scholarly journals Production-Related Surface and Subsurface Properties and Fatigue Life of Hybrid Roller Bearing Components

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1339
Author(s):  
Bernd Breidenstein ◽  
Berend Denkena ◽  
Alexander Krödel ◽  
Vannila Prasanthan ◽  
Gerhard Poll ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Residual Stresses ◽  
Rolling Contact Fatigue ◽  
Roller Bearing ◽  
Contact Fatigue ◽  
High Strength ◽  
Experimental Tests ◽  
Axial Direction ◽  
Rolling Contact ◽  
Deep Rolling

By combining different materials, for example, high-strength steel and unalloyed structural steel, hybrid components with specifically adapted properties to a certain application can be realized. The mechanical processing, required for production, influences the subsurface properties, which have a deep impact on the lifespan of solid components. However, the influence of machining-induced subsurface properties on the operating behavior of hybrid components with a material transition in axial direction has not been investigated. Therefore, friction-welded hybrid shafts were machined with different process parameters for hard-turning and subsequent deep rolling. After machining, subsurface properties such as residual stresses, microstructures, and hardness of the machined components were analyzed. Significant influencing parameters on surface and subsurface properties identified in analogy experiments are the cutting-edge microgeometry, S¯, and the feed, f, during turning. The deep-rolling overlap, u, hardly changes the residual stress depth profile, but it influences the surface roughness strongly. Experimental tests to determine fatigue life under combined rolling and rotating bending stress were carried out. Residual stresses of up to −1000 MPa, at a depth of 200 µm, increased the durability regarding rolling-contact fatigue by 22%, compared to the hard-turned samples. The material transition was not critical for failure.

Prediction of Equivalent Radial Loads for Tapered Roller Bearings

1996 ◽  
Vol 118 (3) ◽  
pp. 651-656
Author(s):  
Ted E. Bailey ◽  
Robert W. Frayer
Keyword(s):  
Fatigue Life ◽  
Rolling Contact Fatigue ◽  
Roller Bearing ◽  
Contact Fatigue ◽  
Subsequent Development ◽  
Rolling Contact ◽  
Tapered Roller Bearing ◽  
Applied Loading ◽  
Tapered Roller ◽  
Tapered Roller Bearings

Calculating the fatigue life of a tapered roller bearing has become a rather straightforward exercise thanks to the accumulation of rolling contact fatigue data and the subsequent development of formulation relating applied loading to bearing fatigue life. An integral part of the prediction process is to define an equivalent radial load (EQRL) by combining a bearing’s applied radial and thrust loading into a single entity. This paper reviews currently accepted formulation and offers a potentially more accurate alternative method for estimating the EQRL of a tapered roller bearing than does the current AFBMA standard.

Improvement of Rolling Contact Fatigue Life by a Preliminary Loading in Elastic-Plastic Domain

2008 ◽  
Author(s):  
Spiridon Cretu
Keyword(s):  
Fatigue Life ◽  
Residual Stresses ◽  
Rolling Contact Fatigue ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Ball Bearings ◽  
Loading Cycle ◽  
Elastic Plastic ◽  
Plastic Domain ◽  
Von Mises

An analysis model has been developed to model the nonlinear strain rate dependent deformation of rolling bearing steel stressed in the elastic-plastic domain. The model is developed in the frame of the incremental theory of plasticity by using the von Mises yield criterion and Prandtl-Reuss equations. By considering the isotropic and non-linear kinematic hardening laws of Lemaitre-Caboche, the model accounts for the cyclic hardening phenomena. To attain the final load of each loading cycle, the two bodies are brought into contact incrementally. For each new load increment new increments for the components of stress and strain tensors, but also increments of residual stresses, are computed for each point of the 3D mesh. Both, the new contact geometry and residual stresses distributions, are further considered as initial values for the next loading cycle, the incremental technique being reiterated. The cyclic evaluation process of both, plastic strains and residual stresses is performed until the material shakedowns. The experimental part of the paper regards to the rolling contact fatigue tests carried out on two groups of line contact test specimens and on two groups of deep groove ball bearings. In both cases, the experimental data reveal more than two times greater fatigue life for the group with induced residual stresses versus the life of the reference group. The von Mises equivalent stress is considered in Ioannides-Harris rolling contact fatigue model to obtain theoretical lives. The theoretical analysis revealed greater fatigue lives for the test specimens and for the ball bearings groups with induced residual stresses than the fatigue lives of the corresponding reference groups.

