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For this paper, the digital twin refers to a digital asset that exists alongside the physical asset during its operational life, providing insight into and feedback on the physical asset’s performance and health. Thus, the focus is on the DTI, with the potential to aggregate data into a DTA for the gearbox design being considered, and within the DTE set up by Hexagon.
In respect of the physical asset across its life, nothing is more important about its performance than its ability to function, i.e., reliability, and for CAE, nothing is of greater importance than to be able to predict the reliability of a product being designed. Thus, for this study, whilst gearbox noise, efficiency, and thermal behavior may be of interest, the primary interest is fatigue and reliability.
Modern spindle applications of rolling bearings require very high speeds and very high loads, often combined with poor lubrication conditions and/or high solid contamination. Examples of these applications are high-speed and high-cutting rate machine tools, where rolling bearings need to survive very though conditions. Rolling bearings in high speed and high load conditions might suffer from poor lubrication and potentially surface distress and adhesive wear.
Steel, iron, and aluminum are the dominant materials in the mechanical power transmission industry for good reason: high power density requires the high strength and stiffness of metallic materials. Plastics, however, offer valuable features that should be utilized for good gearbox design.
When motion system designers need complex, high-speed, multiaxis motion, they might first think of elaborate, prepackaged robot arms. Or, if they need only a few axes, they might configure a separate profile or round rail for each axis. But hiding between those options is simple and proven ball spline technology. This multiaxis motion solution has existed for years and is still highly relevant to today’s complex motion schemes. Ball splines use a unique architecture integrating rotary and linear motion on a single shaft. This gives them more flexibility to implement complex motion schemes in tighter spaces, providing a two-for-one deal in motion control.
The cylindrical die rolling process can produce helical, axial, and annular forms on shaft-like parts at high rates of speed with precision tolerances.
Why use the rolling process to produce high accuracy lead screws, actuator screws, and other power transmission components rather than traditional cutting processes such as turning, grinding, milling, whirling, or hobbing? Rolling processes and cutting processes both produce a precise form on the workpiece. But if the form geometry, tolerances, and material selection allow, rolling is the process to beat. Speed, surface finish, fatigue strength, precision, dimensional stability, and material savings are some of the primary advantages realized when the rolling process is applied.
Randy Stott, publisher of Power Transmission Engineering and Gear Technology magazines, recently sat down with Norm Parker, technical fellow and technical manager for Torque Transfer Systems at Stellantis, to discuss bearing technology during the Motion + Power Technology Expo in Detroit.
This report derives the equation for relative elastohydrodynamic lubrication (EHL) film thickness. Mineral (MIN), polyalphaolefin (PAO), and polyalkylene glycol (PAG) lubricants with viscosity grades of ISO 320, 150, and 32 are analyzed.