Three-Dimensional Elastic-Plastic Stress Analysis of Rolling Contact

2002 ◽  
Vol 124 (4) ◽  
pp. 699-708 ◽  
Author(s):  
Yanyao Jiang ◽  
Biqiang Xu ◽  
Huseyin Sehitoglu
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Stress Analysis ◽  
Tangential Force ◽  
Three Dimensional ◽  
Rolling Contact ◽  
Normal Surface ◽  
Elastic Plastic ◽  
Residual Strains ◽  
Plastic Shakedown

Three-dimensional elastic-plastic rolling contact stress analysis was conducted incorporating elastic and plastic shakedown concepts. The Hertzian distribution was assumed for the normal surface contact load over a circular contact area. The tangential forces in both the rolling and lateral directions were considered and were assumed to be proportional to the Hertzian pressure. The elastic and plastic shakedown limits obtained for the three-dimensional contact problem revealed the role of both longitudinal and lateral shear traction on the shakedown results. An advanced cyclic plasticity model was implemented into a finite element code via the material subroutine. Finite element simulations were conducted to study the influences of the tangential surface forces in the two shear directions on residual stresses and residual strains. For all the cases simulated, the p0/k ratio (p0 is the maximum Hertzian pressure and k is the yield stress in shear) was 6.0. The Qx/P ratio, where Qx is the total tangential force on the contact surface in the rolling direction and P is the total normal surface pressure, ranged from 0 to 0.6. The Qy/P ratio (Qy is the total tangential force in the lateral direction) was either zero or 0.25. Residual stresses increase with increasing rolling passes but tend to stabilize. Residual strains also increase but the increase in residual strain per rolling pass (ratchetting rate) decays with rolling cycles. Residual stress levels can be as high as 2k when the Qx/P ratio is 0.6. Local accumulated shear strains can exceed 20 times the yield strain in shear after six rolling passes under extreme conditions. Comparisons of the two-dimensional and three-dimensional rolling contact results were provided to elucidate the differences in residual stresses and ratchetting strain predictions.

An Analytical Approach to Elastic-Plastic Stress Analysis of Rolling Contact

1994 ◽  
Vol 116 (3) ◽  
pp. 577-587 ◽  
Author(s):  
Yanyao Jiang ◽  
Huseyin Sehitoglu
Keyword(s):  
Residual Stresses ◽  
Stress Analysis ◽  
Analytical Approach ◽  
Kinematic Hardening ◽  
Tangential Force ◽  
Rolling Contact ◽  
Approximate Determination ◽  
Elastic Plastic ◽  
Surface Plasticity ◽  
Plastic Stress

Based on a stress invariant hypothesis and a stress/strain relaxation procedure, an analytical approach is forwarded for approximate determination of residual stresses and strain accumulation in elastic-plastic stress analysis of rolling contact. For line rolling contact problems, the proposed method produces residual stress distributions in favorable agreement with the existing finite element findings. It constitutes a significant improvement over the Merwin-Johnson and the McDowell-Moyar methods established earlier. The proposed approach is employed to study combined rolling and sliding for selected materials, with special attention devoted to 1070 steel behavior. Normal load determines the subsurface residual stresses and the size of the subsurface plastic zone. On the other hand, the influence of tangential force penetrates to a depth of 0.3a, where a is the half width of the contact area, and has diminishing influence on the residual stresses beyond this thin layer. A two-surface plasticity model, commensurate with nonlinear kinematic hardening, is utilized in solution of incremental surface displacements with repeated rolling. It is demonstrated that a driven wheel undergoes greater plastic deformation than the driving wheel, suggesting that the driven wheel experiences enhanced fatigue damage. Furthermore, the calculated residual stresses are compared with the existing experimental data from the literature with exceptional agreements.

