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. 2022 Sep 21;15(19):6558.
doi: 10.3390/ma15196558.

A Thermo-Mechanical Stress Based Fatigue Life Evaluation of a Mine Hoist Drum Brake System Using COMSOL Multiphysics

Sorin Mihai Radu  1 , Florin Dumitru Popescu  1 , Andrei Andraș  1 , Zoltán Virág  2 , Ildiko Brînaș  1 , Manuel-Ionuț Draica  1
Affiliations

A Thermo-Mechanical Stress Based Fatigue Life Evaluation of a Mine Hoist Drum Brake System Using COMSOL Multiphysics

Sorin Mihai Radu et al. Materials (Basel). .

Abstract

In this study, the fatigue usage factors for Findley and Matake stress-based criteria were determined in the case of an MK5×2 mine hoist drum brake system subjected to cyclic maneuver braking. The study was conducted for this type of brake system, because the majority of mine hoists in Romanian mines are equipped with this brake type, being in operation for several decades. A geometric model of the brake was built using SolidWorks and imported in COMSOL Multiphysics to perform thermo-mechanical simulations. Based on the deformations and von Mises stresses determined by the thermomechanical simulation and, considering the calculated endurance limits of the brake system materials, Matake and Findley fatigue life evaluation simulations from COMSOL's fatigue module were conducted. The results show that the highest fatigue is expected on the drum lining surface towards the exit point from under the brake shoe in both cases, and the values of the usage factor of 0.307 (Findley) and 0.401 (Matake) are both under the critical value 1, meaning that the stress limit has not been exceeded for the brake system components and, thus, failure is not expected. Simulations were conducted considering an estimated 1.06 × 105 cycles during one year, more than both the usual service/replacement interval of the friction components of the brake, and the period of mandatory technical inspections imposed by regulations.

Keywords: COMSOL Multiphysics; Findley; Matake; drum brake system; fatigue life evaluation; mine hoist; thermomechanical stress.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
General layout of a friction mine hoist [3].
Figure 2
Figure 2
The MK5×2 hoisting machine: (a) Photo of the drum brake system; (b) detailed drawing of the drum brake system [4].
Figure 3
Figure 3
The step by step approach used in the research.
Figure 4
Figure 4
Characteristic six-phase hoisting diagram of the MK5×2 type hoisting installation.
Figure 5
Figure 5
Diagrams obtained in COMSOL for (a) velocity and (b) acceleration.
Figure 6
Figure 6
Location of the three points of the Cut Point 3D type.
Figure 7
Figure 7
Variation in time of the drum lining surface temperatures for the three points.
Figure 8
Figure 8
The drum lining surface temperature at different times during braking.
Figure 9
Figure 9
Temperature variation in time along the Cut Line 3D data set.
Figure 10
Figure 10
Temperatures along the Cut Line 3D data set, at certain moments of time.
Figure 11
Figure 11
Temperature variation in time along the parameterized curve.
Figure 12
Figure 12
Cross-section of the deformation at t = 9 s.
Figure 13
Figure 13
Variation in time of the deformation along the Cut Line 3D data set.
Figure 14
Figure 14
Variation in time of the deformation along the parameterized curve.
Figure 15
Figure 15
Cross-section of the von Mises effective stress at t = 9 s.
Figure 16
Figure 16
Variation in time of the von Mises stress along the Cut Line 3D data set.
Figure 17
Figure 17
Variation in time of the von Mises stress along the parameterized curve.
Figure 18
Figure 18
The Findley fatigue usage factor determined by simulation.
Figure 19
Figure 19
The Matake fatigue usage factor determined by simulation.
See this image and copyright information in PMC

References

    1. Hustrulid W.A., Bullock R.L. Underground Mining Methods: Engineering Fundamentals and International Case Studies. Society for Mining, Metallurgy, and Exploration, Inc.; Littleton, CO, USA: 2001.
    1. Popescu F.D. Instalaţii de Transport pe Vertical. Editura Focus; Petroșani, Romania: 2010.
    1. Radu S.M., Popescu F.D., Andras A., Kertesz I. Transport si Instalatii Miniere. Editura Universitas; Petroşani, Romania: 2018.
    1. Popescu F.D., Radu S.M. Vertical Hoist Systems, New Trends Optimizations. LAP Lambert Academic Publishing; Saarbrucken, Germany: 2013.
    1. ULKSM Donetsk . Technical Documentation of MK5 × 2 Mine Hoist. ULKSM Donetsk; Donetsk, Ukraine: 1970. (In Russian)

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