Fretting fatigue induced surface cracks under shrink fitted main bearings in wind turbine rotor shafts

Rauert, Thes; Herrmann, Jenni; Dalhoff, Peter; Sander, Manuela

doi:10.1016/j.prostr.2016.06.449

Cited by 16 publications

(10 citation statements)

References 6 publications

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“…This phenomenon was observed in the prior project "BeBen XXL", see Fig. 9, where fatigue runs with forged main shafts of a 2 MW wind turbine as specimens were conducted on the main shaft fatigue test bench [11].…”

Section: Inner Ring Creep In the Main Bearing Seatmentioning

confidence: 70%

“…Due to lightweight design, the overall stiffness of the main shaft will decrease, which influences the contact between the main bearing inner ring and the main shaft bearing seat. In this fitting, there is a high risk of inner ring creep and fretting corrosion, as observed in the previous project "BeBen XXL" [11]. Finite element simulations to determine the creeping tendency of the test bench setup are carried out and a method to experimentally prove the occurrence of inner ring creep is developed.…”

Section: Introductionmentioning

confidence: 95%

“…Inner ring creep is a known issue, which can occur at the bearing outer and inner ring [11,[16][17][18][19]. It can be described as a continuous circumferential movement of the inner ring relative to the main shaft through a surface traveling-wave creeping in the direction of rotation.…”

Section: Inner Ring Creep In the Main Bearing Seatmentioning

confidence: 99%

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Optimized cast components in the drive train of wind turbines and inner ring creep in the main bearing seat

Kirsch

Kyling

2021

Forsch Ingenieurwes

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Using large components made of nodular cast iron (GJS) in wind turbines enables the application of lightweight construction through the high degree of design freedom. Besides the sand-casting process, casting into a permanent metal mould, i.e. chill casting, leads to a finer microstructure and higher quasi-static mechanical properties as well as higher fatigue strength. Unfortunately, in present design methodologies specific fatigue data is only available for sand cast and not for chilled cast GJS. Thus, lightweight design strategies for large, chilled cast components are not achievable, which led to the publicly funded project “Gusswelle”. Based on material investigations of EN-GJS-400-18-LT chill cast, an optimized hollow rotor shaft is developed. The design process and the resulting shaft design are presented. The optimized hollow rotor shaft prototype will be tested on a full-scale test bench to validate the design methodology. The intended validation plan as well as the test bench setup is shown in this paper. Furthermore, the decreasing wall thickness influences the interference fit between main bearing and hollow rotor shaft. Thus, through the applied bending moment, inner ring creep is more probable to occur in the main bearing seat. The creeping behaviour is investigated with finite element simulations and a measuring method is presented.

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Section: Inner Ring Creep In the Main Bearing Seatmentioning

confidence: 70%

Section: Introductionmentioning

confidence: 95%

See 1 more Smart Citation

Optimized cast components in the drive train of wind turbines and inner ring creep in the main bearing seat

Kirsch

Kyling

2021

Forsch Ingenieurwes

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“…The bending moment is resulting from the own weight of the rotor and the vertical and horizontal wind shear. A more in depth explanation of the loads on the rotor shaft can be found in [6].…”

Section: Rotor Shaft Loadsmentioning

confidence: 99%

Finding the ideal strategy: Full-scale fatigue testing of wind turbine rotor shafts

Rauert

Herrmann

Dalhoff

et al. 2016

J. Phys.: Conf. Ser.

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For the purpose of a light weight design of rotor shafts, fatigue testing is necessary. Since full-scale fatigue tests of these large components are time consuming, costly and have not been done before, much effort has to be put into the implementation of a suitable test strategy. The paper presents the boundary conditions that have to be considered to determine the finite life regime of the component S/N-curve. A statistical simulation shows how much the derived S/N-curve is influenced by the specific test procedure.

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“…The load received by the wind turbine in the actual working process is constantly changing with the influence of natural wind [25]. The main bearing is the core component of the wind turbine, and its function is to support the rotation of the main shaft and reduce the frictional influence caused by the rotation of the main shaft [26,27]. Therefore, the quality of the main bearing will directly determine the performance of the entire equipment.…”

Section: Introductionmentioning

confidence: 99%

Mechanical Loading Model of Main Bearing of Wind Turbine Based on Test Bench

Yang¹,

Zhang²,

Li³

et al. 2021

EAS

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Wind-turbine main bearing has to withstand dynamic loads with different directions and different magnitudes in complex environments, and its stable operation has a vital impact on the performance of the entire wind turbine. Therefore, the fatigue strength test of wind turbine bearing is helpful to ensure the normal operation of the whole wind turbine. According to the actual force of main bearing in natural environment, this paper designed a large-scale wind-turbine bearing test bench to detect the deformation performance of the bearing. Through the establishment of the mechanical loading model, the simulation of the actual working conditions of main bearing is realized by the loading of the eight hydraulic cylinders of the test bench, and the radial and axial displacement of the test bearing under different wind conditions are recorded by displacement sensors. A number of temperature sensors are used to monitor the real-time temperature change of the bearing inner ring. The test results show that the loading effect of eight hydraulic cylinders can realize the force of wind turbine bearing under wind load, and the test bench can effectively detect wind-turbine bearings with a diameter of 2.5 m. The mechanical loading method and test results can provide guidance for further inspection of the wind-turbine bearing.

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Fretting fatigue induced surface cracks under shrink fitted main bearings in wind turbine rotor shafts

Cited by 16 publications

References 6 publications

Optimized cast components in the drive train of wind turbines and inner ring creep in the main bearing seat

Optimized cast components in the drive train of wind turbines and inner ring creep in the main bearing seat

Finding the ideal strategy: Full-scale fatigue testing of wind turbine rotor shafts

Mechanical Loading Model of Main Bearing of Wind Turbine Based on Test Bench

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