An Analytical Solution for Three-Dimensional Elliptical Elastic-Plastic Rolling Contact

2014 ◽  
Vol 658 ◽  
pp. 207-212
Author(s):  
Gabriel Popescu
Keyword(s):  
Residual Stresses ◽  
Yield Criterion ◽  
Tangential Force ◽  
Rolling Direction ◽  
Three Dimensional ◽  
Rolling Contact ◽  
Material Behavior ◽  
Hertzian Contact ◽  
Plastic Behavior ◽  
Elastic Plastic

An analytical three-dimensional elastic-plastic over-rolling solution is used to evaluate the plastic strains and residual stresses. Central to this plastic contact formulation is the incremental approach to deal with non-linear material behavior. The Prandtl-Reuss constitutive equations in conjunction with Huber-Mises-Hencky yield criterion and Ramberg-Osgood strain-hardening relationships are applied to describe the plastic behavior of common hardened bearing steel. The model was extended to include the tangential force in the rolling direction, assumed to be proportional to the hertzian contact pressure. Comparisons of three-dimensional pure rolling and rolling/sliding contact results were provided to elucidate the differences in residual stresses and residual profiles in case of kinematic and work-hardening materials.

Effect of Non-Steady State Loading on Rolling-Sliding Contact Stress

2010 ◽  
Vol 97-101 ◽  
pp. 1207-1211
Author(s):  
Jun Guo ◽  
Xue Song Jin ◽  
Ze Feng Wen ◽  
Qi Yue Liu
Keyword(s):  
Steady State ◽  
Residual Stresses ◽  
Tangential Force ◽  
Rolling Contact ◽  
Sliding Contact ◽  
Cyclic Plasticity ◽  
Wave Crest ◽  
Elastic Plastic ◽  
Steady State Rolling ◽  
Residual Strains

The stresses, strains, and deformations produced by repeated, two-dimensional non-steady state rolling-sliding contact were analyzed using an elastic-plastic finite element model. An advanced cyclic plasticity model was used. The non-steady state rolling contact was restricted to a harmonic variation of the normal Herztian contact pressure. Repeated rolling and sliding were simulated by multiple translations of a set of varying normal and tangential surface tractions across an elastic-plastic semi-infinite half space. The non-steady state loading considered results in a wavy contact surface profile. The surface displacements and wave depth of the wavy deformation increase with increasing rolling passes, but the increases in wave depth per rolling pass (ratchetting rate) decay. The residual stresses and strains near the wave trough of the residual wavy deformation are higher than those near the wave crest. The results are in agreement with the experimental observations. The tangential force has a greater influence on the residual strains than on the residual stresses.

A Direct Analysis of Two-Dimensional Elastic-Plastic Rolling Contact

1993 ◽  
Vol 115 (2) ◽  
pp. 227-236 ◽  
Author(s):  
M. Yu ◽  
B. Moran ◽  
L. M. Keer
Keyword(s):  
Finite Element ◽  
Direct Analysis ◽  
Rolling Contact ◽  
Direct Approach ◽  
Two Dimensional ◽  
Elastic Plastic ◽  
Finite Element Calculations ◽  
Plastic Analysis ◽  
Plastic Shakedown ◽  
Residual Problem

A direct approach for elastic-plastic analysis and shakedown is presented and its application to a two-dimensional rolling contact problem is demonstrated. The direct approach consists of an operator split technique, which transforms the elastic-plastic problem into a purely elastic problem and a residual problem with prescribed eigenstrains. The eigenstrains are determined using an incremental projection method which is valid for nonproportional loading and both elastic and plastic shakedown. The residual problem is solved analytically and also by using a finite element procedure which can be readily generalized to more difficult problems such as three-dimensional rolling point contact. The direct analysis employs linear-kinematic-hardening plastic behavior and thus either elastic or plastic shakedown is assured, however, the phenomenon of ratchetting which can lead to incremental collapse, cannot be treated within the present framework. Results are compared with full elastic-plastic finite element calculations and a step-by-step numerical scheme for elastic-plastic analysis. Good agreement between the methods is observed. Furthermore, the direct method results in substantial savings in computational effort over full elastic-plastic finite element calculations and is shown to be a straightforward and efficient method for obtaining the steady state (shakedown) solution in the analysis of rolling and/or sliding contact.

