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 (FE) 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 (CDM) 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 (RS) 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 is 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 (TBTA). 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.
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May 2018
Research-Article
A Novel Modeling Approach to Simulate Rolling Contact Fatigue and Three-Dimensional Spalls
Aditya A. Walvekar,
Aditya A. Walvekar
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: awalveka@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: awalveka@purdue.edu
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Dallin Morris,
Dallin Morris
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: morri295@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: morri295@purdue.edu
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Zamzam Golmohammadi,
Zamzam Golmohammadi
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: zgolmoha@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: zgolmoha@purdue.edu
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Farshid Sadeghi,
Farshid Sadeghi
Cummins Distinguished Professor of
Mechanical Engineering,
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: sadeghi@purdue.edu
Mechanical Engineering,
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: sadeghi@purdue.edu
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Martin Correns
Martin Correns
Schaeffler Technologies GmbH & Co,
KG Industriestraße 1-3,
Herzogenaurach 91074, Germany
e-mail: corremnt@schaeffler.com
KG Industriestraße 1-3,
Herzogenaurach 91074, Germany
e-mail: corremnt@schaeffler.com
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Aditya A. Walvekar
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: awalveka@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: awalveka@purdue.edu
Dallin Morris
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: morri295@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: morri295@purdue.edu
Zamzam Golmohammadi
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: zgolmoha@purdue.edu
Purdue University,
West Lafayette, IN 47907
e-mail: zgolmoha@purdue.edu
Farshid Sadeghi
Cummins Distinguished Professor of
Mechanical Engineering,
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: sadeghi@purdue.edu
Mechanical Engineering,
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: sadeghi@purdue.edu
Martin Correns
Schaeffler Technologies GmbH & Co,
KG Industriestraße 1-3,
Herzogenaurach 91074, Germany
e-mail: corremnt@schaeffler.com
KG Industriestraße 1-3,
Herzogenaurach 91074, Germany
e-mail: corremnt@schaeffler.com
1Corresponding author.
Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received May 1, 2017; final manuscript received August 24, 2017; published online October 23, 2017. Assoc. Editor: Alan Palazzolo.
J. Tribol. May 2018, 140(3): 031101 (12 pages)
Published Online: October 23, 2017
Article history
Received:
May 1, 2017
Revised:
August 24, 2017
Citation
Walvekar, A. A., Morris, D., Golmohammadi, Z., Sadeghi, F., and Correns, M. (October 23, 2017). "A Novel Modeling Approach to Simulate Rolling Contact Fatigue and Three-Dimensional Spalls." ASME. J. Tribol. May 2018; 140(3): 031101. https://doi.org/10.1115/1.4038098
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