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Reliability analysis and optimization of the hammer rotor of forage crusher under multiple failure modes

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Abstract

During the operation of a forage crusher, the common issues usually faced are shorter mean time between failures and low reliability. The hammer rotor, a critical component, is prone to fatigue fracture, hammer wear, violent vibration of the rotor system caused by uneven wear of the hammers, and other issues that reduce the machine’s service life and reliability. In order to avoid failure modes within the design life of the forage crusher and improve its reliability, the functional functions of the fatigue fracture failure, hammer wear failure, and resonance failure modes were established, the marginal distribution functions for each individual failure mode were computed, and the reliability model of the hammer rotor under multiple failure modes is constructed based on the correlation degree between the failure modes. On this basis, the reliability of the forage crusher is improved by optimizing the structure and working parameters. Before optimization, the fatigue reliability, wear reliability, and vibration reliability of the hammer rotor are 0.878, 0.94, and 0.248, respectively, and the reliability of the hammer rotor under multiple failure modes is 0.2116. After optimization, the fatigue, wear, and vibration reliability are 0.979, 0.9997, and 0.932, respectively. The reliability of the hammer rotor under multiple failure modes is 0.923, which reduces the probability of failure within the design life and meets the requirement that the reliability of key parts of agricultural and animal husbandry machinery is not less than 90 %. This study validates the reliability models and multi-objective optimization results and serves as a reference for forage crusher structural reliability design and optimization.

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Abbreviations

S :

The maximum equivalent stress

R :

The ultimate fatigue strength of the material

R 2 :

The fitting degree factor

G 1 :

The performance function for fatigue failure of hammer rotor

G 2 :

The functional function of hammer wear failure

G 3 :

The functional function of the vibration failure mode of the hammer rotor

CFD :

Computational fluid dynamics

DEM :

Discrete element method

EDF :

Edge distribution function

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Acknowledgments

This work was supported by Inner Mongolia Natural Science Foundation Project [Grant No. 2023LHMS05023]; Basic Scientific Research Fund for Universities Directly Under The Inner Mongolia Autonomous Region [Grant No. JY20230077]; Inner Mongolia Higher Education Scientific Research Project [Grant No. NJZY22364]; And 2023 Autonomous Region Postgraduate Scientific Research Innovation Project.

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Authors and Affiliations

  1. School of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot, 010051, China

    Zhiping Zhai, Donghai Yuan, Yuezheng Lan & Haixu Zhao

Authors
  1. Zhiping Zhai
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  2. Donghai Yuan
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  3. Yuezheng Lan
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  4. Haixu Zhao
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Corresponding author

Correspondence to Yuezheng Lan.

Additional information

Zhiping Zhai is a Professor of the College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot, China. She received her Ph.D. in Mechanical Engineering from Inner Mongolia Agricultural University, Hohhot, China. Her research interests include design optimization of agricultural machinery, computational fluid dynamics, vibration noise testing, and reliability analysis.

Donghai Yuan is a Master of the College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot, China. His research interests include design optimization and reliability analysis of agricultural machinery.

Yuezheng Lan is a Master of the College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot, China. He received his M.D. in Mechanical Engineering from Inner Mongolia University of Technology. His research interests include design and theory of machinery.

Haixu Zhao is a Master of the College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot, China. Her research interests include design optimization and reliability analysis of agricultural machinery.

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Zhai, Z., Yuan, D., Lan, Y. et al. Reliability analysis and optimization of the hammer rotor of forage crusher under multiple failure modes. J Mech Sci Technol 37, 5103–5115 (2023). https://doi.org/10.1007/s12206-023-0915-6

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  • DOI: https://doi.org/10.1007/s12206-023-0915-6

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