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OMAE2010-20164
1.5 3
0.5
2
F [N]
0
1.5
-0.5
1
-1
0.5
-1.5
-2 0
1000 1050 1100 1150 1200 1000 1050 1100 1150 1200
t [s] t [s]
Figure 4: Excitation force on the heaving sphere Figure 6: The variation of the sealed pressure p(t) for
produced by incident waves in a sea state with Hs=4.25 m,
the same case as specified in Fig. 5a. This
Tp=9.5 s. pressure is basically determined by the fluid pressure of
2.5 high-pressure side.
2
account for the tribologic performance of the hydraulic cylinder
1.5
than that of other machinery with cyclic sliding velocity and
1 working pressure (e.g. an internal combustion engine). The
0.5 cylinder bore wear damage can only be estimated in the time
domain on the basis of the simulation results.
X [m]
-0.5
CYLINDER BORE WEAR MODEL
-1 Consider a small slice of the cylinder bore which is slid by
-1.5
the ring with length dX between [X, X+dX], as shown in Fig. 7.
The numbers of piston ring crossing (both the positive and
-2
negative crossings) for this region dX during a time interval T is
-2.5
1000 1050 1100 1150 1200
denoted as n(X). The normal force for the i'th crossing at the
t [s] position X is N(X, ti), and then the wear volume loss of this slice
a. dVi(X) for the i'th crossing can be expressed as :
Figure 5a: Time variation for the buoy excursion X(t) for a dVi ( X ) K (i ) N ( X , ti )dX (3)
buoy with r=5 m, Hs=4.25 m, Tp=9.5 s, D=0.16 m, L=5.0 m.
where K(i) is the wear coefficient of the cylinder bore for the
2.5
i'th crossing.
2
1.5
0.5
v [m/s]
-0.5
-1
-1.5
-2
-2.5
1000 1050 1100 1150 1200
t [s]
b. Figure7: The sketch of the motion of piston ring along the
Figure 5b: Time variation for the buoy velocity v(t) for the cylinder bore. The original point of the coordinate is set at
the middle of the cylinder bore.
same case as specified in Fig. 5a.
n( X ) P( X ) i 1
(13)
K (i) K ( X , i ) N ( X , t i )dX
n( X )
dV ( X ) (6)
i 1 Introducing the expected crossing rate κ(X) which is
The average wear depth dc(X) of the cylinder bore with an defined as the ratio of the crossing numbers n(X) to the
inner diameter D can be obtained: corresponding time interval T, the wear damage rate dc ( X ) for
dV ( X ) n ( X )
dc ( X ) K (i ) K ( X , i ) N ( X , ti ) /( D) (7) the cylinder bore can be expressed as:
DdX d (X )
dc ( X ) c
i 1
K ( X ) P ( X )tR (14)
Assuming uniform pressure pc(t) distributed along the T
interface, the total normal load N on the contact region is: Eq. (14) provides an expression for the wear damage for
N (t ) pc (t ) DtR (8) any segment of the cylinder bore slid by the ring during the
where tR is the width of the piston. The contact pressure pc(t) on operation. The product of κ(X) and tR can be considered as an
the bore is the sealed pressure plus the ring tension. The ring equivalent sliding velocity. The modified factor K(X, λi) which
tension is usually much smaller than the sealed pressure [28]. In indicates the effects of the surface roughness and lubrication is
this study, the contact pressure pc(t) is approximately expressed considered in the terms of the average effective pressure P ( X ) .
as: The procedure for computing the cylinder bore wear is
pc (t ) p(t ) (9) then carried out as follows:
Substituting Eqs. (8) and (9) for Eq. (7) yields: 1. Obtain the cylinder chamber P-v or P-X relations for given
n( X ) operation conditions by solving the dynamic model of the
dc ( X ) K (i)K ( X , ) p( X , t )t
i 1
i i R (10) wave energy converter system in different sea states.
2. Based on Eq. (9), determine the contact pressure between the
The formula for film thickness described by Hamrock and ring and cylinder bore.