Optimized Logarithmic Roller Crowning Design of Cylindrical Roller Bearings and Its Experimental Demonstration

2009 ◽  
Author(s):  
Hiroki Fujiwara ◽  
Tatsuo Kawase ◽  
Takuji Kobayashi ◽  
Kazuto Yamauchi
Keyword(s):  
Fatigue Life ◽  
Rolling Contact Fatigue ◽  
Roller Bearing ◽  
Contact Fatigue ◽  
Mathematical Optimization ◽  
Optimization Method ◽  
Rolling Contact ◽  
Contact Fatigue Life ◽  
Life Tests ◽  
Machine Elements

A logarithmic profile is an essentially optimal geometry for rolling machine elements such as bearing rollers and raceways. Under most conditions of loading, it yields less stresses to give longer endurance. Lundberg first suggested the basic profile, and some researchers followed him by modifying it to satisfy engineering requirements. In this paper, the authors propose a mathematical optimization method for various profiles including a logarithmic one in roller bearing applications. Moreover, rolling contact fatigue life tests are carried out to make a comparison among logarithmically-crowned, standard partially-crowned and modified partially-crowned rollers. Results show that the logarithmic and modified partially crowned rollers are comparable in fatigue life, although the logarithmic rollers require less working effort to process the crowning.

Enhancement of roller bearing fatigue life by innovative production processes

2019 ◽  
Vol 71 (8) ◽  
pp. 1003-1006
Author(s):  
Florian Pape ◽  
Oliver Maiss ◽  
Berend Denkena ◽  
Gerhard Poll
Keyword(s):  
Fatigue Life ◽  
Residual Stresses ◽  
Hard Turning ◽  
Roller Bearing ◽  
Rolling Contact ◽  
Deep Rolling ◽  
Process Step ◽  
Content Type ◽  
Machine Elements ◽  
Compressive Residual Stresses

Purpose The efficient and economical use of natural resources is a big issue. Machine elements with a rolling contact are highly relevant because of their wide application in technical systems and a large production quantity. Innovative hard machining can reduce the friction and increase the fatigue strength of rolling element bearings. The purpose of this study is to focus on the surface properties of such parts. Design/methodology/approach A new model to predict bearing fatigue life is presented which takes compressive residual stresses in the bearing subsurface area into consideration. The investigated bearings were machined by the processes of hard turning, hard turning with subsequent deep rolling and a combination of hard turning and deep rolling (turn-rolling) in one process step. Changes in the residual stress state during bearing fatigue tests were investigated and the influence of residual stresses on the bearings fatigue life was researched. Findings Both combinations including the deep rolling process decrease the surface roughness and induce compressive residual stresses. As a result, the L10 fatigue life of roller bearings was increased by the factor of 2.5. Owing to the developed models, this effect can be considered within the design process. Originality/value In the context of the research program “Resource efficient Machine Elements (SPP1551),” machining processes of bearings were investigated regarding the bearing fatigue life. By inducing beneficial residual stresses on the bearings’ subsurface area, the fatigue life could be increased. Thus higher resource efficiency was achieved. To increase the productivity, a combination of hard turning and deep rolling was evaluated.

Basic Study on Rolling Contact Fatigue Life of Cross Roller Bearing

2020 ◽  
Vol 2020 (0) ◽  
pp. S11222
Author(s):  
Yasuyoshi TOZAKI ◽  
Koki NISHIKAWA ◽  
Makishi TAKEYASU ◽  
Kazuhiro MAEKAWA ◽  
Takuzi YAMAMOTO
Keyword(s):  
Fatigue Life ◽  
Rolling Contact Fatigue ◽  
Roller Bearing ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Basic Study ◽  
Contact Fatigue Life

Analysis of Residual Stresses Impact on Fatigue Life of Rolling Contacts

2007 ◽  
Author(s):  
S. Cretu ◽  
M. Benchea
Keyword(s):  
Fatigue Life ◽  
Residual Stresses ◽  
Reference Group ◽  
Yield Criterion ◽  
Rolling Contact Fatigue ◽  
Equivalent Stress ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Deformation Analysis ◽  
Von Mises

