RKB Bearing FEA Analysis

FROM 2D/3D CAD TO FEM ANALYSIS: THE DEVELOPMENT OF AN APPLICATION AT
RKB
RKB TECHNICAL REVIEW - APRIL 2010

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From 2D/3D CAD to FEM Analysis:
the Development of an Application at RKB

Ciprian Radu, Catalin Danaila
RKB Bearing Industries - Advanced Software Engineering Unit

Abstract: RKB Bearing Industries produces a wide range of bearings of different size, but most
of all it is specialized in manufacturing custom-made bearings for special applications. In this
paper, the development of an oil platform will be followed to make clear how the transition
from handmade 2D paper sketch to CAD design has led to an overall enhancement of the
quality, performance, reliability and delivery time of our bearings. We will show how 2D/3D
CAD tools and FEM analysis software are used to study the behavior of the bearings required
by specific applications, providing customers with the best possible technical solutions.

Key words: Bearing, Design, 2D, 3D, CAD, FEM, Oil platform

1. History

Since the earliest times, the need to draw a plan or a sketch of the things to be
built or manufactured appeared. It is very possible that technical drawings
predated even the written language. The drawing board inscripted with a temple
plan from the city of Lagash in Babylon is the oldest known technical drawing (3
rd

millennium B.C.). The ancient Greeks (Euclid, Pythagoras, Thales, Plato, and
Aristotle) had a big contribution on how drawings are made today, with their study
of geometry. One of the oldest examples from the medieval period is the Plan of
Saint Gall (figure 1), which was created somewhere between 819 and 826 A.D. and
depicts an entire Benedictine monastic compound, including churches, houses,
stables, kitchens, workshops, brewery, infirmary, and even a special house for
bloodletting [10].
The contemporary technical drawing has its roots in 15
th
century, in the
Renaissance Era, with artists like the Italian architect Filippo Brunelleschi, who is the
first to use mathematical perspective to redefine Gothic and Romanesque space
and to establish new rules of proportion and symmetry (figure 2). In the 18
th
century,
the mathematician Gaspard Monge was the first to use descriptive geometry,
when he drew up a fortification plan that would prevent enemies from seeing or
firing at a military position (figure 3). The isometric drawing was later introduced, in early 19
th
century, by Englishman
William Farish [11] (figure 4).
Before the 18
th
century, there was no need for interchangeable parts, the components were selected randomly, so
that they fit together, and there was no accurate drawing for them. All products were made one at a time, which
made each one of them unique. Through the 19
th
century, many of the designs started with a handmade sketch,
which was then changed into a wooden model before being constructed [10].
One of the first efforts to create a program, standardize drawings and establish a mechanical drawing school,
came from Philadelphia Franklin Institute, in 1824. Architecture was among the first design disciplines that made use
of conventions of plan, elevation and section, in design and production. The higher complexity of the architectural
projects generated a separation between design and construction. The Industrial Revolution pushed engineers to
use architectural conventions [13; 14].
Together with the Industrial Revolution came the mass production of the same part, and designs started to be
made with the interchangeable concept in mind. For this to be accomplished, parts needed to be identical, within
designed tolerances. Naturally, this is possible only with detailed technical drawings of every part of the assembly to
be built. Sometimes the drafting was handmade by the project engineer, but, due to the massive amount of work
that was necessary, this job was usually left in the hands of specialized drafters. The drafters used a smooth surface

Fig. 1 - The Plan of Saint Gall

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with right angle corners and straight sides, onto which they placed a piece of paper. For drawing, they used a T-
square that was attached on one of the sides of the table and that could slide across the paper [16; 17].

