Modeling and Validation of a Passive Truss-Link Mechanism for Deployable Structures Considering Friction Compensation with Response Surface Methods

In this study, a passive truss-link mechanism applicable to large-scale deployable structures was designed to achieve successful deployment in space. First, we simplified the selected truss-link mechanisms to the two-dimensional geometry and calculated the degrees of freedom (DOF) to determine whether a kinematic over-constraint occurs. The dimensions of the truss-link structure were determined through a deployment kinematic analysis. Second, a deployment simulation with the truss-link was conducted using multibody dynamics (MBD) software. Finally, a deployment test was performed considering gravity compensation, and the results were compared with those of MBD simulation. The results of the deployment simulations were confirmed to be slightly faster than those of the deployment test due to friction effects existing in the joints and gravity compensation devices. To address this issue, inverse identification of the equivalent frictional torque (EFT) at the revolute joints in the deployment test was conducted through response surface methods (RSM) combined with the central composite design technique. As a result, we confirmed that the deployment angle history of the deployment simulation was similar to that of the deployment test.

Static and dynamic characteristics of a Rayleigh-steps mechanical seal with reverse steps

This paper presents a Rayleigh-steps mechanical seal with reverse steps (RS-MS), and the governing equation was solved by the finite difference method (FDM). The effects of angular misalignment, working condition parameters, and film thickness on sealing performance were discussed, including the opening force, cavitation ratio, leakage rate, frictional torque, stiffness and damping coefficients. The results indicate that the cavitation phenomenon in the reverse step groove can restrain the leakage, while it also affects the stability of the seal. The angular misalignment makes the seal have greater stiffness and damping coefficients. The stiffness and damping coefficients decrease rapidly with the increase of the film thickness, and the dynamic stability of the mechanical seal decreases with the increase of the film thickness, which is not conducive to the stable operation of the seal. The research results can guide the optimization design of mechanical seals.

Effect of head size and rotation on taper corrosion in a hip simulator

Aims This study investigates head-neck taper corrosion with varying head size in a novel hip simulator instrumented to measure corrosion related electrical activity under torsional loads. Methods In all, six 28 mm and six 36 mm titanium stem-cobalt chrome head pairs with polyethylene sockets were tested in a novel instrumented hip simulator. Samples were tested using simulated gait data with incremental increasing loads to determine corrosion onset load and electrochemical activity. Half of each head size group were then cycled with simulated gait and the other half with gait compression only. Damage was measured by area and maximum linear wear depth. Results Overall, 36 mm heads had lower corrosion onset load (p = 0.009) and change in open circuit potential (OCP) during simulated gait with (p = 0.006) and without joint movement (p = 0.004). Discontinuing gait’s joint movement decreased corrosion currents (p = 0.042); however, wear testing showed no significant effect of joint movement on taper damage. In addition, 36 mm heads had greater corrosion area (p = 0.050), but no significant difference was found for maximum linear wear depth (p = 0.155). Conclusion Larger heads are more susceptible to taper corrosion; however, not due to frictional torque as hypothesized. An alternative hypothesis of taper flexural rigidity differential is proposed. Further studies are necessary to investigate the clinical significance and underlying mechanism of this finding. Cite this article: Bone Jt Open 2021;2(11):1004–1016.

Horror of three synergistic factors in THA: high mechanical stress, dissimilar metals, low elasticity stem: a case report

Background A large-diameter femoral head is effective in preventing dislocation after total hip arthroplasty. However, although rare, catastrophic stem tribocorrosion may occur at the head-stem junction. Case presentation A 70-year-old woman underwent revision surgery 7.5 years after total hip arthroplasty because of catastrophic stem corrosion with dissociation of the metal head (cobalt/chromium) and stem (TiMo12Zr6Fe2). Abnormal levels of cobalt were found in the intra-articular fluid, capsule, hip muscle, and blood. Revision surgery was performed via the direct anterior approach. The well-fixed femoral stem was explanted, and a cemented stainless stem with stainless head was implanted. Three months after the revision surgery, the cobalt concentration in the blood had decreased to normal. Conclusions Stem dissociation in the present case might have been caused by synergistic combination of a 36-mm-diameter femoral head and long neck length offset with high frictional torque, a cobalt-chromium head with a high risk of galvanic corrosion, and a TMZF (TiMo12Zr6Fe2) alloy stem with a low Young’s modulus of elasticity. The combination of these factors must be avoided.

Einfluss von Gruppe I Grundölen auf die Elastomerverträglichkeit von Radialwellendichtringen

Gear oils on the basis of Group I base oils are the most widely used lubricant in industrial drive systems. With dynamic friction torque tests, the influence of Group I base oils from different regions/refineries on elastomer compatibility of radial shaft seals is investigated by dynamic friction torque tests. The results show a significant influence of base oil on the development of frictional torque in the sealing gap and the elastomer compatibility.

Appearance of Hysteresis Phenomena on Hydrodynamic Lubrication in a Seal-Type Thrust Bearing with Dimples

This paper described unique hysteresis phenomena that appear in the hydrodynamic lubrication properties of dimpled thrust bearings. A seal-type thrust bearing specimen was textured with dimples. The load-carrying capacity and frictional torque were measured with a constant film thickness and compared to those of a dimple-free specimen. For examining the size of cavitation bubbles that occurred in various conditions, the lubricating area was observed during experiments. The used dimpled specimen produced the load-carrying capacity, and it exhibited an interesting hysteresis phenomenon, the difference in the values in the increasing and decreasing processes of rotational speed. The visualization test results revealed that the size of cavitation bubbles occurring within the dimples strongly affected this phenomenon. In addition, the dimpled specimen was able to reduce the frictional torque compared to the dimple-free specimen. However, the frictional torque did not show the hysteresis loop similar to that shown in the load-carrying capacity.

