Empirical, analytical and numerical approaches to failure analysis of a frictional power transmission composite roller

• We proved that the production method affects the life of the composite roller.
• We proved that a type of polyurethane is an adequate candidate for tyre mechanism.
• Delamination of the roller’s outer layer was the main failure mode of the rollers.
• FEM results were in agreement with empirical data regarding failure prediction.

The current study investigated the impact of different parameters on the failure of a frictional power transmission mechanism composed of a steel tyre and a two-layer composite rotating roller. Empirical, analytical and finite element methods were employed to study the mechanism. As for the empirical approach, a few rollers were made with different materials for the outer layer of the composite driver roller in order to examine the probable causes of the failure. In addition, thermography was conducted to find the increase in the temperature due to the working conditions. Analytical formulations were also employed so, as to understand the correlation between stress distribution and deformation regime in the contacting parts. Moreover, through relating the analytical to the empirical data, a homogenous representative cylinder was defined as equivalent to the composite cylinder. In order to reveal the details of stress and deformation distribution inside the roller parts, numerical analysis was performed employing finite element method. The results of such modeling helped us understand the relationship between the tuneable parameters and output results. Furthermore, by relating FEM results to the empirical data, probable causes of the failures were explained. According to the interpretation of the results and the data obtained via the introduced approaches, a few suggestions were presented as applicable in designing proper two-layer composite rollers.