Fig. 2 - Filippo Brunelleschis drawing

Fig. 3 - Example of descriptive geometry

Fig. 4 - Example of geometric
perspective drawing views

There, parallel lines could be drawn by only using the T-square and a technical pen, but usually the T-square was
used to hold other devices like rulers, squares and triangles, that helped the drafter draw lines in different positions
and angles. For the arcs and the circles the drafter basically used the compasses, while for the complex curves he
used particular pieces of plastic. In order to draw recurring objects, like letters, numbers and other standard symbols,
drafting templates were used [13]. With the development of the products, the drawings also became more and
more complex. Even for two lines at a certain angle, several moves were needed; with the T-square, the drafting
process became a very time consuming process [14].
So, a new device appeared, namely the pantograph, which is a "drafting machine" that helped the drafter have
an accurate right angle anywhere on the page, quite quickly. Even with the help of such tools like the pantograph,
the drafter had a very difficult job. Not only he had to master the methodology of drawing lines, arcs, circles,
standard texts and symbols, with regard to the physical object, but he also had to have a good understanding of
geometry, trigonometry and an excellent spatial comprehension [12; 15] (figure 5).

Fig. 5 - Drafting equipment

Since drafters' drawings were based on very complex techniques and were used directly in the manufacturing
process, they required precision, accuracy and attention to detail. In big factories, with complex products with a
multitude of interchangeable parts, there were entire departments of drafters, but that fact was destined to change
with the birth of Computer-Aided Design (CAD) [12].

2. Computer-Aided Design (CAD)

CAD is basically a graphical representation of data. A prime example of computer graphics is the SAGE (Semi-
Automatic Ground Environment), used by the Air Defense Command and Control System in the 1950s. SAGE
converted radar information into computer-generated images, which were displayed by means of a Cathode Ray
Tube (CRT). As an input device, it also used a light pen, so as to select information directly from the CRT screen [19].
In 1963, an important advancement in graphics technology was made by Ivan Sutherland, with his Sketchpad
system, described in detail in his doctoral thesis at MIT. Running on a room-sized Lincoln TX-2 computer, the

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Fig. 6 - The Sketchpad system

Sketchpad system was able to create images that could be
rotated, moved, scaled, stored and modified with the help of a light
pen, which is considered to be the predecessor of the mouse (figure
6). This revolutionized the way people could interact with
computers. The graphical capabilities of the Sketchpad showed the
potential for computerized drawing in design. While he was a
professor of electrical engineering at the University of Utah,
Sutherland continued his research on head-mounted displays
(HMDs) [19]. Later on, in 1968, together with the founder of the
University's Computer Science Department, he cofounded "Evans
and Sutherland", that pioneered computer modeling and software
[19].
At first, CAD was accessible only to big corporations that could
pay big amounts of money for the complicated equipment and
allocate big human resources to the maintenance, operation and
software development, specific for each factory. This meant that only large corporations, like car manufacturers and
other industry giants, had access to the new CAD systems, while the small compani es continued using the old
methods. Beginning with the late 1980s, the appearance of CAD software that could run on personal computers
meant that CAD was now accessible to mid-size and small companies as well. One CAD operator could now do the
job of three to five drafters, using the traditional methods, and furthermore, many engineers started to make their
own drafting work. This immediately led to the start of a massive downsizing of the drafting departments; the time of
the drawing board was coming to an end [19; 20].

3. 2D Computer-Aided Design (2D CAD)

The development of the personal computer started to have an effect on the entire design process, not only in
drafting techniques, from the request of a customer to the delivery of the finished product. These days, CAD has
become not only a platform to replace the old drafting tools, but also, due to the increase in computational power,
the means to do detailed analyses of the products before being launched in production [18].
Before explaining the possible advantages of CAD, the steps of a design project will be presented. Any developing
project has several distinct stages [20]:

1. customer demand,
2. problem definition,
3. synthesis of the possible solutions,
4. analysis and optimization,
5. evaluation of the optimum solution,
6. final design and specification,
7. product release to market.

