Predicting fatigue life for finite roller contacts based on a mixed EHL model using realistic surface roughness

Abstract

Surface contact fatigue is a major failure mode of many mechanical components, such as various gear pairs, bearings, cam-follower systems, and so on. The present study aims to develop a fatigue life prediction approach for finite line contact model using machined surface topography. Based on the developed model, the effect of working conditions and lubrication parameters on the lubrication performance and fatigue life are investigated. The obtained results show that, by introducing the realistic roughness, the distribution of pressure, film thickness and stress field is significant fluctuations. Meanwhile, the location of maximum stress tends to move to subsurface. The effect of load on fatigue life is significant. Yet, the speed does not seem to have a great influence on the fatigue life in various load ranges. It is also indicated that the high ambient viscosity is beneficial to the lubrication performance and fatigue life.