Towards a physics based prognostic model for bearing - Spall initiation and propagation

Gazizulin, Dmitri; Kogan, Gideon; Klein, Renata; Bortman, Jacob

doi:10.1109/aero.2015.7118995

Cited by 7 publications

(5 citation statements)

References 10 publications

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“…The damage rate of evolution is given by:

where

is the number of stress cycles,

is the effective stress that causes the damage, and

and

are material-dependent parameters. More about the damage algorithm and its application can be found in [ 17 , 25 ]. The spall propagation mechanism is divided into several stages where, in each stage, cracks initiate at different locations at the spall edge.…”

Section: Methodsmentioning

confidence: 99%

New Damage Accumulation Model for Spall Propagation Mechanism in Bearing Raceways

Ohana

Klein²,

Shneck

et al. 2023

Materials

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The aim of this study was to investigate the spall propagation mechanism in ball bearing raceways using physics-based models. Spalling is one of the most common types of bearing failures that can lead to catastrophic failure. This research takes a step forward toward developing a prognostic tool for ball bearings. It is first necessary to understand the spall progression process in order to formulate a constitutive law of spall deterioration and to estimate the amount of remaining useful life. Fragment formation in the vicinity of the spall edge was found to consist of surface and sub-surface cracks that eventually coalesce, and a fragment is released from the raceway, based on naturally-developed spalls. Here, we describe a physics-based model, integrating a dynamic model with a finite element one to simulate this process. A continuum damage mechanics (CDM) approach and fracture mechanics tools were embedded into the finite element model to simulate the damage propagation. The formation of cracks in the vicinity of the spall (surface and sub-surface cracks) were studied using this effective stress CDM model, and the propagation of the cracks was examined using two approaches: a fracture mechanics approach and an accumulated inelastic hysteresis energy CDM approach. The latter also predicts the overall process of a single fragment release. The simulation results of the spall propagation models are supported by experimental results of spalls from both laboratory experimental bearings and an in-service Sikorsky CH-53 helicopter swashplate bearing. The results obtained show that the impact of the ball on the spall edge affects the crack propagation and the appearance of the surface and sub-surface cracks. Both release the residual stresses and cause crack propagation until a fragment is released.

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“…The damage rate of evolution is given by:

where

is the number of stress cycles,

is the effective stress that causes the damage, and

and

Section: Methodsmentioning

confidence: 99%

New Damage Accumulation Model for Spall Propagation Mechanism in Bearing Raceways

Ohana

Klein²,

Shneck

et al. 2023

Materials

Self Cite

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“…The Hertzian solution for an ideal line contact in a cylindrical roller bearing was used to represent the contact between the RE and the raceway (Gazizulin et al, 2015), as shown schematically in Fig. 1…”

Section: The Contact Modelmentioning

confidence: 99%

Physics Based Methodology for the Estimation of Bearings' RUL: Physics-Based Models, Diagnostic Methods and Experiments

Gazizulin

Klein²,

Bortman³

2018

PHME_CONF

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Rolling element bearing (REB) is one of the basic mechanical components in a rotating machinery. REBs’ remaining useful life (RUL) estimation allows not only to assess time for maintenance actions but also can prevent a critical failure of the mechanical system. Usually, REB damage occurs in two stages, damage initiation and damage propagation. In the current work, it is assumed that spall is generated on the surface of the raceway during the initiation stage. The spall generation process is modeled based on continuum damage mechanics with the representation of material grain structure and implemented using a Finite Element (FE) software. The results of the model are in a good agreement with published theoretical and experimental data. However, after the first spall formation, the bearing might be fully operational for millions of cycles. For estimation of the bearing RUL it is important to understand the damage propagation process. The material behavior at the trailing edge of the spall during the rolling element (RE) impact is analyzed. The analysis is carried out by using a hybrid modeling approach. This approach integrates non-linear dynamic modeling and FE simulations. The paper also includes a discussion on the ongoing research and the methodology for the development of the prognostic method. Implementation of the proposed methodology has the potential to provide a complete estimation of the bearing’s RUL: from first spall formation to the un-operational bearing.

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“…9 Flow chart of the numerical solution for the damage model. 30 simulate the RCF process. The number of cycles elapsed until the first microcrack is termed the initiation time.…”

Section: Parametric Studymentioning

confidence: 99%

Towards efficient spall generation simulation in rolling element bearing

Gazizulin

Klein²,

Bortman

2017

Fatigue Fract Eng Mat Struct

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Rolling element bearing prognosis is the process of forecasting the remaining operational life, future condition or probability of failure of the bearing. While operational, bearings are subjected to rolling contact fatigue (RCF), and, as a result, a spall is generated on the raceway of the bearing. Complete understanding of the fatigue process is critical for predictive modelling to estimate bearing remaining useful life, which allows improved scheduling of maintenance actions. This work presents an RCF model that was implemented using abaqus finite element software. The RCF model is based on a damage mechanics approach that relates the accumulated microscopic failure mechanisms to a damage state variable and includes representation of material grain structure by a Poisson–Voronoi tessellation. Different microstructures, with a variety of material properties and grain topologies, were constructed for simulation purposes. The geometry of the simulated spalls and the Weibull slopes of the fatigue lives are in good agreement with published theoretical and experimental data. It can be concluded that the assumptions and the simplifications of the current, convenient to use, RCF model yield a sufficiently accurate tool on the basis of previous publications and experimental data.

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Towards a physics based prognostic model for bearing - Spall initiation and propagation

Cited by 7 publications

References 10 publications

New Damage Accumulation Model for Spall Propagation Mechanism in Bearing Raceways

New Damage Accumulation Model for Spall Propagation Mechanism in Bearing Raceways

Physics Based Methodology for the Estimation of Bearings' RUL: Physics-Based Models, Diagnostic Methods and Experiments

Towards efficient spall generation simulation in rolling element bearing

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