The values of residual stresses resulting from a heavily stressed contact are numerically evaluated by employing a three-dimensional strain deformation analysis model. The model is developed in the frame of the incremental theory of plasticity including the von Mises yield criterion, Prandtl-Reuss equations, and Ramberg-Osgood stress-strain equation. Two groups of cylindrical specimens were subjected to rolling contact fatigue, one as the reference group and the other with an induced residual stresses state. To obtain theoretical lives of the tested groups the von Mises equivalent stress is used in Ioannides-Harris rolling contact fatigue model. Both, the experimental data and theoretical analysis reveal more than two times greater fatigue life for the group with induced residual stresses versus the life of the reference group.

On Modeling the Rolling Contact Fatigue Performance Based on Residual Stresses Generated by Superfinish Hard Turning

2000 ◽  
Author(s):  
Salah R. Agha ◽  
C. Richard Liu
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Hard Turning ◽  
Rolling Contact Fatigue ◽  
Equivalent Stress ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Contact Fatigue Life ◽  
The Difference

Abstract It was shown earlier [Agha and Liu, 1998, 1999, 2000] that different cutting conditions, within superfinish hard turning, would lead to significantly different rolling contact fatigue lives. In this study, residual stresses were measured. The rolling contact fatigue life was then modeled using a maximum modified equivalent stress that takes residual stresses into account. It is seen that the maximum modified equivalent stress is a better predictor than the maximum Hertzian stress, but, still not accurate, given the consistent repeatability of the tested workpieces [Agha and Liu, 2000]. The difference in the nature of residual stresses produced by grinding and hard turning is used to show why the inclusion of the maximum modified equivalent stress, its location and the volume at risk, improves the power of the model to predict the rolling contact fatigue lives of the hard turned surfaces. This model is the best up to date for predicting the fatigue life of a surface, especially when residual stress is a factor.

Residual Stresses in Roller Bearing Components

2013 ◽  
Vol 768-769 ◽  
pp. 755-761
Author(s):  
Hans Schlicht ◽  
Hermann Vetters
Keyword(s):  
Residual Stresses ◽  
Contact Area ◽  
Rolling Contact Fatigue ◽  
Roller Bearing ◽  
Three Dimensional ◽  
Contact Fatigue ◽  
Rolling Contact ◽  
Structural Alterations ◽  
Fatigue Process ◽  
Static Conditions

Rolling contact fatigue is a very complex process. The mechanism can only be described by speculative considerations. Because the loading conditions during the elastic- hydro- dynamical contact are not clearly described. The loading cycle runs within extremely short rates and structural alterations occur under high hydrostatic pressure. Widely unknown is therefore, how the materials conditions are influenced by these processes. But by means of simplified considerations an approach to the rolling contact fatigue process can be obtained. Following these conceptions simplifying quasi-static conditions are drawn. A lubricant film inhibits the metallic contact of the revolved bearing components. A HERTZian load stress will be accumulated over an elliptical contact area and within and beneath this contact area three dimensional stresses are acting. The materials strengthening can be described by the hypothesis of alteration of shape. During the fatigue period, the microstructure will be changed by micro- and macro- plastically deformation. By this residual stresses occur. These are superimposed to the operational -loading –stresses which change the distressing conditions of the material. The progressive plastically deformations accompanying the growing fatigue procedure cause perpetually alterations in the distress- conditions of the material. Structural alterations of the rolling contact fatigue process are shown by means of metallography as followed: by dark etching areas (DEA), and by white etching areas (WEA) showing bands, which are positioned beneath the contact area at an angle of 30° (30°WEB) and for instance at 80° (80°WEB), and furthermore by so called butterfly structures (butterflies with “white etched” flanks). All these white etching areas, regarding their morphological structure and the etching conditions, are commonly originated by two axial distressing. The three dimensional materials distressing within the roller-bearing component on the one hand and the two dimensionally originating of the WEA on the other seem to be an antagonism. But when the changes of residual stresses during the contact rolling fatigue process are to be analyzed, it is clear that this antagonism rises only virtually because there exists a real tri-axial stress condition, which tolerates a two axial distressing of the material. By the concept, that the growing plastically deformations cause residual stresses superposing the operational load stresses, the temporary cycle of the structural alterations and the local and angular positions of the 30° WEB can be explained.

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