Elastic-Plastic Finite-Element Analysis of Repeated, Two-Dimensional Wheel-Rail Rolling Contact under Time-Dependent Load

2006 ◽  
Vol 220 (5) ◽  
pp. 603-613 ◽  
Author(s):  
Z. F. Wen ◽  
X. S. Jin
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Contact Force ◽  
Rolling Contact ◽  
Time Dependent ◽  
Two Dimensional ◽  
Normal Contact ◽  
Normal Contact Force ◽  
Residual Strains ◽  
Harmonic Variation

A study was performed using a finite-element model to obtain stresses, strains, and deformations for repeated, two-dimensional rolling contact of a locomotive driving wheel and a rail under time-dependent load. An advanced cyclic plasticity model was used with a commercial finite element code via a material subroutine. The time-dependent load was considered a harmonic variation of the wheel-rail normal contact force. The normal contact pressure was assumed to follow the Hertzian distribution and the tangential force followed the Carter distribution. A wavy profile is formed on the running surface of the rail subjected to the harmonic variation of the normal (vertical) contact force. The developed wavelength of the profile corresponds to the frequency of the normal contact force for the actual train speed. The creepage or rolling-sliding condition plays an important role in the residual strains and deformations, but its influence on the residual stresses is insignificant. The residual stresses at the surface decrease with increasing rolling passes and gradually tend to stabilize. The residual strains and surface displacements increase with increasing rolling cycle, but the increases in residual strain and surface displacement per rolling pass (ratchetting rate) decay. The residual stresses, strains, and deformations near the wave trough of the residual wavy deformation are larger than those near the wave crest. For any given creepage including zero value, when the number of rolling passes increases, the surface depth of the wavy-deformed surface increases but the ratchetting rate decays. The results are useful in investigating the influence of plastic deformation on rail corrugation.

Three-dimensional elastic–plastic stress analysis of wheel–rail rolling contact

Wear ◽  
2011 ◽  
Vol 271 (1-2) ◽  
pp. 426-436 ◽  
Author(s):  
Zefeng Wen ◽  
Lei Wu ◽  
Wei Li ◽  
Xuesong Jin ◽  
Minhao Zhu
Keyword(s):  
Stress Analysis ◽  
Three Dimensional ◽  
Rolling Contact ◽  
Elastic Plastic ◽  
Plastic Stress

Three-Dimensional Finite Element Elastic–Plastic Model for Subsurface Initiated Spalling in Rolling Contacts

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
John A. R. Bomidi ◽  
Farshid Sadeghi
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Fatigue Damage ◽  
Three Dimensional ◽  
Rolling Contact ◽  
Material Behavior ◽  
Lower Percentage ◽  
Fe Model ◽  
Plastic Model ◽  
Elastic Plastic

In this investigation, a three-dimensional (3D) finite element (FE) model was developed to study subsurface initiated spalling observed in rolling line contact of tribo components such as bearings. An elastic–kinematic hardening–plastic material model is employed to capture the material behavior of bearing steel and is coupled with the continuum damage mechanics (CDM) approach to capture the material degradation due to fatigue. The fatigue damage model employs both stress and accumulated plastic strain based damage evolution laws for fatigue failure initiation and propagation. Failure is modeled by mesh partitioning along unstructured, nonplanar, intergranular paths of the microstructure topology represented by randomly generated Voronoi tessellations. The elastic–plastic model coupled with CDM was used to predict both ratcheting behavior and fatigue damage in heavily loaded contacts. Fatigue damage induced due to the accumulated plastic strains around broken intergranular joints drive the majority of the crack propagation stage, resulting in a lower percentage of life spent in propagation. The 3D FE model was used to determine fatigue life at different contact pressures ranging from 2 to 4.5 GPa for 33 different randomly generated microstructure topology models. The effect of change in contact pressure due to subsurface damage and plastic strain accumulation was also captured by explicitly modeling the rolling contact geometry and the results were compared to those generated assuming a Hertzian pressure profile. The spall shape, fatigue lives, and their dispersion characterized by Weibull slopes obtained from the model correlate well with the previously published experimental results.

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