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Liu W, Shan L, Lin Z, Wan B, Yang B, Zeng X, Yang B, Pelenovich V. Dual-Wave ZnO Film Ultrasonic Transducers for Temperature and Stress Measurements. SENSORS (BASEL, SWITZERLAND) 2024; 24:5691. [PMID: 39275602 PMCID: PMC11398250 DOI: 10.3390/s24175691] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/05/2024] [Revised: 08/20/2024] [Accepted: 08/24/2024] [Indexed: 09/16/2024]
Abstract
ZnO film ultrasonic transducers for temperature and stress measurements with dual-mode wave excitation (longitudinal and shear) were deposited using the reactive RF magnetron sputtering technique on Si and stainless steel substrates and construction steel bolts. It was found that the position in the substrate plane had a significant effect on the structure and ultrasonic performance of the transducers. The transducers deposited at the center of the deposition zone demonstrated a straight columnar structure with a c-axis parallel to the substrate normal and the generation of longitudinal waves. The transducers deposited at the edge of the deposition zone demonstrated inclined columnar structures and the generation of dominant shear or longitudinal shear waves. Transducers deposited on the bolts with dual-wave excitation were used to study the effects of high temperatures in the range from 25 to 525 °C and tensile stress in the range from 0 to 268 MPa on ultrasonic response. Dependencies between changes in the relative time of flight and temperature or axial stress were obtained. The dependencies can be described by second-order functions of temperature and stress. An analysis of the contributions of thermal expansion, strain, and the speed of sound to changes in the time of flight was performed. At high temperatures, a decrease in the signal amplitude was observed due to the decreasing resistivity of the transducer. The ZnO ultrasonic transducers can be used up to temperatures of ~500 °C.
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Affiliation(s)
- Wentao Liu
- Aerospace Precision Products Inc., Ltd., Tianjin 300300, China
| | - Longlong Shan
- Aerospace Precision Products Inc., Ltd., Tianjin 300300, China
| | - Zhongliang Lin
- Aerospace Precision Products Inc., Ltd., Tianjin 300300, China
| | - Binghua Wan
- Aerospace Precision Products Inc., Ltd., Tianjin 300300, China
| | - Bin Yang
- Aerospace Precision Products Inc., Ltd., Tianjin 300300, China
| | - Xiaomei Zeng
- Institute of Technological Sciences, Wuhan University, Wuhan 430072, China
- School of Power & Mechanical Engineering, Wuhan University, Wuhan 430072, China
| | - Bing Yang
- School of Power & Mechanical Engineering, Wuhan University, Wuhan 430072, China
| | - Vasiliy Pelenovich
- Institute of Technological Sciences, Wuhan University, Wuhan 430072, China
- School of Power & Mechanical Engineering, Wuhan University, Wuhan 430072, China
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Luo L, Fan J, Ma J, Chen W, Song W, Bao S. A nonlinear ultrasonic wave mixing method for looseness detection of bolted joints. ULTRASONICS 2024; 142:107402. [PMID: 39013349 DOI: 10.1016/j.ultras.2024.107402] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/27/2024] [Revised: 06/30/2024] [Accepted: 07/09/2024] [Indexed: 07/18/2024]
Abstract
Bolted joints are widely used in various machines and engineering structures. The tightening state of bolts directly affects the reliability and safety of bolted joints. Therefore, the bolt looseness detection is very important to ensure the reliability of bolted joints. In this paper, a novel nonlinear ultrasonic wave mixing method is proposed for looseness detection of bolted joints. The basic theory of the nonlinear ultrasonic wave mixing method for detecting the bolt looseness is established. Based on the detection theory, a nonlinear modulation index is defined to quantify the level of bolt looseness. An experimental setup is built to implement the nonlinear ultrasonic wave mixing detection method on bolted joints. Experiments are conducted on two bolted joints with different materials and sizes. The influences of excitation frequencies and voltages of two ultrasonic signals on the detection performance are investigated experimentally. A method is proposed for the selection of appropriate excitation frequencies to improve the detection performance. The experimental results demonstrate that the proposed method can effectively detect bolt looseness and it has good detection sensitivity to the early bolt loosening.
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Affiliation(s)
- Lijia Luo
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310014, China.
