A Novel Algorithm for the Determination of Walker Damage in Loaded Disc Springs

Area of Science:

• Mechanical Engineering
• Materials Science
• Computational Mechanics

Background:

• Disc springs are critical components in various mechanical systems.
• Assessing Walker damage is essential for ensuring the reliability and longevity of disc springs.
• Current methods for damage assessment are time-consuming and may lack precision.

Purpose of the Study:

• To introduce a novel, automated algorithm for determining Walker damage in loaded disc springs.
• To provide a more accurate and efficient method for assessing stress states and potential damage.
• To enable disc spring manufacturers to reduce labor costs and improve quality control.

Main Methods:

• The algorithm utilizes 3D scan data of the disc spring.
• It incorporates measured residual stresses, material properties, and applied loads as input parameters.
• The output is a detailed distribution of Walker damage across the spring's surface.

Main Results:

• The developed algorithm provides a fully automated determination of Walker damage.
• It offers a superior description of stress states compared to traditional analytical formulas and finite element models with idealized geometry.
• The method allows for precise mapping of damage distribution.

Conclusions:

• The novel algorithm presents a significant advancement in the automated assessment of Walker damage in disc springs.
• It offers substantial time savings for manufacturers and improved accuracy in stress analysis.
• This approach enhances the reliability and quality control of disc spring production.