Roles of microstructure, inclusion, and surface roughness on rolling contact fatigue of a wind turbine gear

2020 ◽  
Vol 43 (7) ◽  
pp. 1368-1383
Author(s):  
Hao Zhou ◽  
Peitang Wei ◽  
Huaiju Liu ◽  
Caichao Zhu ◽  
Cheng Lu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Wind Turbine ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact

Service Loading Analysis of Wind Turbine Gearbox Rolling Bearings Based on X-Ray Diffraction Residual Stress Measurements

2013 ◽  
Vol 768-769 ◽  
pp. 723-732 ◽  
Author(s):  
Jürgen Gegner ◽  
Wolfgang Nierlich
Keyword(s):  
Residual Stress ◽  
Wind Turbine ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
X Ray Diffraction ◽  
Rolling Bearings ◽  
Wind Turbine Gearbox ◽  
X Ray ◽  
Stress Measurements

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.

scholarly journals Rolling Contact Fatigue Life of Case−Hardened Steel Treated by Shot Peenings with Shot Diameters of 0.05 mm and 0.30 mm

2011 ◽  
Vol 86 ◽  
pp. 645-648 ◽  
Author(s):  
Lei Wang ◽  
Guang Liang Liu ◽  
Masanori Seki ◽  
Masahiro Fujii ◽  
Qian Li
Keyword(s):  
Surface Roughness ◽  
Fatigue Life ◽  
Shot Peening ◽  
Fine Particle ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Surface Hardness ◽  
Hardened Steel ◽  
Rolling Contact ◽  
Contact Fatigue Life

In order to investigate the influence of different shot peenings on the rolling contact fatigue life of case−hardened steel, the thrust type rolling contact fatigue test was performed with a ball−on−disk contact tester. In this study, the case−hardened steel disks were treated by the fine particle peening with a shot diameter of 0.05 mm and the normal shot peening with a shot diameter of 0.30 mm. The surface hardness and the surface compressive residual stress of the test disks were increased by these peenings. On the other hand, the surface roughness of the test disks was increased by the normal shot peening, and was decreased by the fine particle peening. The rolling contact fatigue test showed that the rolling contact fatigue life of the test disks was improved by the fine particle peening, and was not improved by the normal shot peening. The rolling contact fatigue life of the test disks became longer as their surface roughness became smaller. Therefore, it follows from this that the fine particle peening, which can provide the increase in surface hardness and the decrease in surface roughness, is good for the increase in the rolling contact fatigue life of case−hardened steel.

A Parametric Investigation of Surface Initiated Rolling Contact Fatigue Using the Asperity Point Load Mechanism

2013 ◽  
Vol 577-578 ◽  
pp. 45-48
Author(s):  
Dave Hannes ◽  
B. Alfredsson
Keyword(s):  
Surface Roughness ◽  
Fatigue Life ◽  
Surface Stress ◽  
Crack Path ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Local Stress ◽  
Point Load ◽  
Rolling Contact ◽  
Residual Surface Stress

Rolling contact fatigue (RCF) will eventually become an issue for machine elementsthat are repeatedly over-rolled with high contact loads and small relative sliding motion. Thedamage consists of cracks and craters in the contact surfaces. Asperities on the contact surfacesact as local stress raisers and provide tensile surface stresses which can explain both initiationand propagation of surface initiated RCF damage. A parametric study was performed to inves-tigate the contribution of surface roughness, friction and a residual surface stress to the RCFdamage process. The effects on initiation, crack path and fatigue life at both early and devel-oped damage were examined for a gear application. Both a one-parameter-at-a-time approachand a 2-level full factorial design were carried out. Surface roughness and local friction prop-erties were found to control crack initiation, whereas the simulated crack path was primarilyaffected by the residual surface stress, especially for developed damage. Reduced surface rough-ness, improved lubrication and a compressive residual surface stress all contributed to increasethe simulated fatigue life. The asperity point load model could predict effects on RCF that areobserved with experiments. The results further support the asperity point load mechanism asthe source behind surface initiated RCF.

Early Stages of the Wear Behavior of AISI 440C Stainless Steel under Rolling Contact in Water

2012 ◽  
Vol 566 ◽  
pp. 654-659
Author(s):  
Takashi Honda ◽  
Katsuyuki Kida ◽  
Edson Costa Santos ◽  
Takuya Shibukawa
Keyword(s):  
Surface Roughness ◽  
Wear Track ◽  
Adhesion Force ◽  
Wear Behavior ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Wear Loss ◽  
Adhesion Wear ◽  
Laser Confocal Microscope

In the present work, rolling contact fatigue (RCF) tests in water were performed on AISI 440C stainless steels under different loading. Each test was interrupted at 3.6×104, 7.2×104, 1.44×105, 2.16×105, 2.88×105 and 2.88×105 rotating cycles and the wear track at different stages was observed by using a 3D laser confocal microscope. The wear loss at 2100 N was a significantly higher compared to 500 N or 1000 N. The contact surface roughness in samples tested at 2100 N increased during the rolling contact and severe adhesion wear was present at the entire surface. In case of 500 and 1000 N tests, the surface roughness remained low with mild adhesion wear occurring. It is concluded that adhesion force levels are higher under high load rolling contact. They greatly influence the surface conditions and cause high wear loss.

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