| | - Jingjing Fan
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310014, China
| | - Junming Ma
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310014, China
| | - Wenfei Chen
- Ningbo Special Equipment Inspection & Research Institute, Ningbo 315048, China
| | - Wei Song
- Xinjiang Uygur Autonomous Region Inspection Institute of Special Equipment, Urumqi 830011, China
| | - Shiyi Bao
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310014, China
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Lu X, Zhu M, Li C, Li S, Wang S, Li Z. Prediction of Pre-Loading Relaxation of Bolt Structure of Complex Equipment under Tangential Cyclic Load. SENSORS (BASEL, SWITZERLAND) 2024; 24:3306. [PMID: 38894098 PMCID: PMC11174751 DOI: 10.3390/s24113306] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/28/2024] [Revised: 05/18/2024] [Accepted: 05/20/2024] [Indexed: 06/21/2024]
Abstract
Bolts have the advantages of simple installation and easy removal. They are widely applied in aerospace and high-speed railway traffic. However, the loosening of bolts under mixed loads can lead to nonlinear decreases in pre-loading. This affects the safety performance of the structure and may lead to catastrophic consequences. Existing techniques cannot be used to monitor the bolt performance status in time. This has caused significant problems with the safety and reliability of equipment. In order to study the relaxation law of bolt pre-loading, this paper carries out an experimental analysis for 8.8-grade hexagonal bolts and calibrates the torque coefficient. We also studied different loading waveforms, nickel steel plate surface roughnesses, tangential displacement frequencies, four different strengths and bolt head contact areas of the bolt, the initial pre-loading, and the effects of tangential cyclic displacement on pre-loading relaxation. This was done in order to accurately predict the degree of bolt pre-loading loosening under external loads. The laws are described using the allometric model function and the nine-stage polynomial function. The least squares method is used to identify the parameters in the function. The results show that bolts with a smooth surface of the connected structure nickel steel flat plate, high-frequency working conditions, half-sine wave, and a high-strength have better anti-loosening properties. Taking 5-10 cycles of cyclic loading as a boundary, the pre-loading relaxation is divided into two stages. The first stage is a stage of rapid decrease in bolt pre-loading, and the second stage is the slow decrease process. The performance prediction study shows that the allometric model function is the worst fitted, at 71.7% for the small displacement condition. Other than that, the allometric model function and the nine-stage polynomial function can predict more than 85.5% and 90.4%, which require the use of least squares to identify two and ten unknown parameters, respectively. The complexity of the two is different, but both can by better indicators than the pre-loading relaxation law under specific conditions. It helps to improve the monitoring of bolt loosening and the system use cycle, and it can provide theoretical support for complex equipment working for a long time.
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Affiliation(s)
- Xiaohan Lu
- College of Nuclear Science and Technology, Naval University of Engineering, Wuhan 430033, China
| | - Min Zhu
- College of Nuclear Science and Technology, Naval University of Engineering, Wuhan 430033, China
| | - Chao Li
- College of Nuclear Science and Technology, Naval University of Engineering, Wuhan 430033, China
| | - Shengnan Li
- College of Power Engineering, Naval University of Engineering, Wuhan 430033, China
| | - Shengao Wang
- College of Nuclear Science and Technology, Naval University of Engineering, Wuhan 430033, China
| | - Ziwei Li
- College of Nuclear Science and Technology, Naval University of Engineering, Wuhan 430033, China
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Fan Z, Hong Y, Wang Y, Niu Y, Zhang H, Chu C. Digital Fringe Projection-Based Clamping Force Estimation Algorithm for Railway Fasteners. SENSORS (BASEL, SWITZERLAND) 2023; 23:3299. [PMID: 36992010 PMCID: PMC10051881 DOI: 10.3390/s23063299] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 02/06/2023] [Revised: 03/13/2023] [Accepted: 03/17/2023] [Indexed: 06/19/2023]
Abstract
The inspection of railway fasteners to assess their clamping force can be used to evaluate the looseness of the fasteners and improve railway safety. Although there are various methods for inspecting railway fasteners, there is still a need for non-contact, fast inspection without installing additional devices on fasteners. In this study, a system that uses digital fringe projection technology to measure the 3D topography of the fastener was developed. This system inspects the looseness through a series of algorithms, including point cloud denoising, coarse registration based on fast point feature histograms (FPFH) features, fine registration based on the iterative closest point (ICP) algorithm, specific region selection, kernel density estimation, and ridge regression. Unlike the previous inspection technology, which can only measure the geometric parameters of fasteners to characterize the tightness, this system can directly estimate the tightening torque and the bolt clamping force. Experiments on WJ-8 fasteners showed a root mean square error of 9.272 N·m and 1.94 kN for the tightening torque and clamping force, demonstrating that the system is sufficiently precise to replace manual measurement and can substantially improve inspection efficiency while evaluating railway fastener looseness.
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Gibbs CM, Nelson B, Combs T, Moody D, Kaufmann RA. Posterior Flange Cyclic Loading in a Novel Total Elbow Arthroplasty. JOURNAL OF HAND SURGERY GLOBAL ONLINE 2023. [DOI: 10.1016/j.jhsg.2022.12.008] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/10/2023] Open
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Gartsev S, Zuo P, Rjelka M, Mayer A, Köhler B. Nonlinear interaction of Rayleigh waves in isotropic materials: Numerical and experimental investigation. ULTRASONICS 2022; 122:106664. [PMID: 35144078 DOI: 10.1016/j.ultras.2021.106664] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/02/2021] [Revised: 12/06/2021] [Accepted: 12/08/2021] [Indexed: 06/14/2023]
Abstract
Surface treatment intensity monitoring is still an open and challenging nondestructive testing problem. For the estimation of residual stress with ultrasonic measurements, local linear and nonlinear elastic constants are needed as input. In this paper, nonlinear elastic-wave interactions (also called wave mixing or scattering) - namely, the generation of secondary ultrasonic waves in a nonlinear medium - are considered as a prospective means for near-surface nonlinear elastic parameter evaluation. The allowed interactions between bulk and surface waves, as well as the dependence of the scattering efficiency on the frequency and angle between source waves, were investigated through an analytical model, then compared with FEM simulations and experimental results. Finally, possible future steps for the development of the applied methods for the determination of near-surface higher-order elastic constants are discussed. In addition, several problem-relevant data processing procedures are presented.
