant operating conditions is investigated. The experimental findings on accuracy decay under non-constant operating conditions validate the proposed analysis. The average relative error of accuracy decay between the theoretical and the experimental findings is estimated at 10% (in the range of 10.15%–12.66%). The error is evaluated under the three different amplitudes operating conditions, including AL (non-constant axial load), FR (non-constant feed rate), and AL plus FR. The results show that the accuracy decay prediction model successfully predicts the BS accuracy reliability under non-constant operating conditions. [ABSTRACT FROM AUTHOR]

The ball screw (BS) has become an indispensable key functional component in many fields, such as CNC machine tools, precision transmission system, and special service requirements. Its accuracy reliability is a key performance in many application fields. There is a phenomenon of mixed slip-roll motion during the BS operation; however, both non-constant working conditions and mixed sliding-rolling motion mode affect its accuracy decay. In this paper, the modeling method of accuracy decay for mixed sliding-rolling motion behavior is established under non-constant operating conditions. The accuracy reliability of the BS is analyzed under single non-constant operation condition or multiple non-constant operating conditions, and the accuracy decay is predicted though modeling method proposed. In addition, the experimental analysis of the BS accuracy degradation is carried out under three different amplitudes of AL (non-constant axial load), FR (non-constant feed rate), and AL + FR combination conditions. The average value of the accuracy loss relative error (5.90 ~ 8.50%) between theoretical model and experimental test results is smaller than that (11.18 ~ 12.66%) under pure sliding motion. It shows that the accuracy decay analysis model established is beneficial to predict the BS accuracy reliability. [ABSTRACT FROM AUTHOR]

The distribution of lubricating oil in the bearing cavity is of great significance to bearing lubrication and cooling. A new idea is provided to further study the ball bearings lubrication, to achieve effective lubrication of bearings. The flow field of oil injection lubrication ball bearings is studied by the moving particle semi-implicit (MPS) method. The accuracy of the numerical calculation method is verified by experiments. The oil distribution of the bearing lubrication flow field and churning torque of the ball and cage at different speeds are analyzed. The research results show the maximum oil content in the bearing cavity is distributed in the range of about 90° to 120°. As the increase of rotating speed, the number of particles in the bearing cavity decreases. The churning torque decreases with the increase of rotating speed and increases with the increase of the oil viscosity. This study provides a new numerical calculation method for the lubrication flow field of ball bearings. [ABSTRACT FROM AUTHOR]

Cageless ball bearings are often preferred as a back-up bearing for active magnetic bearings to support a falling rotor, but the contact between the balls of the cageless ball bearing may lead to the deterioration of the bearing performance and affect the dynamic stability of the rotor system. Thus, we studied the discrete dynamics of cageless ball bearings. First, a model is proposed to change the groove curvature center of the local outer raceway to control the ball velocity to achieve dispersion. Combined with the spatial geometry theory, the mathematical model of the discrete raceway is established, the collision between the balls is considered as an abruptly added constraint, and the non-smooth dynamics equation of the cageless ball bearing with a local discrete raceway is established. Then, the fourth-order Adams prediction correction algorithm is used to numerically solve the dynamic discretization of the ball, and the structural parameters of the discrete raceway are preferably selected, according to the phase diagram of the ball and the change in the angular spacing. The results show that the structure of the discrete raceway has a strong influence on the discrete dynamics of the ball. [ABSTRACT FROM AUTHOR]

For the case of magnetic levitation loss, the rotor of an active magnetic bearing is forced by gravity to drop onto stator laminations, and cageless touchdown bearings with high rigidity and load-bearing capacity ensure back-up support. However, the contact collision of rolling elements in a cageless bearing will lead to deterioration of bearing performance and instability of the rotor system. For this purpose, a method based on noncontact between adjacent rolling elements in cageless bearings is proposed in this paper. First, combined with space geometry, the contact process and the change in radius of rotation when a rolling element passes through a discrete groove are analysed, and a clearance between the adjacent rolling elements is generated by changing the rotation speed. Based on this, a design principle for setting a discrete groove on an outer ring raceway is proposed, and the equation for the circumferential discrete clearance for the rolling element based on bearing kinematics is given. Combined with the characteristics of discrete groove structures, a differential equation for the discrete dynamics of rolling elements with variable stiffness coefficients is proposed. We then determine the influence of the discrete groove structure on the discrete motion of the rolling element and bearing dynamic characteristics. Third, the dynamics simulation is combined with a vibration characteristics experiment and discrete motion experiment for a rolling element in a cageless bearing. Our research results show that a discrete groove design for the raceway can be used to realize stable discrete motion of the rolling element, and that such a discrete groove structure will not adversely affect the vibration characteristics of the bearing. The feasibility of the discrete design of cageless bearings with rolling element is verified, and theoretical guidance for the development and application of cageless bearings is provided. [ABSTRACT FROM AUTHOR]

