Key weak position wear analysis method and system
By combining finite element contact analysis and Archard adhesive wear model, a wear analysis method for key weak positions was established, which solved the problem of inaccurate wear assessment in traditional methods, achieved accurate wear assessment and life prediction under multiple working conditions, and provided reliable data support.
Patent Information
- Application Number
- CN202510776627.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-11
- Publication Date
- 2025-09-19
AI Technical Summary
Existing technologies make it difficult to efficiently and accurately assess the wear of key connecting components such as anchor chains and pins in offshore operating environments under multiple working conditions. Traditional methods are insufficiently accurate or have excessively high computational costs, and fail to fully consider factors such as sea conditions, ship speed, cable length, and vibration frequency.
Combining finite element contact analysis and Archard adhesive wear model, a local finite element model was established by screening key weak locations, and mesh convergence was verified. The Archard model was used to calculate the wear depth and volume, and a wear database was constructed, which was corrected based on the experimental data.
It achieves accurate assessment of wear at key weak locations under multiple working conditions. The results are close to reality, providing a basis for ultimate strength analysis and service life assessment, and improving the accuracy and reliability of the assessment.
Smart Images
Figure CN120671456A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of material wear, and in particular to a method and system for analyzing wear at key weak locations. Background Art
[0002] The offshore operating environment is extremely complex. Over the long term, key connecting components such as anchor chains and pins are subject to various forms of wear, including adhesive wear, fatigue wear, and fretting wear, which can affect the overall operational safety of the equipment. Traditional wear assessment methods often rely on simplified tests or empirical formulas, which struggle to accurately account for factors such as sea conditions, ship speed, cable length, vibration frequency, and material nonlinearity, resulting in inaccurate results. Alternatively, large-scale simulations are employed, but these methods are computationally expensive and have limitations in terms of contact boundary conditions and mesh convergence.
[0003] Therefore, there is an urgent need for a systematic wear analysis method and system for key weak locations, which can predict and evaluate the actual service wear conditions of key weak components under multiple working conditions based on the finite element method and combined with the adhesive wear theory of Archard and others, and provide corresponding data support to lay the foundation for subsequent ultimate strength analysis and service life assessment. Summary of the Invention
[0004] The present invention aims to overcome the shortcomings of existing technologies in comprehensively analyzing wear at critical weak points in towing systems, making it difficult to efficiently and accurately determine wear depth and wear rate under multiple operating conditions. This method provides a wear analysis method and system for critical weak points. This method combines finite element contact analysis with the Archard adhesive wear model to quantitatively assess wear under various sea conditions, speeds, cable lengths, and vibration frequencies, further providing an accurate basis for ultimate strength analysis and service life prediction.
[0005] The purpose of the present invention is to achieve the following technical solution: a method for analyzing wear at key weak positions, comprising the following steps:
[0006] S1. Screening of key weak locations: Select several key weak locations and their material parameters on the target component to determine the mating friction pairs and mechanical properties of the key weak locations;
[0007] S2. Construct a model of key weak locations, establish a local finite element model of the key weak locations and verify mesh convergence, using a refined mesh in the contact area;
[0008] S3. Perform wear analysis using the Archard adhesive wear model to extract the contact pressure and sliding distance of the contact unit at each load step, and calculate the wear depth and wear volume of each key component in a typical time;
[0009] S4. Build a wear analysis system to collect statistics on wear data under various working conditions, perform batch calculations, and form a database of wear at key weak locations. Interpolate or extrapolate the database, and continuously revise it in combination with test monitoring data.
[0010] As a further technical solution, S1 includes the following steps:
[0011] S1.1. Screen key weak points on target components based on project requirements;
[0012] S1.2. Determine the materials of each key weak point and the mating friction pair materials, and obtain their yield strength, ultimate strength, cross-sectional elongation, elastic modulus, and Poisson's ratio.
[0013] As a further technical solution, S2 includes the following steps:
[0014] S2.1. Establish local finite element models of key weak locations and mating parts, using solid elements and surface-to-surface contact pairs to simulate contact relationships;
[0015] S2.2. Verify the convergence of the mesh density based on the structural characteristics and service environment of the target component, especially refining the contact area.