Dowson [29] is in the following form: 3. Calculate the ring-bore film thickness loci for the ring and
0.073
v
0.68
N
1 e
h0 determine the lubrication regions of ring-bore contact.
3.63 0 E 0.68 k
0.49
2 4. Determine the expected crossing rate κ(X) on the basis of the
R E R ER
simulated piston motion X for a given sea state.
(11)
5. Determine the K(X, λi) according to the film thickness loci
where:
obtained from step 3.
h0: the film thickness [m];
6. Based on the P-X relations and K(X, λi), calculate the average
v: the entraining surface velocity and equals the piston velocity
value of K(X, λi) p(X,ti) for each segment by using Eq. (13),
in this study [m/s];
then get the distributions of the average effective pressure
η0: the viscosity at atmospheric pressure of the lubricant [Pas];
α: the pressure-viscosity coefficient [m2/N]. For mineral oils, P ( X ) along the cylinder bore.
0.6 0.965log10 0 108 [22]; 7. Combining with steps 4~6 and using Eq.(14) to obtain the
N: the contact load [N]; wear damage rate dc ( X ) along the cylinder bore for one
E': equivalent elastic modulus [Pa], sea state.
filmthickness [m]
CASE STUDY 6
In order to meet the requirements of this wave energy
5
converter, an un-slit piston ring which is broadly used in
Hägglunds hydraulic motor [27] is adopted here. The piston 4
ring has a symmetric outer crowning with a radius half the 3
inner cylinder bore diameter D. The piston width and thickness
shown in Fig. 1 are 3 mm. The working fluid is standard 2
mineral hydraulic oil. The oil surrounds the piston ring (i.e. the 1
ring is in a fully flooded condition). The piston ring is made of
hardened bearing steel while the cylinder bore is nodular cast -2 -1 0 1 2
iron. The mechanical properties and surface roughness are X [m]
presented in Table 1. The composite surface roughness σ is Figure 8: The film thickness distribution along the
equal to 0.65 μm. The main parameters of this ring-bore system cylinder bore for r=5 m, Hs=4.25 m, TP=9.5 s, D=0.16 m,
are shown in Table 2 [27]. Based on the simulation results of L=5.0 m. X is the coordinate of the piston ring position
this WEC system, this ring-bore combination fulfills the along the cylinder bore. The composite surface
requirements when the buoy exposed to different sea states roughness of the piston ring and cylinder bore is 0.65 μm.
(excluding extreme sea states). In addition. due to the higher The red line represents the critical value for dividing the
hardness of this hardened steel compared to the elastomer seals, boundary and mix lubrication regimes.
the wear resistance is much higher for this type of ring [10].
The film thickness h0 can be calculated for this piston ring and
cylinder bore system by using Eq. (11). Fig. 8 shows a SIMULATION RESULTS
distribution of the film thickness along the cylinder bore of a In order to get the correct statistical properties of the
sea state with Hs=4.25 m and TP=9.5 s. The induced cylinder WEC's response, the wave spectrum was discretized with 1000
bore wear can be considered by following the procedure frequency components in the range of 0.25 2.5 rad/s (i.e.,
mentioned in the above section. longest period without repetition is 2793 s). The piston motion,
film thickness and sealed pressure can be numerically obtained
Table 1. The mechanical properties and surface by solving the established governing equations. The cylinder
roughness of the piston ring and cylinder bore. bore wear is a function of the expected crossing rate κ(X),
Modulus of Surface lubrication film thickness h and the sealed pressure p(t).
elasticity
Poisson's Hardness
roughness Usually, the distribution of expected crossing rate κ(X) of a
Ratio υ [-] H [MPa] linear response caused by a Gaussian process can be
E [GPa] σ [μm]
analytically expressed by using the Rice distribution [30]. Due
Piston
206 0.3 2110 0.39 to the nonlinearity , the actual process is non-Gaussian process
ring
[3] and the analysis can only be done in the time domain.