The combination of sliding/rolling motion can influence the degree of precision degradation of ball screw. Precision degradation modeling and factors analysis can reveal the evolution law of ball screw precision. This paper presents a precision degradation model for factors analysis influencing precision due to mixed sliding-rolling motion. The precision loss model was verified through the comparison of theoretical models and experimental tests. The precision degradation due to rolling motion between the ball and raceway accounted for 29.09% of the screw precision loss due to sliding motion. Additionally, the total precision degradation due to rolling motion accounted for 21.03% of the total sliding precision loss of the screw and nut, and 17.38% of the overall ball screw precision loss under mixed sliding-rolling motion. In addition, the effects of operating conditions and structural parameters on precision loss were analyzed. The sensitivity coefficients of factors influencing were used to quantitatively describe impact degree on precision degradation. [ABSTRACT FROM AUTHOR]

Based on the mechanical model, the friction loss between the ball and the raceway along the major axis of the contact ellipse is analyzed. The result shows that this part of the loss accounts for about 13.67% of the overall loss, which is mainly determined by the ball sliding length and cannot be ignored. The effects of the radial force, torque, rotational speed and groove curvature ratio on the sliding are all studied. Compared with other factors, radial force has the greatest influence on the sliding loss. As bearing speed gradually grows, the sliding on the inner raceway gradually increases while it gradually decreases on the outer raceway. Compared to the outer raceway curvature ratio, the sliding length is less sensitive to changes in the curvature ratio of the inner raceway. The paper provides theoretical guidance for the design and application of low-friction bearings.

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This article deals with the design of slewing rings (slewing bearings). A fully parametric, 3D virtual model of a ball slewing ring with four-point contact was created in the PTC/Creo Parametric CAD system. This model was subsequently used for finite-element analysis using Ansys/Workbench CAE software. The purpose of the FEM analysis was to determine the axial stiffness characteristics. Results of FEM analysis were experimentally verified using a test bench. At the end of the article, we present the nomograms of the deformation constant for different pitch diameters, rolling element diameters and contact angles. [ABSTRACT FROM AUTHOR]

The purpose of this paper is investigating the characteristics of dynamic contact and dynamic stiffness of the single nut ball screw pair (SNBSP). Then a new sensorless method is proposed to extract the SNBSP dynamic contact stiffness of a mass production CNC machine tool feed system. First of all, the transformation relationship between each coordinate system of SNBSP is established. Secondly, the dynamic model of all ball–raceway contact pairs is established. Based on this, a dynamic contact stiffness model is established. The dynamic contact parameters are obtained by the numerical method. It is found that the influence of screw speed on screw and nut raceway normal force distribution are opposite. This will affect the variations of dynamic contact stiffness. It is also clear that the effect of axial load on dynamic stiffness is significant. Then, an effective method is proposed to estimate the dynamic contact stiffness of a mass production CNC machine tool feed system without any external sensors. The axial force of feed system is estimated by using torque current of servo motor. Current signals can be obtained through FANUC Open CNC API Specifications (FOCAS) library functions, and then dynamic contact stiffness can be calculated through the stiffness model without external sensors. Finally, a feed system dynamic model is built, and the contact model and sensorless stiffness estimating method are verified by experiments in this dynamic system. [ABSTRACT FROM AUTHOR]

Double-nut ball screws bear the action of bidirectional pretightening force, leading to the deformation of the contact area between the ball and the raceway. Under this condition, it is important to analyze and calculate the static stiffness of the ball screw. However, the conventional calculation method is inaccurate. Hence, a new method for the static stiffness analysis of a double-nut ball screw is proposed. Through the structural analysis of the ball screw and internal load distribution, a load deformation model was established based on the Hertzian contact theory. Through the load analysis of the ball screw, a static stiffness model of the ball screw was established and applied to a case study and a finite element simulation. The rigidity of THK double-nut ball screws used in the X-axis feed system of a high-stiffness heavy-duty friction stir welding robot (developed by the research group) was calculated. When the workload was lower than 1.1 × 104 N, the slope of the double-nut static stiffness curve increased significantly with the increase in the workload, and when the workload was greater than 1.1 × 104 N, its upward slope tended to stabilize. The simulated and experimental stiffness curves were in good agreement; when the external axial load was greater than 2.8 × 104 N, the stiffness value calculated using the finite element method gradually converged to the theoretical value; and when the axial load reached 3.0 × 104 N, the simulation and test curves matched well. The analysis method of the double-nut ball screw was found to be concise and accurate, and the stiffness curves calculated using the two methods were consistent. The simulation analysis of the static stiffness presented herein is expected to aid the design of double-nut ball screws of high-rigidity heavy-duty equipment. [ABSTRACT FROM AUTHOR]

