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<p>High-speed variable-length axially moving beams with multiple discrete clearances exhibit coupled geometric nonlinearity, time-varying transport, and nonsmooth impact and friction. These effects jointly govern vibration response and wear-induced failure. A remaining challenge is to quantitatively connect transient multi-point clearance interactions to long-term wear evolution and service-life prediction. This study develops an integrated dynamics and wear framework for a rapier-loom weft-insertion mechanism. The rapier tape is modeled as a variable-length Euler–Bernoulli beam with von Kármán geometric nonlinearity derived from generalized Hamilton’s principle and reduced via Galerkin discretization. Guide-hook clearances are described by complementarity conditions within a nonsmooth time-stepping scheme, enabling robust simulation of intermittent impact and Coulomb friction. An Archard-type wear model driven by the reconstructed transient contact actions is then used to predict wear accumulation and service life. Simulations show that increasing drive speed raises both impact force and impact frequency, resulting in a nonlinear increase in wear. Parametric analyses further reveal the role of guide-hook layout in shaping the dynamic response and wear accumulation. Based on cycle-wide dynamic characteristics, a dynamics-informed variable-density guide-hook placement scheme is proposed to suppress vibration, mitigate clearance interactions, reduce wear growth, and extend service life compared with a uniform layout. The proposed framework supports dynamic design, layout optimization, and life prediction of high-speed variable-length flexible beam systems under discretely distributed clearances.</p>

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Dynamic analysis and wear prediction of variable-length flexible beams with discrete clearances

  • 期刊论文

  • 发表日期：

    2026年7月2日

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  • Dandan Li,
  • Zhenxing Yan,
  • Zhan Wei,
  • Dong Liang,
  • Meng Li,
  • Zhikai Zhang

摘要

High-speed variable-length axially moving beams with multiple discrete clearances exhibit coupled geometric nonlinearity, time-varying transport, and nonsmooth impact and friction. These effects jointly govern vibration response and wear-induced failure. A remaining challenge is to quantitatively connect transient multi-point clearance interactions to long-term wear evolution and service-life prediction. This study develops an integrated dynamics and wear framework for a rapier-loom weft-insertion mechanism. The rapier tape is modeled as a variable-length Euler–Bernoulli beam with von Kármán geometric nonlinearity derived from generalized Hamilton’s principle and reduced via Galerkin discretization. Guide-hook clearances are described by complementarity conditions within a nonsmooth time-stepping scheme, enabling robust simulation of intermittent impact and Coulomb friction. An Archard-type wear model driven by the reconstructed transient contact actions is then used to predict wear accumulation and service life. Simulations show that increasing drive speed raises both impact force and impact frequency, resulting in a nonlinear increase in wear. Parametric analyses further reveal the role of guide-hook layout in shaping the dynamic response and wear accumulation. Based on cycle-wide dynamic characteristics, a dynamics-informed variable-density guide-hook placement scheme is proposed to suppress vibration, mitigate clearance interactions, reduce wear growth, and extend service life compared with a uniform layout. The proposed framework supports dynamic design, layout optimization, and life prediction of high-speed variable-length flexible beam systems under discretely distributed clearances.