[0016] S2.3. Select the contact algorithm and adjust the contact stiffness factor FKN and friction coefficient to ensure the accuracy and convergence of the simulation calculation.
[0017] As a further technical solution, in S2.3, a bilinear kinematic reinforcement material model is used to handle material nonlinearity, and the contact stiffness factor FKN is adjusted in combination with the contact algorithm to achieve a balance between contact stress and penetration error, ensure the accuracy and convergence of wear calculations, and apply vibration loads or cyclic loads; the contact algorithm is the augmented Lagrangian method.
[0018] As a further technical solution, S3 includes the following steps:
[0019] S3.1. Combine sea state level, ship speed, and cable length to extract typical load-time curves under each operating condition;
[0020] S3.2. Consider the impact and slip effects of the vibration frequency on the mating pair and divide each typical cycle into multiple load steps for simulation;
[0021] S3.3. Combined with the adhesive wear mechanism, the Archard model is selected to calculate the wear depth;
[0022] S3.4. In finite element analysis, the total wear amount is accumulated by summing the contact pressure and sliding distance of the contact surface at each load step. The wear amount is mapped to the model geometry or post-processed to obtain the maximum / average wear depth, wear velocity, and wear volume per unit time.
[0023] As a further technical solution, in S3, when performing wear analysis, torsion and out-of-plane bending effects are considered separately. When the torsion and bending angles are less than the preset threshold, only pure tensile effects are retained for simplified calculations. The movement mode is simulated through the structural form, vibration frequency and periodic changes of load at key weak positions, and the wear distribution is calculated using a simplified model. The numerical accuracy is checked through comparative tests of different models.
[0024] As a further technical solution, S4 includes the following steps:
[0025] S4.1. Perform batch calculations for different combinations of sea conditions, ship speeds, cable lengths, and vibration frequencies, and interpolate or extrapolate the wear data for all these combinations to form a database of "sea conditions - ship speed - cable length - vibration frequency - wear";
[0026] S4.2. Provide the database for subsequent ultimate strength analysis and remaining life assessment, and make corrections based on actual test data; in actual engineering, regularly measure key weak points and match the database information to make wear predictions and maintenance decisions.
[0027] As a further technical solution, in S4.1, when performing batch calculations for multiple working conditions, the sea state level, ship speed, cable length and vibration frequency are gridded and combined, and interpolation or extrapolation is used to obtain the wear results under any intermediate working condition.
[0028] A key weak point wear analysis system, comprising:
[0029] The data acquisition module is used to collect and store the geometric dimensions of key weak points, material mechanical properties, and measured loads, vibration frequencies, cable lengths, and ship speeds under various working conditions;
[0030] Finite element modeling module, used to establish local finite element models based on geometric models and contact algorithms, and define contact elements and material nonlinearity;
[0031] The wear simulation module is used to call the Archard model to iteratively calculate the contact pressure and sliding distance to obtain the wear depth of each node under a specific load step; it accumulates the total wear per unit time or typical cycle and outputs the wear depth and wear volume;
[0032] A database generation module is used to establish a database based on the wear results of key weak locations under various working conditions and the service conditions as dimensions; and
[0033] The output and visualization module is used to visualize the calculation results and time history data, and combine them with wear rate information to achieve a comprehensive prediction of service life and subsequent strength.
[0034] A computer-readable storage medium stores a computer program, which, when executed by a processor, implements the above-mentioned key weak position wear analysis method.
[0035] The beneficial effects of the present invention are:
[0036] 1. Adaptability to multiple working conditions: Wear calculation can be performed based on combined working conditions such as sea state level, ship speed, cable length, vibration frequency, etc., and the results are applicable to a wide range of conditions;
[0037] 2. High Accuracy: By combining finite element simulation with the Archard adhesive wear model, and comprehensively considering factors such as contact pressure, sliding distance, material hardness, and vibration frequency, the wear results obtained are closer to actual service conditions;
[0038] 3. Scalability: The established database of "sea conditions - ship speed - cable length - vibration frequency - wear depth" can be continuously updated and revised with subsequent test data;
[0039] 4. Reliability verification: Through comparative verification of simplified models, it is proved that the influence of contact stiffness factor FKN, mesh density selection, etc. on the results is within a controllable range and can meet the accuracy requirements of engineering applications. BRIEF DESCRIPTION OF THE DRAWINGS
[0040] Figure 1 Schematic diagram of the process of the method in the embodiment of the present invention.