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Affiliation(s)
- Sergey Gartsev
- Fraunhofer IKTS, Maria Reiche Str. 2, 01109 Dresden, Germany.
| | - Peng Zuo
- Imperial College London, City and Guilds Building, London SW7 2AZ, UK
| | - Marek Rjelka
- Fraunhofer IKTS, Maria Reiche Str. 2, 01109 Dresden, Germany
| | - Andreas Mayer
- Offenburg University of Applied Sciences, Klosterstr. 14, 77723 Gengenbach, Germany
| | - Bernd Köhler
- Fraunhofer IKTS, Maria Reiche Str. 2, 01109 Dresden, Germany
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Abstract
The article deals with the determination of the resistance to cyclic loading of the threaded joints of pressure vessels and defective elements according to the failure mechanics criteria. Theoretical and experimental studies do not provide a sufficient basis for the existing calculation methods for the cyclic strength of the threaded joints of pressure vessels. The short crack kinetics in the threaded joints, a shakedown in one of the joint elements of pressure vessels, i.e., in the bolt or stud, has not been studied sufficiently. The calculation methods designed and improved within the study were based on theoretical and experimental investigations and were simplified for convenient application to engineering practice. The findings could be used to investigate the shakedown of studs of a different cross-section with an initiating and propagating crack. Value: the developed model for the assessment of durability of the threaded joints covers the patterns of resistance to cyclic failure (limit states: crack initiation, propagation, final failure) and shakedown (limit states: progressive shape change and plastic failure). Analysis-based solutions of plastic failure conditions and progressive shape change were accurate (the result was reached using a two-sided approach; the solutions were obtained in view of the parameters of the cyclic failure process in the stud (bolt) and based on experimental investigations of the threaded joints).
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Vibration-Based Diagnostics of Radial Clearances and Bolts Loosening in the Bearing Supports of the Heavy-Duty Gearboxes. SENSORS 2020; 20:s20247284. [PMID: 33353160 PMCID: PMC7766838 DOI: 10.3390/s20247284] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/23/2020] [Revised: 12/15/2020] [Accepted: 12/15/2020] [Indexed: 11/16/2022]
Abstract
The problem solved in this research is the diagnosis of the radial clearances in bearing supports and the loosening of fastening bolts due to their plastic elongation (creep) or weak tightening using vibration signals. This is an important issue for the maintenance of the heavy-duty gearboxes of powerful mining machines and rolling mills working in non-stationary regimes. Based on a comprehensive overview of bolted joint diagnostic methods, a solution to this problem based on a developed nonlinear dynamical model of bearing supports is proposed. Diagnostic rules are developed by comparing the changes of natural frequency and its harmonics, the amplitudes and phases of shaft transient oscillations. Then, the vibration signals are measured on real gearboxes while the torque is increasing in the transmission during several series of industrial trials under changing bearings and bolts conditions. In parallel, dynamical torque is measured and its interrelation with vibration is determined. It is concluded that the radial clearances are the most influencing factors among the failure parameters in heavy-duty gearboxes of industrial machines working under impulsive and step-like loading. The developed diagnostics algorithm allows condition monitoring of bearings and fastening bolts, allowing one to undertake timely maintenance actions to prevent failures.
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Nazarko P, Ziemiański L. Application of Elastic Waves and Neural Networks for the Prediction of Forces in Bolts of Flange Connections Subjected to Static Tension Tests. MATERIALS 2020; 13:ma13163607. [PMID: 32824054 PMCID: PMC7475816 DOI: 10.3390/ma13163607] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/30/2020] [Revised: 08/10/2020] [Accepted: 08/11/2020] [Indexed: 11/27/2022]
Abstract
There is a group of measurement techniques that can be used in the task of force identification in steel bolts. In this paper, the potential of elastic wave propagation signals was studied for possible application in force monitoring systems. A series of laboratory tests was carried out on flange connections subjected to static tensile tests. Each one contained six screws of the same diameter. Four bolts were equipped with washer load cells. Alternatively, selected bolts were equipped with piezoelectric transducers (actuator and sensor) in order to measure the elastic wave signals. Principal components analysis, time of arrival, and neural network compression were used for dimensionality reduction of the measured signals. Examples of the obtained results with respect to the studied connections show that the tension forces in bolts can be estimated with relatively good accuracy.
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