Next-generation aircraft engines will have to face more stringent requirements for reliability, thrust to weight, efficiency, environment protection, and profitability. These requirements affect all engine modules and components, including rolling element bearings. To cope with the above-mentioned requirements, next-generation aircraft engine main shaft bearings will operate under higher loads, speeds, and temperatures and increased reliability. In addition, lighter weight components are desirable. Hence, new material and cooling technologies including weight- and stress-optimized designs need to be developed. In this article, the experimental investigation results of a novel main shaft ball bearing featuring ceramic balls, direct outer ring cooling, squeeze film damping, as well as surface-nitrided raceways are presented. Bearing rig testing under typical aircraft engine flight conditions has been performed. Savings for oil flow quantity of more than 45% and for power loss of more than 15% were identified. Outer ring temperature reductions of more than 20 K were achieved due to the use of ceramic ball material and the direct outer ring cooling concept. The ultra-high-speed capability of the bearing was demonstrated. Rotational speeds of 24,000 rpm were achieved at bearing temperatures below 200°C. The fundamental experimental results including oil and bearing temperature distribution, power dissipation, and bearing efficiency are presented. In addition, experimental power loss and temperature results are compared with data for a conventional all-steel bearing. [ABSTRACT FROM AUTHOR]

When a ball bearing is designed with thin rings or is mounted in a flexible housing, the assumption of rigid rings is not true anymore. In this article, an experimental study is presented and a comparison with a numerical model is performed. The numerical approach is based on the coupling between a semi-analytical code and a finite element (FE) model that computes the deformation of the rings and housings. The numerical model accounts for ring ovalization, raceway opening, change of conformity, and structural displacements of the whole assembly. The experimental setup allows investigation of the load–displacement behavior of a four-point contact ball bearing submitted to a static thrust loading. Displacements are measured by an optical method (stereo-correlation) that enables comparison of the surface deformation of the two tested bearings and computation of the rigid-body displacement of the inner ring with respect to the outer ring. A comparison between experimental results, numerical results, with and without consideration of ring and housing stiffness, is presented. The numerical results show the importance of the housing stiffness in the modeling, even with standard ball bearings with relatively large and thick rings. Good agreement between measured quantities and numerical results was found. This permits the prediction of the real nonlinear bearing stiffness (load–displacement curve) with a reasonable margin of error. [ABSTRACT FROM PUBLISHER]

The contact angles formed at the position of each ball in ball screws are conventionally assumed to be a constant value in determination of contact stiffness. In this study, instead of being treated as pre-assumed constants, the contact angle is formulated as functions of the position angle of balls to reflect their distribution dependent on the operation condition and design parameters. After establishing a proper transformed coordinate system according to the ball screw mechanism, the variable contact angles and normal forces of the ball screw are predicted. Then the contact stiffness obtained by numerical calculations is validated by experiment and several characteristics arising from the variable contact angle will be discussed. [ABSTRACT FROM PUBLISHER]

The paper features the development of multi-dimensional mathematical models used for evaluating the impact of selected factors on the vibration generated by 6304ZZ type rolling ball bearings from three manufacturers in the aspect of the wear process. The bearings were manufactured of AISI 52100 bearing steel. The analyzed factors included the inner and outer raceways' roundness and waviness deviations, radial clearance and the total curvature ratio. The models were developed for vibration recorded in three frequency ranges: 50–300 Hz, 300–1800 Hz and 1800–10,000 Hz. The paper includes a specification of the principles of operation of innovative measuring systems intended for testing bearing vibration, raceway geometries and radial clearance. Furthermore, it features a specification of particular stages of the multi-dimensional mathematical models' development and verification. Testing with the purpose of statistical evaluation of the analyzed factors is also presented. The test results and mathematical models indicate that the inner raceway's waviness deviation had a dominant impact on the vibration examined in all frequencies. The roundness and waviness deviation of bearing raceways made of AISI 52100 steel propagates the bearing wear process. [ABSTRACT FROM AUTHOR]