Modelling of rolling-contact fatigue pitting phenomena by phase field method

Abstract

The paper proposes a novel numerical framework for modelling of the pitting damage mechanism, based on the application of the three-layered residual control staggered phase-field algorithm. Proposed numerical framework can be applied to all contacting mechanical elements subjected to rolling contact fatigue, but in this paper, it is applied on gears. More precisely, gear teeth flanks subjected to the rolling-contact fatigue conditions are investigated, which consequently results in governing pitting mechanisms. Loading of the teeth flanks is imposed via moving load, with assumption of the full-film lubrication and pressure distribution according to the elastohydrodynamic lubrication theory, as well as Hertzian theory. The Coulomb's law is used to compute the friction force distribution. The numerical framework is embedded into finite element software ABAQUS via user subroutines. The validity of the proposed numerical scheme is tested by comparison to the examples from the literature. The main mechanisms of the pitting formation have been verified, i.e., surface- and subsurface-initiated pitting formation. Furthermore, an influence of the microstructure has been considered in the modelling of pitting phenomena. It has been demonstrated that the proposed numerical framework provides satisfactory results, and it is able to capture governing pitting mechanisms.