[0041] Figure 2 Schematic diagram of the structure of the key weak position wear analysis system in an embodiment of the present invention. DETAILED DESCRIPTION
[0042] The present invention will be described in detail below with reference to the accompanying drawings:
[0043] Example 1: As shown in the attached Figure 1 As shown, a wear analysis method for key weak positions includes the following steps:
[0044] S1. Screening of key weak locations: Select several key weak locations on the target component and determine the matching friction pairs and mechanical properties of the key weak locations based on material performance parameters, providing initial conditions for subsequent finite element modeling and friction pair analysis.
[0045] Furthermore, S1 also includes:
[0046] S1.1. Screen key weak points on target components based on project requirements;
[0047] S1.2. Determine the materials of each key weak point and the mating friction pair materials, such as TC4, TA15, CM690, etc., and obtain their mechanical properties such as yield strength, ultimate strength, elongation, elastic modulus, Poisson's ratio, etc.
[0048] S2. Construct a model of key weak locations, establish a local finite element model of the key weak locations and verify mesh convergence, using a refined mesh in the contact area;
[0049] Furthermore, S2 also includes:
[0050] S2.1. Establish local finite element models of key weak locations and mating parts, using solid elements and surface-to-surface contact pairs to simulate contact relationships;
[0051] S2.2. Verify the convergence of the mesh density based on the structural characteristics and service environment of the target component, especially refining the contact area.
[0052] S2.3. Select appropriate contact algorithms such as the augmented Lagrangian method, and adjust the contact stiffness factor FKN and friction coefficient to ensure the accuracy and convergence of the simulation calculation.
[0053] Preferably, in S2.3, the bilinear kinematic hardening material model (BKIN) is used to handle material nonlinearity, and the contact stiffness factor FKN is adjusted in combination with the contact algorithm to achieve a balance between contact stress and penetration error, ensure the accuracy and convergence of wear calculation, and apply vibration load or cyclic load.
[0054] S3. Perform wear analysis using the Archard adhesive wear model to extract the contact pressure and sliding distance of the contact unit at each load step, and calculate the wear depth and wear volume of each key component within 1 hour or other typical time;
[0055] Furthermore, S3 also includes:
[0056] S3.1. Combine sea state level, ship speed, and cable length to extract typical load-time curves under each operating condition;
[0057] S3.2. Consider the impact and slip effects of the vibration frequency on the mating pair and divide each typical cycle into multiple load steps for simulation;
[0058] S3.3. Combined with the adhesive wear mechanism, the Archard model is selected to calculate the wear depth;
[0059] S3.4. In finite element analysis, the total wear volume is accumulated by summing the contact pressure and sliding distance at each load step on the contact surface. The wear volume is then mapped to the model geometry or post-processed to obtain the maximum / average wear depth, wear velocity, and wear volume within a 1-hour or other time period (unit time). The maximum wear location is analyzed, and the wear depth and total wear volume are calculated at different times. This is then combined with the frequency to convert it into hourly wear velocity. An interpolation function for "vibration frequency-wear depth" is established, and the maximum wear depth distribution within a 1-hour period is obtained under different sea conditions and cable lengths.
[0060] Preferably, in S3, when performing wear analysis, torsion and out-of-plane bending effects are considered separately. When the torsion and bending angles are less than a preset threshold (for example, 0.05°), only pure tensile effects can be retained for simplified calculations. The motion mode is simulated by the structural form, vibration frequency and periodic changes of load at key weak positions, and the wear distribution is calculated using a simplified model. The numerical accuracy is checked through comparative tests of different models.
[0061] S4. Construction of a wear analysis system. By integrating finite element simulation results, statistics on wear data under various working conditions (sea state level, cable length, and different vibration frequencies) are collected for batch calculation to form a database of wear at key weak locations. Interpolation or extrapolation is performed on this database to quickly query the wear level and wear rate of key weak locations under any working condition (sea state level, speed, cable length, vibration frequency). This can be used for dynamic evaluation during service or for continuous revision of the model in combination with test monitoring data.
