Study of rolling contact fatigue behavior of a wind turbine gear based on damage-coupled elastic-plastic model

Rolling bearings in wind turbine gearboxes occasionally fail prematurely by so-called white etching cracks. The appearance of the damage indicates brittle spontaneous tensile stress induced surface cracking followed by corrosion fatigue driven crack growth. An X-ray diffraction based residual stress analysis reveals vibrations in service as the root cause. The occurrence of high local friction coefficients in the rolling contact is described by a tribological model. Depth profiles of the equivalent shear and normal stresses are compared with residual stress patterns and a relevant fracture strength, respectively. White etching crack failures are reproduced on a rolling contact fatigue test rig under increased mixed friction. Causative vibration loading is evident from residual stress measurements. Cold working compressive residual stresses are an effective countermeasure.

Download Full-text

Influence of Surface Roughness on Rolling Contact Fatigue Behavior of Fe-Cr Alloy Coatings

Journal of Materials Engineering and Performance ◽

10.1007/s11665-012-0315-z ◽

2012 ◽

Vol 22 (3) ◽

pp. 767-773 ◽

Cited By ~ 16

Author(s):

Zhong-yu Piao ◽

Bin-shi Xu ◽

Hai-dou Wang ◽

Dong-hui Wen

Keyword(s):

Surface Roughness ◽

Fatigue Behavior ◽

Rolling Contact Fatigue ◽

Contact Fatigue ◽

Rolling Contact

Download Full-text

Rolling contact fatigue behavior of TiN based coatings deposited on ADI by cathodic arc deposition and plasma based ion implantation and deposition

Thin Solid Films ◽

10.1016/j.tsf.2018.12.014 ◽

2019 ◽

Vol 671 ◽

pp. 95-102 ◽

Cited By ~ 1

Author(s):

Juan Pablo Quintana ◽

Juan Miguel Massone ◽

Adriana Beatriz Márquez ◽

Diego Alejandro Colombo

Keyword(s):

Ion Implantation ◽

Fatigue Behavior ◽

Rolling Contact Fatigue ◽

Contact Fatigue ◽

Rolling Contact ◽

Cathodic Arc Deposition ◽

Cathodic Arc ◽

Arc Deposition

Download Full-text

Effects of microstructure on rolling contact fatigue of a wind turbine gear based on crystal plasticity modeling

International Journal of Fatigue ◽

10.1016/j.ijfatigue.2018.10.022 ◽

2019 ◽

Vol 120 ◽

pp. 73-86 ◽

Cited By ~ 16

Author(s):

Wei Wang ◽

Huaiju Liu ◽

Caichao Zhu ◽

Peitang Wei ◽

Jinyuan Tang

Keyword(s):

Wind Turbine ◽

Crystal Plasticity ◽

Rolling Contact Fatigue ◽

Contact Fatigue ◽

Rolling Contact

Download Full-text

A Coupled Multibody Finite Element Model for Investigating Effects of Surface Defects on Rolling Contact Fatigue

Journal of Tribology ◽

10.1115/1.4042270 ◽

2019 ◽

Vol 141 (4) ◽

Cited By ~ 4

Author(s):

Zamzam Golmohammadi ◽

Farshid Sadeghi

Keyword(s):

Finite Element ◽

Fatigue Life ◽

Surface Defects ◽

Rolling Contact Fatigue ◽

Contact Fatigue ◽

Rolling Contact ◽

Internal Stresses ◽

Fe Model ◽

Elastic Plastic ◽

Pile Up

A coupled multibody elastic–plastic finite element (FE) model was developed to investigate the effects of surface defects, such as dents on rolling contact fatigue (RCF). The coupled Voronoi FE model was used to determine the contact pressure acting over the surface defect, internal stresses, damage, etc. In order to determine the shape of a dent and material pile up during the over rolling process, a rigid indenter was pressed against an elastic plastic semi-infinite domain. Continuum damage mechanics (CDM) was used to account for material degradation during RCF. Using CDM, spall initiation and propagation in a line contact was modeled and investigated. A parametric study using the model was performed to examine the effects of dent sharpness, pile up ratio, and applied load on the spall formation and fatigue life. The spall patterns were found to be consistent with experimental observations from the open literature. Moreover, the results demonstrated that the dent shape and sharpness had a significant effect on pressure and thus fatigue life. Higher dent sharpness ratios significantly reduced the fatigue life.

Download Full-text