In today's competitive market, customer demand is extremely diverse and changes rapidly. In order to survive,
companies need to answer a lot quicker to satisfy customer needs. Being specialized in the development of custom-
made bearings for special applications, RKB uses CAD systems to get improved product performance, reliability and
manufacturing timetables.
As an example of how the Group makes use of these systems, the steps that RKB has taken to provide two bearings
for an oil platform will be followed.
In the old days, the development of a design started with time consuming manual drafting, resulting in detailed
drawings that afterward were manually analyzed using complex mathematical formulas. When this process was
done, the improvements that resulted had to be implemented in the drawings, which meant going back to the
drawing board for the drafters [21].
Today, there are many programs for CAD drafting: AutoCAD, Solid Edge, AutoSketch, eDrawings, and more. CAD
drafting has several advantages [21; 22]:

- the time to make a drawing with CAD tools is a lot shorter;
- during the modeling process, CAD systems use mathematical operations that can be easily stored and
retrieved for review, analysis and modification;
- a 2D database of all the drawings can be built, which means that they can be easily accessed and
modified for new projects or improved for ongoing projects;
- the friendly interface lets the operator quickly use the drafting tools, templates and standardized symbols
and letters;

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Fig. 7 - Application sketch with the position of the bearings
- elimination of human drawing errors;
- shift from paper-based work to electronic
paperless one.

RKB Bearing Industries has the full benefit of the 2D
drafting and uses AutoCAD for the representation of
its 2D bearing drawings, assemblies and components.
For the RKB application, the 23248CAW33XS1A and
23048CAW33XS1A spherical roller bearings have
been used (figure 7).
The assembly drawings are made in a standard
template, used for all RKB bearing drawings, which is
inserted very easily. In this template, the following
information is introduced: release date, type of
bearing, identification number, weight, manufacturer
(RKB plant), total mass and a component table (with
the order number, description, quantity, material, unit of measurement of each part) (figures 8, 9). The drawings also
contain detailed information regarding the assembly: relative position of the components, dimensions, tolerances,
reference plans, load ratings, radial clearance, and optimum operating temperature.

Fig. 8 - RKB spherical roller bearing 23248CAW33XS1A

Fig. 9 - RKB spherical roller bearing 23048CAW33XS1A

4. 3D Computer-Aided Design (3D CAD)

The drafting capabilities of CAD systems are useful to make production drawings and have good representations
of the technical information required for manufacturing, but do little to help designers [1].
Bearing A
Bearing B

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The next step in CAD is represented by the 3D modeling of the components, and the simulating operation of the
assembly model. There are many 3D CAD software on the market, the most notable being CATIA, Pro/ENGINEER,
SolidWorks, Solid Edge and Inventor [9].
While 2D CAD revolutionized the way drawings are made, 3D CAD revolutionized the way products are designed.
In the beginning of 3D CAD, in the 1990's, companies purchased software with no clear modeling strategy and
without knowing their full potential. These days, companies are aware of the benefits and know what impact 3D
CAD modeling has on the entire production chain. 3D CAD gives designers a new perspective, new tools and
possibilities, which ultimately have a huge influence on the development of a project [3].
The main benefits of 3D CAD are listed below [1; 5; 9]:

- the rapid progress in IT made computer hardware and software accessible to all enterprises; there is no need
for huge initial investment and, with a proper strategy, the results appear quickly;
- 3D models greatly improve the value of designs, because they are displayed in a true to life representation,
show quantities with accuracy and are a lot easier to understand;
- 3D CAD gives the possibility to realize complicated assemblies, made from real to life models; in this way, it
makes very easy to study the geometrical interaction between different components;
- it eliminates complicated formulas, used with 2D drawings, to study the tolerances between different
components;
- it greatly reduces both the necessity for prototypes and costs, while significantly shortening projects
timetables;
- 3D models can be easily stored for later use and, through a Product Life Management (PLM) system, they
can be used very efficiently in the management of even the most complex multisite projects;
- after all the model information is introduced in the 3D CAD model, the designer can easily obtain valuable
information, like the volume, center of inertia, mass (depending on the material used), eliminating human
errors and giving high quality information;
- after the 3D model is in its final stage of the design process, 2D drawings can be obtained with ease and
great accuracy, eliminating redundant work in drafting; these drawings can be used for documenting the
project or for manufacturing processes;
- the 3D model can be later used for stress analysis with the Finite Element Method (FEM).

