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research-article

FEA Simulation of the effect of induction hardening on rolling contact fatigue

[+] Author and Article Information
Hoa Ngan Nguyen

Department of Mechanical Engineering, École de Technologie Supérieure, 1100 Notre-Dame Street West, H3C 1K3, Montréal, Québec, Canada
nguyenhoangan77@gmail.com

philippe Bocher

Department of Mechanical Engineering, École de Technologie Supérieure, 1100 Notre-Dame Street West, H3C 1K3, Montréal, Québec, Canada
philippe.bocher@etsmtl.ca

1Corresponding author.

ASME doi:10.1115/1.4040305 History: Received December 11, 2017; Revised May 08, 2018

Abstract

The objective of this research is to conduct a finite element analysis to better understand the effects of induction hardening on rolling contact fatigue (RCF). The finite element analysis was developed in 3D to estimate the maximal loading and the positions of the crack nucleation sites in the case of cylinder contact rolling. Rolling contact with or without surface compressive residual stress were studied and compared. The residual stress profile was chosen to simulate the effects of an induction hardening treatment on a 48HRC tempered AISI4340 steel component. As this hardening process not only generates a residual stress gradient in the treated component, but also a hardness gradient (called over-tempered region), both types of gradients were introduced in the present model. Residual stresses in compression were generated in the hard case (about 60HRC), tension values were introduced in the over-tempered region, where hardness as low as 38HRC were set. In order to estimate the maximal allowable loadings in the rotating cylinders to target a life of 106 cycles, a multiaxial Dang Van criterion and a shear stress fatigue limit were used in the positive and negative hydrostatic conditions, respectively. With the proposed approach, the induction hardened component was found to have a maximal allowable loading significantly higher than that obtained with a non-treated one, and it was observed that the residual tensile stress peak found in the over-tempered region could become a limiting factor for fatigue rolling contact life.

Copyright (c) 2018 by ASME
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