A 3D Finite Element Model of Rolling Contact Fatigue for Evolved Material Response and Residual Stress Estimation
TL;DR: In this paper, a 3D Finite Element Model (FEM) was employed to simulate the material hardening response evolved during cyclic loadings. But, the model was only applied on a standard AISI 52100 bearing steel with the help of a semi-empirical approach.
Abstract: Rolling bearing elements develop structural changes during rolling contact fatigue (RCF) along with the non-proportional stress histories, evolved residual stresses and extensive work hardening. Considerable work has been reported in the past few decades to model bearing material hardening response under RCF; however, they are mainly based on torsion testing or uniaxial compression testing data. An effort has been made here to model the RCF loading on a standard AISI 52100 bearing steel with the help of a 3D Finite Element Model (FEM) which employs a semi-empirical approach to mimic the material hardening response evolved during cyclic loadings. Standard bearing balls were tested in a rotary tribometer where pure rolling cycles were simulated in a 4-ball configuration. The localised material properties were derived from post-experimental subsurface analysis with the help of nanoindentation in conjunction with the expanding cavity model. These constitutive properties were used as input cyclic hardening parameters for FEM. Simulation results have revealed that the simplistic power-law hardening model based on monotonic compression test underpredicts the residual generation, whereas the semi-empirical approach employed in current study corroborated well with the experimental findings from current research work as well as literature cited. The presence of high compressive residual stresses, evolved over millions of RCF cycles, showed a significant reduction of maximum Mises stress, predicting significant improvement in fatigue life. Moreover, the predicted evolved flow stresses are comparable with the progression of subsurface structural changes and be extended to develop numerical models for microstructural alterations.
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TL;DR: In this article , a shot-peened layer of nickel-based single crystal superalloy DD6 was experimentally obtained by nanoindentation under a maximum load of 100 mN.
17 citations
TL;DR: In this article, a shot-peened layer of nickel-based single crystal superalloy DD6 was experimentally obtained by nanoindentation under a maximum load of 100mN.
17 citations
TL;DR: In this article, the formation mechanism of white etching bands (WEBs) in bearing components has been investigated in a rotary tribometer under accelerated conditions, where rolling cycles are simulated in a 4-ball test configuration.
7 citations
TL;DR: In this article , a multiscale overview of modeling cyclic fatigue in terms of plastic deformation and corresponding microstructural alterations is presented, and a multidisciplinary approach at various length scales is required to fully understand the micromechanical and metallurgical response of bearing steels widely used in industry.
Abstract: During service, bearing components experience rolling cyclic fatigue (RCF), resulting in subsurface plasticity and decay of the parent microstructure. The accumulation of micro strains spans billions of rolling cycles, resulting in the continuous evolution of the bearing steel microstructure. The bearing steel composition, non-metallic inclusions, continuously evolving residual stresses, and substantial work hardening, followed by subsurface softening, create further complications in modelling bearing steel at different length scales. The current study presents a multiscale overview of modelling RCF in terms of plastic deformation and the corresponding microstructural alterations. This article investigates previous models to predict microstructural alterations and material hardening approaches widely adopted to mimic the cyclic hardening response of the evolved bearing steel microstructure. This review presents state-of-the-art, relevant reviews in terms of this subject and provides a robust academic critique to enhance the understanding of the elastoplastic response of bearing steel under non-proportional loadings, damage evolution, and the formation mechanics of microstructural alterations, leading to the increased fatigue life of bearing components. It is suggested that a multidisciplinary approach at various length scales is required to fully understand the micromechanical and metallurgical response of bearing steels widely used in industry. This review will make significant contributions to novel design methodologies and improved product design specifications to deliver the durability and reliability of bearing elements.
2 citations
TL;DR: In this article , the formation mechanism of white etching bands (WEBs) and dark etching regions (DERs) has been investigated in bearing elements under rolling contact fatigue (RCF).
Abstract: Bearing elements under rolling contact fatigue (RCF) exhibit microstructural features, known as white etching bands (WEBs) and dark etching regions (DERs). The formation mechanism of these microstructural features has been questionable and therefore warranted this study to gain further understanding. Current research describes mechanistic investigations of standard AISI 52100 bearing steel balls subjected to RCF testing under tempering conditions. Subsurface analyses of RCF-tested samples at tempering conditions have indicated that the microstructural alterations are progressed with subsurface yielding and primarily dominated by thermal tempering. Furthermore, bearing balls are subjected to static load tests in order to evaluate the effect of lattice deformation. It is suggested from the comparative analyses that a complete rolling sequence with non-proportional stress history is essential for the initiation and progression of WEBs, supported by the combination of carbon flux, assisted by dislocation and thermally activated carbon diffusion. These novel findings will lead to developing a contemporary and new-fangled prognostic model applied to microstructural alterations.
