Method for predicting service life of wear-resistant coating for airplane flap slide rail and roller contact

Abstract

The invention belongs to the technical field of flap slide rail surface wear-resistant coating maintenance design, and particularly relates to an aircraft flap slide rail and roller contact wear-resistant coating life prediction method, which comprises the following steps: step 1, simplifying the movement of a flap slide rail and a roller into relative rolling of two discs, and establishing a relative rolling model of a slide rail disc and a roller disc; 2, based on the relative rolling model of the slide rail disc and the roller disc, calculating the rolling contact stress when the slide rail disc rotates by one circle; and 3, calculating the service life of the wear-resistant coating based on the rolling contact stress generated when the slide rail disc rotates by one circle.

Description

Technical Field

[0001] This application belongs to the technical field of wear-resistant coating maintenance design for flap rail surfaces, specifically relating to a method for predicting the lifespan of wear-resistant coatings in contact between aircraft flap rails and rollers. Background Technology

[0002] The flap rail is a core actuating component controlling an aircraft's lift and drag, and its reliability is directly related to flight safety. There is high-frequency rolling contact between the flap rail and the rollers. To ensure smooth and reliable long-term operation, a high-performance wear-resistant coating is typically applied to the flap rail surface. If this wear-resistant coating peels off or fails due to fatigue, wear, or other reasons, it can cause the flaps to jam during deployment and retraction, potentially leading to serious flight accidents.

[0003] Accurately assessing the service life of the wear-resistant coating on the flap rail surface, and developing a scientific maintenance and replacement plan accordingly, is crucial for ensuring safe aircraft flight. Currently, the service life of the wear-resistant coating is mainly assessed through flight testing, which is time-consuming and costly. Therefore, this application is submitted. Summary of the Invention

[0004] The purpose of this application is to provide a method for predicting the life of wear-resistant coatings in contact with aircraft flap rails and rollers. By combining finite element analysis with fatigue life calculation, the method can efficiently and accurately simulate the failure process of wear-resistant coatings under specific loads, thereby achieving rapid and accurate prediction of the life of wear-resistant coatings and providing support for the development of scientific maintenance and replacement plans.

[0005] The technical solution of this application is:

[0006] A method for predicting the life of wear-resistant coatings in contact between aircraft flap rails and rollers includes:

[0007] Step 1: Simplify the motion of the flap rail and roller into the relative rolling of two disks, and establish a relative rolling model of the rail disk and the roller disk;

[0008] Step 2: Based on the relative rolling model of the slide rail disk and the roller disk, calculate the rolling contact stress of the slide rail disk in one revolution;

[0009] Step 3: Calculate the lifespan of the wear-resistant coating based on the rolling contact stress of the slide rail disc rotating one revolution.

[0010] According to at least one embodiment of this application, in the above-described method for predicting the life of the wear-resistant coating in contact between the aircraft flap slide rail and the roller, in step one, a relative rolling model of the slide rail disk and the roller disk is established in Abaqus software.

[0011] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact between aircraft flap slide rail and roller, in step one, when establishing the relative rolling model of slide rail disk and roller disk, firstly, draw two-dimensional planar models of slide rail disk and roller disk to ensure the intersection of slide rail disk and roller disk, and then assemble the two-dimensional planar models of slide rail disk and roller disk to make the surfaces of slide rail disk and roller disk contact.

[0012] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact between aircraft flap slide rail and roller, in step one, the basic material parameters of the slide rail disc and roller disc are set, including mass density, elastic modulus and Poisson's ratio.

[0013] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact between aircraft flap slide rail and roller, in step one, the basic material parameters of the slide rail disc are set with reference to titanium alloy.

[0014] The basic material parameters of the roller disc are set with reference to steel.

[0015] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact between aircraft flap slide rail and roller, in step two, the relative rolling model of slide rail disk and roller disk is meshed, the unit size is set to 0.2, and a contact calculation point is set every 0.2 mm.

[0016] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact between aircraft flap slide rail and roller, in step two, the friction formula adopts Lagrange multipliers for the tangential behavior of the slide rail disk and the roller disk.

[0017] For the normal constraints of the slide rail disk and roller disk, a penalty function is used.

[0018] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact between aircraft flap slide rail and roller, in step two, the stiffness ratio factor of the slide rail disk and the roller disk is set to a small value of 0.1.

[0019] According to at least one embodiment of this application, in the above-described method for predicting the life of the wear-resistant coating in contact with the aircraft flap slide rail and roller, in step two, contact control is added to the slide rail disc and roller disc to accelerate convergence.

[0020] According to at least one embodiment of this application, in the above-described method for predicting the life of wear-resistant coating in contact between aircraft flap rails and rollers, step two includes setting up analysis step one to simulate indentation stress conditions and setting up analysis step two to simulate rolling contact.

[0021] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact between aircraft flap slide rail and roller, in step two, the displacement and degree of freedom of the slide rail disk and roller disk are set according to the simulated working conditions.