Tibial tray debonding from the cement mantle is associated with deformation of the backside of polyethylene tibial inserts

Aims The aim of this study was to investigate whether wear and backside deformation of polyethylene (PE) tibial inserts may influence the cement cover of tibial trays of explanted total knee arthroplasties (TKAs). Methods At our retrieval centre, we measured changes in the wear and deformation of PE inserts using coordinate measuring machines and light microscopy. The amount of cement cover on the backside of tibial trays was quantified as a percentage of the total surface. The study involved data from the explanted fixed-bearing components of four widely used contemporary designs of TKA (Attune, NexGen, Press Fit Condylar (PFC), and Triathlon), revised for any indication, and we compared them with components that used previous generations of PE. Regression modelling was used to identify variables related to the amount of cement cover on the retrieved trays. Results A total of 114 explanted fixed-bearing TKAs were examined. This included 76 used with contemporary PE inserts which were compared with 15 used with older generation PEs. The Attune and NexGen (central locking) trays were found to have significantly less cement cover than Triathlon and PFC trays (peripheral locking group) (p = 0.001). The median planicity values of the PE inserts used with central locking trays were significantly greater than of those with peripheral locking inserts (205 vs 85 microns; p < 0.001). Attune and NexGen inserts had a characteristic pattern of backside deformation, with the outer edges of the PE deviating inferiorly, leaving the PE margins as the primary areas of articulation. Conclusion Explanted TKAs with central locking mechanisms were significantly more likely to debond from the cement mantle. The PE inserts of these designs showed characteristic patterns of deformation, which appeared to relate to the manufacturing process and may be exacerbated in vivo. This pattern of deformation was associated with PE wear occurring at the outer edges of the articulation, potentially increasing the frictional torque generated at this interface.

Evaluation of Tribological Properties of Bearing Materials for Marine Diesel Engines Utilising the Contact Voltage Method

The contact voltage (CV) method, which can detect miniature failures, has been tested under laboratory conditions to monitor the condition of bearings. In this study, the bearing materials for marine diesel engines, aluminium and copper alloy, were tested on a bearing fatigue wear test bench in the boundary lubrication state, which was found through tests of the different parameters. The frictional torque, the oil film thickness and the bearing temperature were measured, as well as the CV signals. The possibility of using the CV technique to monitor the condition of the bearings was also assessed by evaluating the tribological properties. After 10 h of the test, the aluminium alloy bearing was worn to the alloy layer. Then, the wear-reducing layer on the surface of the bearing slowly peeled off, and the wear was intensified. Due to its higher wear-resisting property, the amount of wear on the copper alloy bearing increased slowly. After 20 h of the fatigue wear test, the aluminium alloy bearing became severely worn, the CV characteristic was up to 81% of the initial value, the bearing temperature increased by 6.3%, and the torque value increased by 32%. This indicates that the CV method is more sensitive to wear failure. Due to better wear resistance, the copper alloy bearing showed only slightly wear and a small increase in its CV value. The main contribution is that the CV method is useful for monitoring the lubricated condition and for evaluating the tribological properties of bearings. This research has laid technical foundations for the engineering of the sliding bearing wear monitoring system based on the CV method.

Comparative study of a simulative bearing design with an experimentally determined data of a prototype bearing

In some specific applications, the need of an optimized rolling bearing, having a similar load carrying capacity as a tapered roller bearing but with much lower friction losses is still to be addressed. In this paper, a new model is developed using a multibody simulation software and its experimental validation is presented.After studying many different (in use and only patented) roller geometries and based on an existing and already validated model for tapered roller bearings, a new model has been created changing the basis of its geometry. When the rolling bearing is highly loaded, the new geometry will show lower friction losses than a conventional tapered roller bearing. In order to confirm this premise, as well as to validate the model, a prototype of the new optimized geometry has been manufactured and experimentally tested, together with a tapered roller bearing of same main dimensions. The tests have taken place in a frictional torque test rig, where it is possible to realistically reproduce the loads and misalignments occurring on a bearing.The results of these tests together with its comparisons with the results of the multibody simulation models are discussed here. It has been observed, that the new model not only can be validated, but also presents less friction losses than the ones obtained when using a tapered roller bearing under some operating points with highly loaded bearings.

Optimization of the Structural Parameters and the Teeth Shape of Slip in Drill Rig

In order to improve the performance of slip and reduce the extrusion damage of the drill pipe in the drill rig, the optimization of structural parameters and teeth shape of the slip while clamping the drill pipe had been researched in this article. On the macroscale, the structural parameters of the slip had been optimized with response surface method (RSM) and Multiobjective Genetic Algorithm (MOGA). The optimized result showed that the single weight of the slip had been reduced from 3.99 kg to 2.91 kg and the maximum deformation of the drill pipe was reduced from 3.75 mm on both sides to 2.56 mm on both sides. On the microscale, a mathematical model for the single slip teeth while clamping the drill pipe had been established to give a detailed description to calculate the equivalent coefficient of friction and provide the relationship between the frictional torque with the allowable compression strength. In addition, the finite element model that had been set up by ABAQUS was used to verify the mathematical model, and the comparison of results had shown the accuracy of the mathematical model of the slip teeth while clamping the drill pipe. According to the mathematical model of the slip teeth in the drill rig, while clamping the drill pipe, the optimal shape of the slip teeth in the drill rig was achieved under the following condition: the slope of the slip teeth θ is 60°, the top width of the slip teeth w h is 1.5 mm, and the depth of the slip teeth clamping the drill pipe d is 0.5 mm. The equivalent coefficient of friction f v can be increased from 1.73 to 2.06, and the optimal result f v increases 11.3%.