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TL;DR: In this paper, the authors used a Berkovich indenter to determine hardness and elastic modulus from indentation load-displacement data, and showed that the curve of the curve is not linear, even in the initial stages of the unloading process.
Abstract: The indentation load-displacement behavior of six materials tested with a Berkovich indenter has been carefully documented to establish an improved method for determining hardness and elastic modulus from indentation load-displacement data. The materials included fused silica, soda–lime glass, and single crystals of aluminum, tungsten, quartz, and sapphire. It is shown that the load–displacement curves during unloading in these materials are not linear, even in the initial stages, thereby suggesting that the flat punch approximation used so often in the analysis of unloading data is not entirely adequate. An analysis technique is presented that accounts for the curvature in the unloading data and provides a physically justifiable procedure for determining the depth which should be used in conjunction with the indenter shape function to establish the contact area at peak load. The hardnesses and elastic moduli of the six materials are computed using the analysis procedure and compared with values determined by independent means to assess the accuracy of the method. The results show that with good technique, moduli can be measured to within 5%.
22,557 citations
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28 Sep 1990TL;DR: In this article, the physical mechanisms of deformation and fracture are discussed, including linear elasticity, thermo-elasticity, and viscoelastic properties of real solids.
Abstract: 1. Elements of the physical mechanisms of deformation and fracture 2. Elements of continuum mechanics and thermodynamics 3. Identification and theological classification of real solids 4. Linear elasticity, thermoelasticity and viscoelasticity 5. Plasticity 6. Viscoplasticity 7. Damage mechanics 8. Crack mechanics.
3,644 citations
"A 3D Finite Element Model of Rollin..." refers background or methods in this paper
...The non-linear isotropic and kinematic hardening (NIKH) model was presented by Chaboche and Lamaitre to study the cyclic response of material under multiaxial fatigue [28]....
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...The generalised associative flow [28] is given as where ‘S’ is the stress vector, ‘q’ is the back-stress tensor,...
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TL;DR: In this paper, the main ingredients and assumptions of developing macroscopic inelastic constitutive equations, mainly for metals and low strain cyclic conditions, have been discussed, with some comparisons with the previous ones, including more recent developments that offer potential new capabilities.
1,414 citations
"A 3D Finite Element Model of Rollin..." refers background in this paper
...plastic shakedown, cyclic hardening, and ratcheting in the steady-state regime of RCF cycles [29]....
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01 Oct 1976
TL;DR: The influence of the ellipticity parameter and the dimensionless speed U, load W, and material G on minimum film thickness was investigated in this paper, where conditions corresponding to the use of solid materials of bronze, steel, and silicon nitride and lubricants of paraffinic and naphthenic mineral oils were considered.
Abstract: The influence of the ellipticity parameter and the dimensionless speed U, load W, and material G parameters on minimum film thickness was investigated. The ellipticity parameter k was varied from 1 (a ball-on-plate configuration) to 8 (a configuration approaching a line contact). The dimensionless speed parameter was varied over a range of nearly two orders of magnitude. And the dimensionless load parameter was varied over a range of one order of magnitude. Conditions corresponding to the use of solid materials of bronze, steel, and silicon nitride and lubricants of paraffinic and naphthenic mineral oils were considered in obtaining the exponent on the dimensionless material parameter.
764 citations
TL;DR: In this article, some of the most widely used RCF models are reviewed and discussed, and their limitations are addressed, and the modeling approaches recently proposed by the authors to develop life models and better understanding of the RCF.
Abstract: Ball and rolling element bearings are perhaps the most widely used components in industrial machinery. They are used to support load and allow relative motion inherent in the mechanism to take place. Subsurface originated spalling has been recognized as one of the main modes of failure for rolling contact fatigue (RCF) of bearings. In the past few decades a significant number of investigators have attempted to determine the physical mechanisms involved in rolling contact fatigue of bearings and proposed models to predict their fatigue lives. In this paper, some of the most widely used RCF models are reviewed and discussed, and their limitations are addressed. The paper also presents the modeling approaches recently proposed by the authors to develop life models and better understanding of the RCF.
438 citations
"A 3D Finite Element Model of Rollin..." refers background in this paper
...The gradual structural alterations have been termed Dark Etching regions (DERs) and White Etching bands (WEBs) [2, 15, 16] owing to decomposition of retained austenite and parent martensite....
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...RCF is, however, different from the conventional low cyclic and high cyclic fatigue due to complex multiaxial nature and non-proportional loading [2]....
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