[0022] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact between aircraft flap slide rail and roller, in step two, the rolling contact stress of the slide rail disk rotating one revolution is calculated by full integration.

[0023] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact with aircraft flap rails and rollers, in step three, the post-processing file of Abaqus software is imported into Fesafe software for co-simulation, and the wear-resistant coating is used as the analysis group in Fesafe software.

[0024] According to at least one embodiment of this application, in the above-described method for predicting the life of wear-resistant coating in contact with aircraft flap rails and rollers, in step three, the tensile strength and elastic modulus of the wear-resistant coating are set in Fesafe software, and the SN curve of the wear-resistant coating is corrected using Goodman curves.

[0025] According to at least one embodiment of this application, in the above-mentioned method for predicting the life of wear-resistant coating in contact with aircraft flap slide rail and roller, in step three, the analysis step and time corresponding to one revolution of the wear-resistant coating on the slide rail disk are found, submitted in Fesafe software, and the life of the wear-resistant coating is calculated.

[0026] This application has at least the following beneficial technical effects:

[0027] This paper presents a method for predicting the life of wear-resistant coatings in contact between aircraft flap rails and rollers. The method simplifies the three-dimensional spatial motion of the flap rails and rollers into the relative rolling of two disks in a two-dimensional plane, making the motion of the flap rails and rollers straightforward. Abaqus and Fesafe software are used in conjunction to simulate the rolling contact behavior of the rails and rollers, calculating the rolling contact stress of the rail disks in one revolution. This reduces rolling contact stress errors. Fatigue life calculations are then performed on the wear-resistant coating on the rail surface, enabling rapid and accurate prediction of the wear-resistant coating's lifespan. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the method for predicting the life of the wear-resistant coating in contact with the aircraft flap rail and roller provided in the embodiments of this application;

[0029] Figure 2 This is a schematic diagram provided in the embodiments of this application, which simplifies the movement of the flap slide rail and rollers to the relative rolling of two discs.

[0030] To better illustrate this embodiment, some content in the accompanying drawings may be omitted, enlarged, or reduced. They are for illustrative purposes only and should not be construed as limiting the scope of this application. Detailed Implementation

[0031] To make the technical solution and advantages of this application clearer, the technical solution of this application will be described in a clearer and more complete manner below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only some embodiments of this application, and are only used to explain this application, not to limit this application. It should be noted that, for ease of description, only the parts related to this application are shown in the accompanying drawings, and other related parts can be referred to the general design.

[0032] Furthermore, unless otherwise defined, the technical or scientific terms used in this application description shall have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The word "comprising" as used in this application description indicates that the concept preceding the word encompasses the concepts listed following the word and their equivalents, without excluding other related concepts.

[0033] A method for predicting the lifespan of wear-resistant coatings in contact between aircraft flap rails and rollers, such as... Figure 1 As shown, based on the movement attitude of the flaps during aircraft takeoff and landing, the three-dimensional spatial motion of the flap rail and rollers is simplified to the relative rolling of two disks in a two-dimensional plane, as follows: Figure 2 As shown, the disc representing the slide rail is made of titanium alloy with a wear-resistant coating, while the disc representing the roller is made of steel. The Abquas software is used to simulate the rolling contact behavior of the slide rail disc and the roller disc, and the rolling contact stress within one rotation cycle of the slide rail disc is calculated. Then, the Abquas and Fesafe software are combined to calculate the fatigue life of the wear-resistant coating on the slide rail surface under the rolling contact stress, thereby achieving a fast and accurate prediction of the service life of the wear-resistant coating.

[0034] Step 1: Simplify the motion of the flap rail and roller into the relative rolling of two disks, and establish a relative rolling model of the rail disk and the roller disk.

[0035] To create a relative rolling model of the slide rail disk and roller disk in Abaqus software, first, draw a two-dimensional planar model of the slide rail disk and roller disk, ensuring the intersection of the slide rail disk and roller disk. Then, assemble the two-dimensional planar models of the slide rail disk and roller disk so that the surfaces of the slide rail disk and roller disk are in contact, thus obtaining the relative rolling model of the slide rail disk and roller disk.

[0036] Set the basic material parameters for the slide rail disc and roller disc, including mass density, elastic modulus and Poisson's ratio. The basic material parameters for the slide rail disc are set with reference to titanium alloy, and the basic material parameters for the roller disc are set with reference to steel.

[0037] Step 2: Based on the relative rolling model of the slide rail disk and the roller disk, calculate the rolling contact stress of the slide rail disk in one revolution.

[0038] The relative rolling model of the slide rail disk and the roller disk is meshed with an element size of 0.2 and a contact calculation point is set every 0.2 mm.

[0039] For the tangential behavior of slide rail disks and roller disks, the friction formula uses Lagrange multipliers to strictly satisfy the no-penetration condition.

[0040] For the normal constraints of the slide rail disk and roller disk, a penalty function is used.

[0041] Set a small stiffness scaling factor for the slide rail disk and roller disk, for example, 0.1.

[0042] Contact control is added to the slide rail disk and roller disk to accelerate convergence.

