A continuum damage mechanics finite element model for investigating effects of surface roughness on rolling contact fatigue

Lorenz, Steven J; Sadeghi, Farshid; Trivedi, Hitesh K.; Rosado, Lewis; Kirsch, Mathew; Wang, Chinpei

doi:10.1016/j.ijfatigue.2020.105986

Cited by 54 publications

(13 citation statements)

References 52 publications

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“…A higher surface roughness results in a lower minimum film thickness over the equivalent root‐mean‐square (RMS) roughness of two surfaces (λ‐ratio or specific film thickness). At the same time, fatigue failure is closely related to the amplitude and frequency of surface roughness 36 . The local stress caused by roughness is too high leading to plastic deformation in the surface micro‐area, where many micro‐cracks will inevitably occur.…”

Section: Discussionmentioning

confidence: 99%

“…At the same time, fatigue failure is closely related to the amplitude and frequency of surface roughness. 36 The local stress caused by roughness is too high leading to plastic deformation in the surface micro-area, where many micro-cracks will inevitably occur. All RCF tests in our study were performed under initial conditions in which the value of λ was very low (λ < 0.45).…”

Section: Formation Mechanism Of Surfaceinitiated Pitsmentioning

confidence: 99%

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Re‐recognition of deep spalling damage mechanism of rolling contact fatigue under heavy load

Xia

Zhang

et al. 2023

Fatigue Fract Eng Mat Struct

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This paper presents a detailed analysis of the nucleation and propagation of surface‐initiated crack in rolling contact fatigue (RCF) of bearing steel under heavy load. The cracks initiated from the junction of machining marks and trailing edge of dents formed by the plastic deformation. Crack propagation and spalling were mainly composed of three stages: (1) cracks initiating from surface defects propagate downward to form small spalling pits; (2) due to the surface stress and the maximum Hertz stress form a stress bridge, the cracks continue to expand towards the Hertz stress peak forming big spall; (3) the trailing edge of the spalling pit is used as the stress raiser to initiate next subsurface cracks and spalling expansion in successive. Different from previous understanding on the formation of subsurface‐initiated spalling, the results indicate that under heavy load the spalling at depth of the maximum shear stress zone in the subsurface can initiate from surface cracks.

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Section: Discussionmentioning

confidence: 99%

Section: Formation Mechanism Of Surfaceinitiated Pitsmentioning

confidence: 99%

Re‐recognition of deep spalling damage mechanism of rolling contact fatigue under heavy load

Xia

Zhang

et al. 2023

Fatigue Fract Eng Mat Struct

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“…[1][2][3][4][5][6][7][8][9] The second is fractal methods, based on data obtained from surface topography and the fractal parameters. [10][11][12][13] Statistical methods in contacting asperities modeling have been at the center of attention in researchers' society for the last decades. The parametric analysis and checking of the effects of physical phenomena in contact problems could be a significant achievement for researchers.…”

Section: Introductionmentioning

confidence: 99%

A new analytical-numerical model for contact problem counting asperities and strain hardening effects

Sarabi

Tehrani

2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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The roughness effects on the wheel-rail contact problem is an essential topic. In this paper, a new analytical-numerical model has considered assessing the specifications of a rough surface contact problem. The new model includes asperities and strain hardening effects together. Consideration of these assumptions is more realistic in comparison to similar simplified works. In this work, the effects of material properties variation on a contact problem realize. Besides, considering the strain hardening effects, the contact results for wheel-rail material are obtained. The contact characteristics variations versus separation, such as contact force, contact stiffness, and contact area, are shown in semilogarithmic diagrams considering different surface roughnesses and hardening parameters. The new model results show the significant influence of the assumed hypothesis on the contact characteristics.

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“…Spur gear has been extensively implemented in vehicles, ships, aviation and other fields with its advantages of accurate and stable transmission and high efficiency (Dai et al, 2021;Liu et al, 2020;Mo et al, 2019Mo et al, , 2020a. The state of the tooth surface is one of the key factors that determine lubrication characteristics, load capacity and service life of the gear (Fernandez-Del-Rincon et al, 2019;Lorenz et al, 2021;Simon, 2019;Wang and Zhu, 2021). Generally, gear tooth surface roughness is of the same order of magnitude as the minimum film thickness.…”

Section: Introductionmentioning

confidence: 99%

Effect of micro-textures on lubrication characteristics of spur gears under 3D line-contact EHL model

Zhao

Zhou

et al. 2021

ILT

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Purpose The purpose of this paper is to use a combination of numerical simulation and experiment to evaluate the performance of laser surface texturing (LST) in the field of gear lubrication, and to more accurately predict the lubrication characteristics of different surfaces. Design/methodology/approach The method used in this paper is developed on the basis of the deterministic solution of the three-dimensional (3D) mixed elasto-hydrodynamic lubrication (EHL) model and the model parameters are corrected by friction test. The film pressure, film thickness and friction coefficient of different micro-textured tooth surfaces are predicted on the basis of accurate 3D mixed EHL models. Findings The results demonstrate that the micro-texture structure of the tooth surface can increase the local film thickness and enhance the lubricating performance of the tooth surface without drastically reducing the contact fatigue life. The stress distribution and friction characteristics of the tooth surface can be optimized by adjusting the micro-texture arrangement and the size of the micro-textures. Originality/value A new evaluation method using a 3D hybrid EHL model and friction test to predict the lubrication characteristics of LST is proposed, which can effectively improve the processing economy and save time. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2020-0423

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A continuum damage mechanics finite element model for investigating effects of surface roughness on rolling contact fatigue

Cited by 54 publications

References 52 publications

Re‐recognition of deep spalling damage mechanism of rolling contact fatigue under heavy load

Re‐recognition of deep spalling damage mechanism of rolling contact fatigue under heavy load

A new analytical-numerical model for contact problem counting asperities and strain hardening effects

Effect of micro-textures on lubrication characteristics of spur gears under 3D line-contact EHL model

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