CAD design opens the gates for Computer-Aided Manufacturing (CAM), making it possible, through CNC
machines, to jump from 3D models directly to prototyping or even to serial production. So, the Computer-Aided
Engineering (CAE) concept appeared, involving the computer from sketch to production. Due to the strong
interdependence between the different stages of the development process, it is now necessary for the designer not
only to have knowledge of design technology, but also a better understanding of manufacturing processes,
production technology and, most of all, analysis technology [7].
There are two ways to make 3D models: the parametric approach and the explicit approach. Both of them have
advantages and disadvantages [9]:

- the parametric approach is better suited for the product designs, where there are multiple variations or
families of products. The way in which 3D models are made captures the intended product behavior,
enables design automation and favors the creation of platforms and families for optimized design and
product development processes. This method is highly engineered, complex, and emphasizes the constraints
and relationships between the operations made on the model;
- the explicit approach is better suited for companies that make a one-off design (none is similar to a previous
one). With this method, it is much faster to create a 3D model without parameters or features. This type of
approach is not suitable for highly engineered models with many constraints and high similarity between
models.

In the case of RKB, with its large range of families of products, each one with many constructive dimensional
variants, taking into consideration that we are specialized in providing custom-made, highly engineered bearings,
the parametric approach is the best one. Taking this into account, RKB has chosen to use a well known developing
software package, with a wide range of designing tools: CATIA V5.
CATIA has several types of modeling approaches for 3D representation [9; 22]:

- the wireframe model is a skeletal representation of a 3D object (figure 10). It consists only of points, lines and
curves that describe the boundaries of the object, with no surfaces displayed. Because it is a 3D
representation on a 2D screen, without surfaces, it is very difficult to distinguish from which particular side it is
viewed;
- the surface model contains not only the edges, but also the surfaces. There are two types of surfaces that
can be generated: faceted surfaces, using a polygon mesh (figure 11), and true curve surfaces (figure 12).

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There can be represented a wide range of curves and, due to point to point representation, it is perfect for
CAM applications;
- the solid model represents the surface of the model with the added attributes of volume and mass (figure
13). This type of representation allows the calculation of the product's physical proprieties. The model can be
obtained through constructive solid geometry (that uses Boolean operations) or boundary representation
(that uses surface boundaries: faces, edges and vertices);
- the hybrid solid model is a mixture of wireframe, surface modeling and solid geometry.

Even though bearings generally consist of only four main components (inner ring, outer ring, cage and rollers), RKB
Bearing Industries gets important benefits from using 3D CAD, as this paper will emphasize following the oil platform
project development. Through 3D CAD, RKB can use FEM analysis to test and improve the bearings design.
First of all, it is crucial to see how an RKB bearing goes from 2D to 3D in the CATIA V5 environment. The information
from the 2D drawings (figures 14, 17, 20, 23) is sufficient to create the 3D model, provided that it is used in a proper
way. The starting point is a sketch, that mimics the 2D model; then, using a circular generator, as all the components
in a bearing are circular, we get the 3D model.

Fig. 10 - Wireframe view

Fig. 11 - Surface view,
polygon mesh

Fig. 12 - Surface view, true
curve surfaces

Fig. 13 - Solid model,
constructive solid geometry

In 3D CAD the designer is enabled to make sections of the model along different patterns. This operation is
particularly useful in assemblies, to study the geometrical interaction between different components. We show a
section of each 3D model to see the resemblance to the starting 2D model (figures 16, 19, 22).
One of the first advantages of a 3D model is the easiness with which one can get a better understanding of how
the real object looks like (figures 15, 18, 21, 24).