[0043] Set up analysis step one to simulate the indentation stress condition, and set up analysis step two to simulate rolling contact.

[0044] The displacement and degrees of freedom of the slide rail disk and roller disk are set according to the simulated working conditions.

[0045] The rolling contact stress of the slide rail disk in one revolution is calculated using full integration.

[0046] Step 3: Calculate the lifespan of the wear-resistant coating based on the rolling contact stress and calculation time of one revolution of the slide rail disc.

[0047] The post-processed files from Abaqus software were imported into Fesafe software for co-simulation, with the wear-resistant coating used as the analysis group in Fesafe software.

[0048] In Fesafe software, the tensile strength and elastic modulus of the wear-resistant coating are set, and the SN curve of the wear-resistant coating is corrected using Goodman curves.

[0049] Find the analysis step and time corresponding to one revolution of the wear-resistant coating on the slide rail disk, submit it in Fesafe software, and calculate the life of the wear-resistant coating.

[0050] The method for predicting the life of the wear-resistant coating in the contact between the aircraft flap rail and the roller disclosed in the above embodiments simplifies the three-dimensional spatial motion process of the flap rail and the roller into the relative rolling of two disks in a two-dimensional plane, making the motion of the flap rail and the roller simple and clear. The method uses Abaqus software and Fesafe software to jointly simulate the rolling contact behavior of the rail and the roller, calculates the rolling contact stress of the rail disk in one revolution, which can reduce the contact stress error, calculate the fatigue life of the wear-resistant coating on the rail surface, and realize the rapid and accurate prediction of the service life of the wear-resistant coating.

[0051] The technical solution of this application has been described in conjunction with the preferred embodiments shown in the accompanying drawings. Those skilled in the art should understand that the scope of protection of this application is obviously not limited to these specific embodiments. Without departing from the principles of this application, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of this application.

Claims

1. A method for predicting the lifespan of a wear-resistant coating in contact between an aircraft flap rail and a roller, characterized in that, include: Step 1: Simplify the motion of the flap rail and roller into the relative rolling of two disks, and establish a relative rolling model of the rail disk and the roller disk; Step 2: Based on the relative rolling model of the slide rail disk and the roller disk, calculate the rolling contact stress of the slide rail disk in one revolution; Step 3: Calculate the lifespan of the wear-resistant coating based on the rolling contact stress of the slide rail disc rotating one revolution.

2. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 1, characterized in that, In step one, a relative rolling model of the slide rail disk and the roller disk is created in the Abaqus software.

3. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 2, characterized in that, In step one, when establishing the relative rolling model of the slide rail disk and the roller disk, firstly, draw the two-dimensional planar model of the slide rail disk and the roller disk to ensure the intersection of the slide rail disk and the roller disk. Then, assemble the two-dimensional planar model of the slide rail disk and the roller disk so that the surfaces of the slide rail disk and the roller disk are in contact.

4. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap rail and roller according to claim 3, characterized in that, In step one, the basic material parameters of the slide rail disk and roller disk are set, including mass density, elastic modulus and Poisson's ratio.

5. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 4, characterized in that, In step one, the basic material parameters of the slide rail disc are set with reference to titanium alloy; The basic material parameters of the roller disc are set with reference to steel.

6. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 5, characterized in that, In step two, the relative rolling model of the slide rail disk and the roller disk is meshed, with the element size set to 0.2 and a contact calculation point set every 0.2 mm.

7. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 6, characterized in that, In step two, the friction formula uses Lagrange multipliers for the tangential behavior of the slide rail disk and the roller disk. For the normal constraints of the slide rail disk and roller disk, a penalty function is used.

8. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 7, characterized in that, In step two, the stiffness scaling factor of the slide rail disk and roller disk is set to a smaller value of 0.

1.

9. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 8, characterized in that, In step two, contact control is added to the slide rail disk and roller disk to accelerate convergence.

10. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 9, characterized in that, In step two, analysis step one is set up to simulate the indentation stress condition, and analysis step two is set up to simulate rolling contact.

11. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap rail and roller according to claim 10, characterized in that, In step two, the displacement and degrees of freedom of the slide rail disk and roller disk are set according to the simulated working conditions.

12. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 11, characterized in that, In step two, the rolling contact stress of the slide rail disk rotating one revolution is calculated using full integration.

13. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 12, characterized in that, In step three, the post-processing files from Abaqus software are imported into Fesafe software for co-simulation, with the wear-resistant coating used as the analysis group in Fesafe software.

14. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap slide rail and roller according to claim 13, characterized in that, In step three, the tensile strength and elastic modulus of the wear-resistant coating are set in the Fesafe software, and the SN curve of the wear-resistant coating is corrected using the Goodman curve.

15. The method for predicting the lifespan of the wear-resistant coating in contact with the aircraft flap rail and roller according to claim 14, characterized in that, In step three, find the analysis step and time corresponding to one revolution of the wear-resistant coating on the slide rail disk, submit it in the Fesafe software, and calculate the life of the wear-resistant coating.

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