0
research-article

A Novel Modeling Approach to Simulate Rolling Contact Fatigue and 3D Spalls

[+] Author and Article Information
Aditya A. Walvekar

School of Mechanical Engineering Purdue University, West Lafayette, Indiana 47907
awalveka@purdue.edu

Dallin Morris

School of Mechanical Engineering Purdue University, West Lafayette, Indiana 47907
morri295@purdue.edu

Zamzam Golmohammadi

School of Mechanical Engineering Purdue University, West Lafayette, Indiana 47907
zgolmoha@purdue.edu

Farshid Sadeghi

Cummins Distinguished Professor of Mechanical Engineering School of Mechanical Engineering Purdue University, West Lafayette, Indiana 47907
sadeghi@purdue.edu

Martin Correns

Schaeffler Technologies GmbH & Co. KG Industriestraße 1-3 91074 Herzogenaurach, Germany
corremnt@schaeffler.com

1Corresponding author.

ASME doi:10.1115/1.4038098 History: Received May 01, 2017; Revised August 24, 2017

Abstract

In this study, a new approach has been developed to simulate three-dimensional (3D) experimental rolling contact fatigue (RCF) spalls using a two-dimensional (2D) finite element model. The model introduces a novel concept of dividing the 3D Hertzian pressure profile into 2D sections and utilizing them in a 2D continuum damage mechanics RCF model. The distance between the two sections was determined by the size of the grains in the material microstructure. The 2D RCF model simulates characteristics of case carburized steels by incorporating hardness gradient and residual stress distribution with depth. The model also accounts for the topological randomness in the material microstructure using Voronoi tessellation. In order to define the failure criterion for the current model, sub-surface stress analysis was conducted for the Hertzian elliptical contact. It was predicted that the high shear stress region near the end of the major axis of the contact are the cause of catastrophic damage and spall formation. This prediction was validated by analyzing the spalls observed during RCF experiments using a surface Profilometer. The model was implemented to predict RCF lives for 33 random material domains for different contact geometry and maximum Hertzian pressures. The model results were then compared to the RCF experiments conducted on two different test rigs, a three-ball-on-rod and a thrust bearing test apparatus. It was found that the RCF lives obtained from the model are in good agreement with the experimental results. The results also demonstrated that the spalls generated using the analytical results resemble the spalls observed in experiments.

Copyright (c) 2017 by ASME
Your Session has timed out. Please sign back in to continue.

References

Figures

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In