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Research Papers: Contact Mechanics

A Coupled Multibody Finite Element Model for Investigating Effects of Surface Defects on Rolling Contact Fatigue

[+] Author and Article Information
Zamzam Golmohammadi

School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: zgolmoha@purdue.edu

Farshid Sadeghi

Fellow ASME
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: sadeghi@purdue.edu

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received July 26, 2018; final manuscript received December 3, 2018; published online January 22, 2019. Assoc. Editor: Wenzhong Wang.

J. Tribol 141(4), 041402 (Jan 22, 2019) (11 pages) Paper No: TRIB-18-1299; doi: 10.1115/1.4042270 History: Received July 26, 2018; Revised December 03, 2018

A coupled multibody elastic–plastic finite element (FE) model was developed to investigate the effects of surface defects, such as dents on rolling contact fatigue (RCF). The coupled Voronoi FE model was used to determine the contact pressure acting over the surface defect, internal stresses, damage, etc. In order to determine the shape of a dent and material pile up during the over rolling process, a rigid indenter was pressed against an elastic plastic semi-infinite domain. Continuum damage mechanics (CDM) was used to account for material degradation during RCF. Using CDM, spall initiation and propagation in a line contact was modeled and investigated. A parametric study using the model was performed to examine the effects of dent sharpness, pile up ratio, and applied load on the spall formation and fatigue life. The spall patterns were found to be consistent with experimental observations from the open literature. Moreover, the results demonstrated that the dent shape and sharpness had a significant effect on pressure and thus fatigue life. Higher dent sharpness ratios significantly reduced the fatigue life.

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Figures

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Fig. 1

Geometry of roller and the flat domain in contact for RCF simulation (b is half contact width)

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Fig. 2

Flowchart for developed FE model with the effect of surface dent

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Fig. 3

Experimental Torsion S-N data and power law fit to the data for through hardened bearing steel JIS SUJ2 (AISI 52100 variant) from Ref. [75]

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Fig. 4

Bilinear profile of cyclic stress strain curve to calculate plastic strains corresponding to applied stresses over one fatigue cycle (Δεp)

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Fig. 5

A dented Voronoi domain using indentation simulation

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Fig. 6

The obtained contact pressure distribution over RVE for the first cycle from multibody FE model for (a) Voronoi domain without a dent and (b) dented Voronoi domain

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Fig. 7

The contact pressure distribution for the first cycle as the roller moves over the dent

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Fig. 8

The von Mises stress and accumulated plastic strains for (a) smooth Voronoi domain and (b) dented Voronoi domain

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Fig. 9

Spall initiation and propagation with corresponding plastic strains for different passes

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Fig. 10

Contact pressure and corresponding von Mises stress when roller moves over the dent for a different cycles (spall propagation)

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Fig. 11

Dent profiles with different sharpness

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Fig. 12

Weibull probability of RCF lives of Voronoi domains with different sharpness at a maximum contact pressure of (a) 2.5 GPa, (b) 2 GPa, and (c) 1.5 GPa

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Fig. 13

(a) Sharpness and (b) pile up ratio effects on RCF lives at various applied loads

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