Fig. 14 - Outer ring 2D model

Fig. 15 - Outer ring 3D model

Fig. 16 - Outer ring 3D model section

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Fig. 17 - Inner ring 2D model

Fig. 18 - Inner ring 3D model

Fig. 19 - Inner ring 3D model section

Fig. 20 - Cage 2D model

Fig. 21 - Cage 3D model

Fig. 22 - Cage 3D model section

Fig. 23 - Roller 2D model

Fig. 24 - Roller 3D model

With the information from the 2D assembly (figure 25) and the 2D components, we can take all the 3D models of
the parts and create a 3D assembly model (figure 26).

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Fig. 25 - Bearing 2D assembly

Fig. 26 - Bearing 3D assembly

Fig. 27 - Exploded view of a bearing 3D model

Fig. 28 - 3D assembly section

The 3D assembly model, through real to life models and constraints between them, replaces the need for an
expensive prototype. In the 3D CAD environment, it is possible to manipulate every component with ease, store it for
later use, and modify it to see the impact on the overall assembly; engineers can link the components, making them
interdependent, as in real life. The 3D model gives the opportunity to examine the geometrical interactions between
components, that couldn't have been noticed with prototype parts. For example, the contact surfaces, clearances
and any problems that might appear in the 3D model can be examined [9].

Fig. 29 - Contact area between rollers and outer ring

Fig. 30 - Contact area between rollers and inner ring

For visual exemplification, the contact between rollers and outer and inner ring is shown in figures 29 and 30. The
component surfaces that are in contact, respectively the rollers, the ribs and the raceways of the inner and outer
ring, are represented with red surfaces. The contact profile is of vital importance for the performance of the bearing
in real life conditions, because these contacts have a major influence over the stress distribution, friction, heat
generation, that ultimately lead to wear and actually determine the operating life of the bearing. Furthermore, the
clearance between the cage and the other components can be clearly seen and, by bringing modification to any
component, it is possible to immediately notice the impact on the value of that clearance (figures 31, 32, 33). The
red surfaces represent the bearing component surfaces between which the clearance is determined.

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Fig. 34 - Loaded rollers with
misalignment
By using the "Clearance function", it becomes possible to determine the clearance values between bearing
components. This fact is very important, especially when the radial or axial clearance of the bearing has to be
verified and then compared with the true value given by the bearing technical sheet.

Fig. 31 - Clearance between the cage and the inner ring

Fig. 32 - Clearance between the rollers and the cage

Fig. 33 - Clearance between the rollers and the cage
after modifications to the rollers diameter

Designers can also see the effect that external factors can have on the
bearing. For example, in case of misalignment, one can establish how many and
at what degree the rollers would be affected (figure 34). This can be helpful for
the designer to see the effect of different parameters that can be modified over
the contact area.
For the oil platform application, from the assembly sketch where the two RKB
bearings would be mounted, we have created a 3D model, containing (figure
35):

1. 23248CAW33XS1A spherical roller bearing,
2. 23048CAW33XS1A spherical roller bearing,
3. housing,
4. shaft,
5. spacer,
6. pinion.

This model is not only used to see how the bearings fit inside the application of our customer, but also and most of
all to see how the bearings will behave under the different loads to which the entire mechanism is subjected. For the
calculation of the reaction forces inside the bearing, another major step in CAD has been taken: FEM - Finite Element
Method, which shows the level of commitment that RKB has in providing its own customers with the best possible
product.

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Fig. 35 - 3D model of the oil platform application