[0062] Furthermore, S4 also includes:
[0063] S4.1. Perform batch calculations on combined working conditions of different sea conditions, ship speeds, cable payout lengths, and vibration frequencies, and interpolate or extrapolate the wear data of all combined working conditions to form a database of "sea condition - ship speed - cable payout length - vibration frequency - wear amount". Preferably, in S4.1, when performing batch calculations of multiple working conditions, grid-based combinations of sea condition levels, ship speeds, cable payout lengths, and vibration frequencies are performed, and wear results under any intermediate working condition are obtained by interpolation or extrapolation.
[0064] S4.2. Provide the database for subsequent ultimate strength analysis and remaining life assessment, and make corrections based on actual test data; in actual engineering, regularly measure key weak points and match the database information to make wear predictions and maintenance decisions.
[0065] Example 2: Figure 2 As shown, as an implementation of the method described in Example 1, a key weak position wear analysis system is provided in Example 2, including:
[0066] The data acquisition module can collect and store the geometric dimensions of key weak points, material mechanical properties, and external data such as measured load, vibration frequency, cable length, and ship speed under various working conditions;
[0067] Finite element modeling module, which can establish local finite element models based on geometric models and contact algorithms, and define contact elements and material nonlinearity;
[0068] The wear simulation module can call the Archard model to iteratively calculate the contact pressure and sliding distance to obtain the wear depth of each node under a specific load step; accumulate the total wear per unit time or typical cycle, and output the wear depth and wear volume;
[0069] A database generation module that can build a database based on the wear results (maximum wear depth, average wear depth, wear volume, etc.) of key weak points under various operating conditions and based on the service conditions (sea state level, speed, cable length, vibration frequency, etc.); and
[0070] The output and visualization module can visualize the calculation results and time history data to facilitate subsequent analysis, and combine with wear rate information to achieve a comprehensive prediction of service life and subsequent strength.
[0071] Example 3: The method described in Example 1, refer to the flow chart (attached Figure 1 The process described in the above may be implemented as a computer software program. For example, a computer readable storage medium may store a computer program containing a program for executing the process. Figure 1 Meanwhile, the program can be downloaded and installed from the network via a communication device, or installed from a storage device.
[0072] The computer-readable storage medium described in some embodiments of the present invention may be, but is not limited to, an electrical, magnetic, optical, electromagnetic, or semiconductor system, device or component, or any combination thereof. More specific examples of computer-readable storage media may include, but are not limited to, a portable computer disk, a hard disk, a random access memory (main memory), an optical fiber, an optical storage device, a magnetic storage device, or any suitable combination thereof having one or more wires. In some embodiments of the present invention, a computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, device or component. The program code contained on the computer-readable storage medium may be transmitted using any appropriate medium, including but not limited to: wires, optical cables, etc., or any suitable combination thereof.
[0073] The present invention provides a wear analysis method and system for key weak locations. By using finite element analysis and the Archard adhesive wear model, combined with multi-condition loads of different sea conditions, ship speeds, cable lengths, and vibration frequencies, the wear distribution of key weak locations is accurately calculated. By constructing a corresponding wear database, a reliable basis can be provided for service status monitoring, maintenance decision-making, and ultimate strength assessment of components in marine engineering, thereby improving the safety and economy of system operation.
[0074] It is understandable that for those skilled in the art, any equivalent replacement or change to the technical solution and inventive concept of the present invention should fall within the scope of protection of the claims attached to the present invention.
Claims
1. A method for analyzing wear at key weak points, characterized in that: The following steps are involved: S1. Screening of key weak locations: Select several key weak locations and their material parameters on the target component to determine the mating friction pairs and mechanical properties of the key weak locations; S2. Construct a model of key weak locations, establish a local finite element model of the key weak locations and verify mesh convergence, using a refined mesh in the contact area; S3. Perform wear analysis using the Archard adhesive wear model to extract the contact pressure and sliding distance of the contact unit at each load step, and calculate the wear depth and wear volume of each key component in a typical time; S4. Build a wear analysis system to collect statistics on wear data under various working conditions, perform batch calculations, and form a database of wear at key weak locations. Interpolate or extrapolate the database, and continuously revise it in combination with test monitoring data.
