Identification of mesoscopic fault of full ceramic ball bearings based on strain energy theory
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摘要:
针对全陶瓷球轴承外圈内部存在亚毫米级甚至毫米级的细观缺陷，传统钢制轴承外圈缺陷动力学模型无法表征的问题，基于应变能理论建立针对全陶瓷球轴承外圈亚表面细观缺陷识别的动力学模型，研究细观缺陷尺度下不同缺陷深度对全陶瓷球轴承外圈运行状态的影响，通过仿真，证实了当轴承外圈亚表面存在细观缺陷时，振动时域信号中会存在小波峰现象，在频域信号中转频附近存在与其对应的特征频率，以经验模态分解(EMD)三阶分量幅值正向最大值与其对应的转频峰值的比值判断缺陷演化程度，通过实验验证了所建模型的有效性。所建模型实现了对全陶瓷球轴承外圈是否存在亚表面细观缺陷及缺陷演化程度的判断，为全陶瓷球轴承的缺陷诊断提供了新的思路，为全陶瓷轴承转子系统的安全稳定运转提供理论参考。
Abstract:The traditional steel bearing outer ring dynamics model is unable to describe the issue of sub-millimeter or even millimeter-scale mesoscopic flaws inside the outer ring of complete ceramic ball bearings. Based on the strain energy theory, a dynamic model is established for the subsurface mesoscopic defects of the outer ring of full ceramic ball bearings, and the influence of different defect depths on the running state of the outer ring of full ceramic ball bearings is investigated at the scale of mesoscopic defects. Through simulation, it is confirmed that when a mesoscopic defect exists on the subsurface of the outer ring of the bearing. There is a corresponding characteristic frequency near the intermediate frequency of the frequency domain signal, and the degree of defect evolution is determined by the ratio of the maximum positive value of its empirical mode decomposition (EMD) third-order component amplitude to its corresponding peak value of the intermediate frequency. Finally, the effectiveness of the constructed model is verified through experiments. Finally, the validity of the proposed dynamics model and simulation results is verified by experiments. The established model makes it possible to determine the degree of defect evolution and if sub-surface mesoscopic defects are present in the outer rings of complete ceramic ball bearings. The established model provides a new idea for the defect diagnosis of full ceramic ball bearings and a theoretical reference for the safe and stable operation of full ceramic bearing rotor systems.
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图 1 外圈亚表面缺陷和局部截面示意图
Figure 1. Schematic diagram of subsurface fault and local section of outer ring
图 2 外圈亚表面细观缺陷处局部截面示意图
Figure 2. Schematic diagram of local cross-section at sub surface fault of the outer ring
图 3 外圈亚表面细观缺陷处局部示意图
Figure 3. Partial schematic diagram of subsurface defects on outer ring
图 4 轴承外圈分布载荷示意图
Figure 4. Schematic diagram of load distribution on outer ring of bearing
图 5 二自由度非线性动力学模型示意图
Figure 5. Schematic diagram of a two-degree-of-freedom nonlinear dynamic model
图 6 全陶瓷球轴承外圈亚表面细观缺陷研究技术流程图
Figure 6. Technical flow chart of research on subsurface meso-fault of outer ring of full ceramic ball bearing
图 7 刚度削弱系数及其变化率趋势
Figure 7. Change in stiffness weakening coefficient and trend of change rate
图 8 实际接触刚度及其变化率趋势
Figure 8. Change in actual contact stiffness and trend of change rate
图 9 模拟无缺陷与存在缺陷时接触力、时域信号对比
Figure 9. Comparison of contact force and time-domain signal between simulated defect-free and defect-present
图 11 模拟缺陷振动信号和经验模态分解
Figure 11. Simulated defect vibration signal and empirical mode decomposition
图 12 相对峰值高度H与相对深度e映射关系
Figure 12. Mapping relationship between relative peak height H and relative depth e
图 13 MFS-MG机械缺陷综合模拟实验台
Figure 13. MFS-MG mechanical defect synthetic simulating experiment bench
图 15 细观缺陷轴承外圈振动响应
Figure 15. Fine view of vibration response of outer ring of faulty bearing
图 16 实验和仿真亚表面缺陷振动信号频域对比
Figure 16. Frequency domain comparison of vibration signals from experimental and simulated subsurface defects
表 1 全陶瓷球轴承外圈亚表面细观缺陷实验参数
Table 1. Full ceramic ball bearing outer ring sub-surface mesoscopic fault experimental parameters
主轴转速ωs/
(r·min−1)径向载
荷Fr/N轴承型号 采样
频率/Hz1800 300 6304 4096 
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