5. Finite Element Method (FEM)

Before a product is launched in the market, it is necessary to test its functionality and reliability and check if it
behaves as intended in the design. An engineering analysis needs to be performed, and this can be done in two
ways: analytical and experimental.
The experimental analysis requires a prototype of the product to be tested (in real life conditions) and data to be
collected for interpretation. This type of analysis gives designers a very good feedback regarding the performance of
the product, but it is costly and very time consuming, and sometimes the bad results from tests push the designers
back to the "drawing board" [6].
In the analytical analysis, the CAD model is subjected, in a software environment, to simulated conditions, using a
number of mathematical formulas. The analytical analyses represent numerical solutions of the test, being able to
solve even the very complicated stress problems. The great advantage of analytical analysis is that, if properly used,
it gives designers a quick feedback over the product performance [8].
On the market, there are several well known FEM programs, like ANSYS, Abaqus, LS-DYNA, Nastran.
The FEM uses codes less complicated than most of the word processing and spreadsheet packages. Basically, FEM
doesn't use very complex formulas for an entire process of the examined system; it divides the examined subject into
many segments, and calculates each one of them. The result of the entire problem is the sum of each finite element,
each one of them being interconnected with its neighbors [2].
The connection is made through the nodes, and the interaction, for example, is given by the stress that appears in
each point, due to the force that they are subjected to [2].

Fig. 36 - Stress at a point

Fig. 37 - Finite element

5
6 2
3
1
4
6

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Before showing the steps necessary for a FEM analysis, the types of problems that can be encountered with this
mathematical method are presented below:

- linear statics: it is the basic type of analysis. In this case, the stress is proportional, linear, to the force that is
generating it. Static comes from the fact that the forces do not vary in time, or if they do, the change is so
insignificant that it can be safely ignored. In a linear static case, a beam under constant load can be
analyzed as a linear static problem. Another example is the steady state temperature distribution within a
material with a constant property structure. In the case of temperature differences, thermal expansions
appear, generating thermal stress [8];
- buckling: it is a linear static analysis. A structure is considered to have a stable equilibrium, which means that
when the load is removed, the structure is assumed to return to its original state. However, under certain
combinations of load, the structure continues to deform without any modification of the input data. In this
case, the structure has become unstable, has buckled. For elastic or linear, in buckling analysis it is
considered that the structure does not yield and that the direction of input data (applied forces) does not
change. Elastic buckling includes the effects of differential stiffness, which implies a higher order strain-
displacement relation, which is a function of the geometry, of the element type and of loads. In physical
terms, the differential stiffness represents the softening or stiffening of the material. In the buckling analysis,
the eigenvalues, which represent the scaling factor, are first calculated. Then they are used to multiply the
loads and obtain the new values, namely the buckling loads. The only buckling load that is of interest is the
lowest one, since the structure will fail before reaching any of the higher buckling loads [2; 8];
- normal modes: in this type of analysis, the natural frequencies and mode shapes of a structure are
computed. By natural frequencies, it is understood the frequency at which a structure will tend to vibrate.
The deformed shape of the structure at a specific natural frequency is called the mode shape. Because it
includes the natural vibrating frequency, the normal mode analysis is also known as the real -eigenvalue
analysis. Normal mode analysis gives a thorough understanding of the dynamic characteristics of structures.
In static analysis the displacements are equivalent to those in reality and, because there is no load
considered, each shape component can be scaled by an arbitrary factor [6];
- nonlinear statics: nonlinear structural analysis must be used if large displacements occur with linear materials,
if nonlinear materials are studied under load, or if it is necessary to understand the behavior of a composite
material (linear material combined with nonlinear material). An example of nonlinear statics is when a
structure is loaded beyond its wield point, when permanent deformation occurs and linear statics no longer
applies. In nonlinear material, the material stiffness matrix will change during computation. Another example
where nonlinear statics can be applied is the contact problem, where a gap or a sliding effect occurs
between components during the load application or removal. Taking in consideration that this type of
phenomenon appears between the roller and raceways, nonlinear statics analysis is recommended to study
the bearing behavior [2; 8];
- dynamic response: it consists of frequency and transient response. The frequency response analysis
computes the structural response to a steady-state oscillatory excitation (rotating machinery, unbalanced
tires, helicopters blades etc.). In frequency response, the loads are applied within a frequency domain. The
forces can be in the form of enforced forces or motions. The most common engineering problem is to apply
steady-state sinusoidal varying loads to several points of a structure and calculate its response within a
frequency range. Transient response analysis computes the behavior of a structure under well determined
time-varying excitations. The result of a transient response analysis consists of displacements, velocities,
accelerations and stresses, which appear in the structure analyzed [2].