2. The critical weak position wear analysis method according to claim 1, characterized in that: Said S1 comprises the following steps: S1.
1. Screen key weak points on target components based on project requirements; S1.
2. Determine the materials of each key weak point and the mating friction pair materials, and obtain their yield strength, ultimate strength, cross-sectional elongation, elastic modulus, and Poisson's ratio.
3. The critical weak position wear analysis method according to claim 1, characterized in that: The S2 comprises the following steps: S2.
1. Establish local finite element models of key weak locations and mating parts, using solid elements and surface-to-surface contact pairs to simulate contact relationships; S2.
2. Verify the convergence of the mesh density based on the structural characteristics and service environment of the target component, especially refining the mesh in the contact area. S2.
3. Select the contact algorithm and adjust the contact stiffness factor FKN and friction coefficient to ensure the accuracy and convergence of the simulation calculation.
4. The wear analysis method for key weak points according to claim 3, characterized in that: In S2.3, a bilinear kinematic reinforcement material model is used to handle material nonlinearity, and the contact stiffness factor FKN is adjusted in combination with the contact algorithm to achieve a balance between contact stress and penetration error, ensure the accuracy and convergence of wear calculation, and apply vibration load or cyclic load; the contact algorithm is the augmented Lagrangian method.
5. The critical weak position wear analysis method according to claim 1, characterized in that: The S3 includes the following steps: S3.
1. Combine sea state level, ship speed, and cable length to extract typical load-time curves under each operating condition; S3.
2. Consider the impact and slip effects of the vibration frequency on the mating pair and divide each typical cycle into multiple load steps for simulation; S3.
3. Combined with the adhesive wear mechanism, the Archard model is selected to calculate the wear depth; S3.
4. In finite element analysis, the total wear amount is accumulated by summing the contact pressure and sliding distance of the contact surface at each load step. The wear amount is mapped to the model geometry or post-processed to obtain the maximum / average wear depth, wear velocity, and wear volume per unit time.
6. The critical weak position wear analysis method according to claim 1, characterized in that: In S3, when performing wear analysis, torsion and out-of-plane bending effects are considered separately. When the torsion and bending angles are less than the preset thresholds, only pure tensile effects are retained for simplified calculations. The motion mode is simulated through the structural form, vibration frequency and periodic changes of load at key weak positions, and the wear distribution is calculated using a simplified model. The numerical accuracy is checked through comparative tests of different models.
7. The critical weak position wear analysis method according to claim 1, characterized in that: The S4 comprises the following steps: S4.
1. Perform batch calculations for different combinations of sea conditions, ship speeds, cable lengths, and vibration frequencies, and interpolate or extrapolate the wear data for all these combinations to form a database of "sea conditions - ship speed - cable length - vibration frequency - wear"; S4.
2. Provide the database for subsequent ultimate strength analysis and remaining life assessment, and make corrections based on actual test data; in actual engineering, regularly measure key weak points and match the database information to make wear predictions and maintenance decisions.
8. The critical weak position wear analysis method according to claim 7, characterized in that: In S4.1, when performing batch calculations for multiple working conditions, the sea state level, ship speed, cable length and vibration frequency are gridded and combined, and the wear results under any intermediate working condition are obtained by interpolation or extrapolation.
9. A key weak point wear analysis system, characterized in that: include: The data acquisition module is used to collect and store the geometric dimensions of key weak points, material mechanical properties, and measured loads, vibration frequencies, cable lengths, and ship speeds under various working conditions; Finite element modeling module, used to establish local finite element models based on geometric models and contact algorithms, and define contact elements and material nonlinearity; The wear simulation module is used to call the Archard model to iteratively calculate the contact pressure and sliding distance to obtain the wear depth of each node under a specific load step; it accumulates the total wear per unit time or typical cycle and outputs the wear depth and wear volume; A database generation module is used to establish a database based on the wear results of key weak locations under various working conditions with the service condition as the dimension; and The output and visualization module is used to visualize the calculation results and time history data, and combine them with wear rate information to achieve a comprehensive prediction of service life and subsequent strength.
10. A computer-readable storage medium, characterized in that: The storage medium stores a computer program, and when the computer program is executed by a processor, the method steps according to any one of claims 1 to 8 are implemented.