Cylinder
175 0.3 814 0.52 According to Eq. (14), in order to get stable values of the
bore
cylinder bore wear damage, one must check the statistical
characteristics of the motion, film thickness and the sealed
Table 2. The main ring characteristics in hydraulic motors
pressure. The statistical properties of these three vairables as
(Reproduced from Sätra [27])
obtained for a sea state with Hs=4.75 m and TP=9.5 s are shown
Parameter Unit Limit Hydraulic motor in Figs.9-14. The simulated realizations of these related
Fluid to seal Oil variables are given for the time interval between 500 s and 3000
Pressure Mpa max 42 s (i.e., a 2500-second sample is used for statistical analysis),
Constant or after excluding the transient start-up. These realizations are
Type of service
intermittent divided into 25 samples, each with duration of 100 s. It is
max 6.3 observed that a stable statistics is obtained by running at least
velocity m/s
min 0 15 samples. The fact implied that 1500 simulation seconds are
Temperature ºC max 50 needed.
The long-term analysis is based on the scatter diagram of
waves provided by Statoil ASA [31]. These data were recorded
over a period of 29 years (from 1974 to 2002) by wave buoys in
2.4
Mean value of motion [m]
-0.05
-0.1 2
1.8
-0.15
1.6
Each sample
Ensemble average 1.4
-0.2
5 10 15 20 25
Simulation No. 0 5 10 15 20 25
Simulation No.
Figure 9: Mean value of the piston motion in each sample
and for the ensemble for a sea state of Hs=4.25 m and Figure 12: Standard deviation of the film thickness in
TP=9.5 s. ('Each sample' corresponds a duration of 100 s; each sample and for the ensemble as obtained for a sea
'Ensemble average' means the average over Sample No. state of Hs=4.25 m and TP=9.5 s.
1 up to Sample No. i). x 10
7
3
Each sample
1.3 2.9 Ensemble average
Each sample
1.2 Ensemble average 2.8
1 2.6
0.9 2.5
0.8 2.4
0.7 2.3
0.6 2.2
0 5 10 15 20 25
Simulation No.
0.5
0 5 10 15 20 25
Simulation No. Figure 13: Mean value of the sealed pressure in each
Figure 10: Standard deviation of the piston motion in sample and for the ensemble as obtained for a sea state
each sample and for the ensemble as obtained for a sea of Hs=4.25 m and TP=9.5 s.
state of Hs=4.25 m and TP=9.5 s. x 10
6
x 10
-7 8.5
2.8 Each sample
Each sample 8 Ensemble average
2.6 Ensemble average
7.5
Mean value of film thickness [m]
2.4 7
Std of pressure [Pa]
2.2 6.5
6
2
5.5
1.8
5
1.6
4.5
1.4
4
3.5
0 5 10 15 20 25 0 5 10 15 20 25
Simulation No. Simulation No.
Figure 11: Mean value of the film thickness in each Figure 14: Standard deviation of the sealed pressure in
sample and for the ensemble as obtained for a sea state each sample and for the ensemble as obtained for a sea
of Hs=4.25 m and TP=9.5 s. state of Hs=4.25 m and TP=9.5 s.
5
04
damage with the parameters chosen in this wave energy 3 0.01
5
0.
0. 0
0. 0
6 0. 0
6 3 5
converter system. The histogram of the positions at which the . 0
15
0 0.01
maximum wear index occurs is shown in Fig. 18. For most of 4
the sea states, the maximum cylinder bore wear occurs in the
2
interval of -0.2<X<0 m. The non-symmetry in the histogram is
mainly due to the single-rod hydraulic piston used in this 0
0 1 2 3 4 5 6
system. As shown in Fig. 1, the area ratio of the rod and piston Hs [m]
α is set as 0.25, which makes the mean position of the piston a
Figure 15: Contour plot of the joint probability density
little lower than the mid-point of the cylinder. In this work, we
function of Hs and TP using the 29-year data.