A finite element analysis consists of three main steps:

1. Preprocessing: in this stage the user constructs the model of the parts to be analyzed, then the geometry is
divided into a number of discrete elements which are interconnected through the nodes. Some of the
nodes will have fixed displacements, while others will have prescribed loads. These models can be very time
consuming to prepare, and the FEM software on the market try to give the best user friendly interface to
work with. Some of these software packages can overlay a mesh over a preexisting CAD model, and so the
finite element analysis becomes a part of the CAD technology [6]. This is the case of the model from the oil
platform project, which is presented in this review. First of all, the 3D model is imported from CATIA to ANSYS.
During importing process, the assembly components are differently colored by default for a better
visualization and selection of the assembly components (figure 38). The gear has been eliminated from the
model because it is not the subject of our study.

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Fig. 38 - 3D model imported from CATIA to ANSYS

The next step is the meshing of the model. The mesh consists of over 237525 nodes (hexaeders and
tetrahedrons) and 65117 elements (figure 39).

Fig. 39 - 3D model with mesh

When meshing the parts, it is of paramount importance to give special attention both to the geometry and
to the points of interest in the analysis. Usually, the parts are divided into much smaller components at the
points of contact, or where the parts might break: these areas represent stress concentrators. This process is
crucial, because in this way the results will be more accurate and much closer to reality [4] (figure 40).

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Fig. 41 - Structural steel properties used
in the model

Fig. 40 - Finer mesh in the contact areas

The next step is to assign the material with its elastic and plastic characteristics. It is important that the
material proprieties are as close as possible to the real life material. It is recommended that special
measurements of material samples be tested under precise specifications, in order to determine the exact
characteristics of the material [6] (figure 41). Then, the contacts definition, the loads and constraints follow. In
the case of the RKB application, the following connections have been considered:

- the housing is fixed;
- the outer rings have a rigid connection to the housing;
- each roller is considered to have a sliding contact to the
respective inner ring, outer ring and cage;
- the inner rings have a rigid connection to the shaft;
- the spacer has a rigid connection to the two inner rings;
- the shaft is rigid with both inner rings, and is also the part to
which the input force is connected.

2. Analysis: the database prepared by the preprocessor is used as an input to the finite element code, which
constructs and solves a system of linear or nonlinear algebraic equations [2]:

K
ij
= f
i,
(1)

where:
f: external applied force,
K: calculation matrix,
i: line number,
j: column number.

The formation of the K matrix depends on the studied problem. Commercial software tools have large
element libraries for a wide range of problems [2]. In the case of the RKB application, we have used both
linear and nonlinear calculations, so as to compare the results and see if it is relevant to use the more
complex and time consuming nonlinear method. Mainly because of the sliding effect that occurs between
the rollers and the inner and outer rings, the nonlinear calculation is more accurate.

3. Postprocessing: in the early days of finite element analysis, the designer would have to go through a huge
quantity of data generated in the analysis step. The data contains displacements and stress, in discrete
positions, in the model. It is easy to miss important information, points with high stress or trends that occur in
the model; so, modern FEM software tools provide graphical display of the information [2].

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Not all the information from a FEM model is of interest. In the case of the RKB model, several key data that
needed to be extracted has been identified:

- the number of rollers in contact with the rings: under load, only 4-5 rollers are in contact with the rings
(figure 42). This is of vital importance for the operating life of the bearing; the contact area between
the rollers and the rings is also displayed;

Fig. 42 - Number of rollers in contact

- the stress distribution: it is of great importance to the designer, in order to locate the weak spots in
which the system might brake under load. With this information, he can change the design and see
the effect that the modification might have over the results [4];

Fig. 43 - Equivalent (von-Mises) stress distribution in the assembly

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- reaction forces: these forces give the actual load on the bearings:

Fig. 44 - Reaction forces in the bearings

- the cases in which the parts have suffered irreversible deformation;
- displacement: it shows the effect of the loads on the bearings, so that it can be easily determined if
the deformations are elastic or plastic [4];
- stress in the bearings: it gives the contact stress values that appear inside the bearing, the most
important being the contact stress values between the roller and the raceways of the inner and
outer rings (figure 45).

