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Abstract
A theoretical framework is developed for the evaluation of favorable residual stress profiles, suppressing fatigue damage initiation in rolling contact fatigue. Non-metallic inclusions at the microstructure of bearings are one of the most important reasons for fatigue damage initiation since they act as stress risers. In order to evaluate the stress state around such inclusions at the micro-scale, macroscopic stress histories are determined by Hertzian contact theory at different depths below the raceway for a typical roller bearing. These stress distributions are then used as far-field stresses for a micro-scale model accounting for single inclusions of different geometries and orientations. Eshelby’s method is used to relate far-field and local stresses in the vicinity of inclusions. The von Mises stress criterion is then used as a conservative estimator of crack initiation due to micro-scale plasticity. The effect of compressive residual stresses added to the axial and circumferential normal stress components at different depths is analyzed. The von Mises stress field around different inclusions at different depths is investigated in order to determine the most critical case in terms of micro-scale plastic deformation. Finally, an optimization process is carried out in order to determine the residual stresses that minimize the maximum observed von Mises stress as a function of depth.
Highlights
Rolling element bearings are widely used in modern machinery like wind turbines, aerospace applications, engines, etc. to support rotary elements
Geometrical and material parameters used in this study are provided first, followed by von Mises stresses calculated without and with inclusions, and the effect of superimposed compressive residual stresses is investigated
Microscale von Mises stresses are calculated at a large number of points around the inclusion analyzed at 16 different depths from the surface
Summary
Rolling element bearings are widely used in modern machinery like wind turbines, aerospace applications, engines, etc. to support rotary elements. Shen et al [24] developed a two dimensional finite element model based on continuum damage mechanics to investigate the effects of retained austenite and residual stresses on rolling contact fatigue and compared their results with experiments. Ooi et al [28] investigated the effect of retained austenite and residual stress on rolling contact fatigue of carburized steel numerically based on a 2D extended finite element model and experimentally. Golmohammadi et al [29] developed a 3D elastoplastic finite element model to characterize the rolling contact fatigue behavior of through hardened steel at high loads incorporating compressive residual stresses induced by plastic deformation. Using von Mises stress as an indicator for crack initiation due to micro-scale plasticity, optimal compressive residual stresses added to the axial and circumferential stress components are determined as a function of depth
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