take the position X=-0.06 m at which the histogram has its
30
maximum value as the most severe position. The cylinder bore Effective Pressure
wear rate at this position is calculated in different sea states. CrossingRate
0.25
Long-term wear damage can be calculated by summing up
the short-term wear damage multiplied by the occurrence
Effective Pressure [MPa]
25 0.2
CrossingRate [1/s]
probability of each sea state. The relative contribution of the
wear damage from different sea states, considering the North
0.15
Sea wave conditions as obtained by use of the present time-
domain method, are plotted in Fig. 19. For the sake of
20 0.1
convenience, the total long-term wear damage is normalized to
be 1. In the figure, we can clearly identify the sea states which
0.05
contribute the most to long-term wear damage, i.e. the sea
states with Hs from 0.5 m to 3.5 m and TP from 5 s to 10 s. This
is mainly due to the dynamic characteristics of the wave energy 15 0
-2.5 -2 -1.5 -1 -0.5 0 0.5 1 1.5 2
X [m]
converter system. As we know, waves with a small significant
height can produce smaller excitation force. The high pressure Figure 16: The distribution of the average effective
converted by this force will have a small chance to overcome pressure P ( X ) and expected crossing rare κ(X) along the
the high pressure in the hydraulic circuit. This will enlarge the cylinder bore for a sea state of Hs=4.25 m and TP=9.5 s.
3
wear damage is largely dependent on the wear coefficient K
2.5 which can vary enormously from very high values under
2 particularly aggressive conditions to very low values in more
1.5
benign circumstances. The full exploitation of this information
and the ability to quantitatively predict future performance or
1
life expectancy, requires an understanding of the sources and
0.5
mechanisms related to the generation of the extracted and
0
-2.5 -2 -1.5 -1 -0.5 0 0.5 1 1.5 2
sampled particulate debris. This estimated number should be
X [m] verified by the actual in-service components.
Figure 17: The distribution of the wear index along the
cylinder bore for a sea state of Hs=4.25 m and TP=9.5 s. 18
The red dot is the maximum value of this paramter. 0.0
0.001 01
30
16 0. 001
25
14
6
00
0.006
0.001
0.
0.006
20
Statistic Times
12 00
6 0.0
11
Tp [s]
11
0. 0. 0
0.01
1
15 6
1
01
01
0.
0.
10 0.016 0. 016
1 0.0
02 31 26 0.021 06
0. 0.0 0.0
36 0.031
10
6
. 0 0.036
0.01
0
0.026
8
1
01
01
0.026
21 0.0
0.
0.0
6
03 1 06
0. 0.03 0.0
5 6
0.01.011
6 1
0
0.001
0. 0 02
31 0.
0.036 .026 06
0 0. 0
0.01
0 6
0.011
0.001
-0.4 -0.2 0 0.2 0.4 4
1 2 3 4 5 6
X [m] Hs [m]
Figure 18: Histogram of the positions at which maximum Figure 19: Relative contribution of the bore wear damage
wear index occurs for 100 sea states. The largest value is at X=-0.06 m from different sea states considering the
shown around X=-0.06 m. Northern North Sea wave conditions.
should be avoided or reduced as small as possible, e.g. based on According to other studies as well as analysis in this work,
suggestions given by Yang et al [8]. To sum up, the sea states recommendations for cylinder bore wear reduction are made as
with small Hs and TP make important contribution to the below:
cylinder bore wear. As it is very time-consuming to compute 1. Try to reduce the wear coefficient K as much as possible.
the long-term period wear damage in the time domain by This can be achieved in the following ways: a) Keep the oil
considering all the sea states, the information we have got in as clean as possible; b) Select materials which are
the work could be useful for estimating the long-term wear sufficiently wear resistant; c) Use of coating to protect the
damage by running the time-domain simulations only for the bore; d) Use the antiwear oil for the media.
identified important sea states. 2. Reduce the composite surface roughness. The modified wear
In this case study, if a wear coefficient of 1 1018 m2/N is factor in Eq. (4) can be reduced if the two surfaces are much
assumed for the cylinder bore, the wear rate can be predicted by smoother.
using Eq. (14). At the position X=-0.06 m, long term wear index
(0.06) P (0.06) is calculated by summing up the short term