Fig. 45 - Equivalent (von-Mises) stress distribution in the bearings
F: system input force,
FA: 23048CAW33XS1A bearing reaction force,
FB: 23248CAW33XS1A bearing reaction force.
F = 2243 kN
FB = 912,73 kN
kN
FA = 1330,27 kN

RKB

16

The comparison between the linear and nonlinear analysis shows that the nonlinear method is more consistent and
closer to reality (figure 46).
The result of this investigation on the oil platform application is that RKB bearings can withstand even the most
demanding forces they might be subjected to in real life conditions.

Fig. 45 - Comparison between linear and nonlinear analysis

6. Conclusions

FEM analysis does not eliminate real tests. In order to have precise FEM analysis results, they should be compared
with the results from real tests. The FEM model should go through a continuous improvement process, based on real
tests, experience of the designer and new mathematical evolutions in CAD technology. CAD technology is a
multibillion dollar industry; it is used from car crash simulations to factory floors testing, from aerodynamic testing to
complete simulation of an airplane, from electrical circuits testing to fluid simulations.
For RKB it is of paramount importance to provide its customers with products of the highest possible reliability. Being
committed to this principle, RKB makes use of the best available technology.

References

[1] Bertoline G. R., Technical Graphics Communication, McGraw-Hill Professional, 2002.
[2] Bioengineering Institute, Finite Element Basis Functions, The University of Auckland, New Zealand, 2005.
[3] Hope N., From CAD Systems to Customers, Manufacturing Business Technology Magazine, 2009.
[4] Harada K., Sakaguchi T., Dynamic Analysis of a High-Load Capacity Tapered Roller Bearing, NTN Technical
Review, No. 73, 2005.
[5] Kuric I., Computer Aided Systems, University of Zilina, Faculty of Mechanical Engineering, Department of
Machining and Automation, Slovak Republic, 2005.
[6] Koyama T., Applying FEM to the Design of Automotive Bearings, Automotive Bearing Technology Department,
Motion and Control Magazine, No. 2, 1997.
[7] McMahon C., Browne J., CADCAM: Principles, Practice and Manufacturing Management, Practice Hall, 1998.
[8] Roylance D., Finite Element Analysis, Department of Materials Science and Engineering, Massachusetts Institute
of Technology, Cambridge, 2001.
[9] Yamashita T., Introduction of 3D CAD in Bearing Development, Engineering Administration Department, Bearing
Engineering Center, Koyo Engineering Journal, English Edition, No. 159E, 2001.
[10] http://en.wikipedia.org/wiki/User:Mdd/Architectural_drawing
[11] http://www.search.com/reference/Perspective_(graphical)
[12] http://www.elinedesign.com/drafting_methods.htm
[13] http://www.artdesignweb.com/learn_art/drawing/drawing_technical.htm
[14] http://www.wikid.eu/index.php/Technical_drawing
[15] http://www.absoluteastronomy.com/topics/Technical_drawing
[16] http://www.statemaster.com/encyclopedia/Technical-drawing
[17] http://www.drftsmn.com/2010/03/technical-drawing/
[18] http://punetech.com/an-overview-of-computer-aided-design-cad/
[19] http://senthilnet.com/cad-cam-history.html
[20] http://en.wikipedia.org/wiki/Computer-aided_design
[21] http://www.answers.com/topic/computer-aided-design
[22] http://docs.autodesk.com/ACD/2010/ENU/AutoCAD%202010%20User%20Documentation/index.html?url=WS1a9
193826455f5ffa23ce210c4a30acaf-67c8.htm,topicNumber=d0e100543
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FROM 2D/3D CAD TO FEM ANALYSIS: THE DEVELOPMENT OF AN APPLICATION AT

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