Research Papers: Applications

Bearing Life Evaluation of Wheel Hub Ball Bearing Based on Finite Element Analysis

[+] Author and Article Information
D. V. Raju

R&D Tata Steel,
Jamshedpur 831001, India
e-mail: venkat.dasu@tatasteel.com

Pravin Dixit

Tata Steel Bearings,
Kharagpur 721301, India
e-mail: pravin.dixit@tatasteel.com

Nitin Rathore

Tata Steel Bearings,
Kharagpur 721301, India
e-mail: nitin.rathore@tatasteel.com

Pala Lakshmikant

R&D Tata Steel,
Jamshedpur 831001, India
e-mail: pala.lakshmikant@tatasteel.com

Rudra Bubai

R&D Tata Steel,
Jamshedpur 831001, India
e-mail: rudra.sarkar@tatasteel.com

Rahul Verma

R&D Tata Steel,
Jamshedpur 831001, India
e-mail: rahul.verma@tatasteel.com

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received December 5, 2017; final manuscript received February 22, 2018; published online April 30, 2018. Assoc. Editor: Longqiu Li.

J. Tribol 140(5), 051102 (Apr 30, 2018) (12 pages) Paper No: TRIB-17-1471; doi: 10.1115/1.4039526 History: Received December 05, 2017; Revised February 22, 2018

Automobile deep groove ball bearings experience severe contact stresses during vehicle maneuvering near the contact with inner and outer races. The accurate prediction of the contact stresses and life estimation of ball bearings has always been challenging, following the complex nature of the contact involved and the resulting rolling contact fatigue (RCF). The present paper performs the finite element (FE) analysis by using a general FE code, abaqus to accurately predict the contact stresses, bearing loads and bearing life in form of ISO 281 (1990) life of an automobile wheel hub ball bearings. Lundberg and Palmgren method is employed for the determination of the bearing life. RomaxDESIGNER, a bearing design software, is also applied to consider the effects of various bearing life adjustment factors, which are used to determine the DIN ISO 281 life. Large amount of bearing failure field data is used to validate the predictions from the study, achieving a very good correlation. Theoretical contact stress calculations based on the Hertz contact theory are also presented for each load case. Finally, an attempt has been made to develop a relation between the contact stress and the bearing life for the hub assembly ball bearings.

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Fig. 1

Wheel hub deep groove ball bearing arrangement and cross section of 3D model

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Fig. 2

Mesh details of the assembly and the bearing components (TET elements)

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Fig. 3

Boundary conditions on the bearing hub assembly

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Fig. 4

Wheel hub ball bearing arrangement and cross section of 3D model in RomaxDESIGNER (cross-sectional view)

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Fig. 5

Displacement contour comparison from FE and RomaxDESIGNER studies: (a) straight on, (b) straight on shock, (c) light right cornering, (d) light left cornering, (e) tight right cornering, and (f) tight left cornering

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Fig. 6

Ball bearing showing the basic geometrical parameters and diametral clearance

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Fig. 7

Contact stress contours on Inboard (a) balls and (b) inner race

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Fig. 8

von Mises and shear stress contours on the ball contact regions with the inner and the outer races, the critical region is observed on the outer race contact

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Fig. 9

Contact stress contour on the bottom ball. The highlighted region corresponds to the highest load sharing ball contact on the inner race. The radial load acts in perpendicular direction to the plane of the figure: (a) S1, (b) S2, (c) R1, (d) L1, (e) R2, and (f) L2.

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Fig. 10

Normal load on each ball from inboard bearing for different loading conditions

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Fig. 11

Histogram and box plot for deep groove ball bearing field failure data and FE study/RomaxDESIGNER. The Figure also shows insight for the details.

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Fig. 12

Spalling on the inner race and deep groove ball bearings from the field

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Fig. 13

Bearing life graph with respect to contact stress from FE study: (a) proposal of life equation and (b) application of proposed life equation



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