Design method for hollow cylindrical rollers based on load distribution calculation using equivalent modulus of elasticity

Abstract Cylindrical rollers are widely used in heavy machinery, including wind turbines, shield machines, and rolling mills. Hollow cylindrical rollers can effectively reduce the contact stresses on the rollers and improve their fatigue strength. Existing contact theories cannot determine the load distribution on the line contacts of hollow cylindrical rollers, and thus cannot guide design. To clarify the load distribution and deformation of hollow cylindrical roller, this paper proposes a novel design method through the equivalent modulus of elasticity. The equivalent modulus of elasticity of the hollow cylindrical roller is determined by the Hertz contact theory and the Energy method. The load distribution and deformation of the hollow cylindrical roller in line contact are determined through the Elastic half-space contact theory. The load distribution of hollow cylindrical roller with different hollow ratios and different loads is obtained by the equivalent modulus of elasticity method. The hollow cylindrical roller effectively reduces the load distribution of line contact and increases the contact area, which can improve the elastic performance of the roller. Meanwhile, the load distribution of hollow cylindrical roller under different shaping and bias angles is obtained. The deformation of the hollow cylindrical roller is verified by the finite element simulation analysis with the errors are less than 10% at the middle position. Under a 4 kN load, the maximum contact stress ratio for a hollow roller with a 0.5 hollow ratio is reduced by 37% compared to a solid roller. The strain gauges affixed to the inner wall of the hollow roller, combined with a sensing system, form smart roller capable of measuring bending deformation in the contact area. Experimental research is performed using a static loading test platform, with strain gauges used to validate the accuracy of the theoretical model. During the design process, this method helps reduce stress concentration phenomena and bias load phenomena of hollow cylindrical rollers.