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1
Didier, Adrien. "Mobiliser le chargement ultrasonique pour caractériser la fatigue de contact roulant : Une étude de l’amorçage." Electronic Thesis or Diss., Lyon, INSA, 2024. http://www.theses.fr/2024ISAL0133.
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Les phénomènes d’endommagements causés par la fatigue de contact roulant sur une surface indentée sont reconnus comme responsables de la majorité des dysfonctionnements de roulements aéronautiques. Ces mécanismes d’endommagements sont encore mal compris en raison d’un manque crucial de données expérimentales. En effet, ces phénomènes ne se manifestent qu’après de nombreuses années, voire plusieurs décennies de fonctionnement, ce qui rend toute analyse expérimentale conventionnelle particulièrement laborieuse et chronophage. De plus, la simulation numérique de ce type d’endommagements est actuellement impossible, tant en raison du manque de données expérimentales disponibles que du nombre extrêmement élevé de cycles à simuler. Afin de rendre accessible l’étude des sollicitations à très grand nombre de cycles, nous avons conçu un dispositif de fatigue ultrasonique capable de reproduire un trajet de chargement analogue à celui d’un roulement sur une surface indentée, avec un chargement localement multiaxial et non proportionnel. Ce parallèle entre les deux trajets de chargement a été établi grâce à des simulations numériques par éléments finis. Ainsi, le dispositif expérimental permet de simuler l’équivalent de plusieurs décennies d’utilisation, soit plusieurs milliards de cycles, en seulement quelques dizaines d’heures. Cette étude a ainsi permis d’établir de nombreux liens entre la fatigue de contact roulant et la fatigue ultrasonique. Elle a notamment permis d’expliquer le phénomène de transition des sites d’amorçage de fissures, qui se déplacent de la surface vers la profondeur du matériau, dans le cadre de la fatigue à très grand nombre de cycles. De plus, une analyse approfondie du raffinement local de la microstructure a été réalisée, mettant en évidence un lien direct avec l’amorçage en fatigue à très grand nombre de cycles. Ce phénomène de raffinement a pu être expliqué et attribué à la même cause sous-jacente dans le cas de la fatigue des roulements et de la fatigue ultrasonique : le glissement dévié des dislocations (cross-slip)Damage phenomena caused by rolling contact fatigue on an indented surface are recognized as being responsible for the majority of failures in aerospace bearings. These damage mechanisms remain poorly understood due to a critical lack of experimental data. Indeed, such phenomena only manifest after many years, or even several decades, of operation, making conventional experimental analysis particularly labor-intensive and time-consuming. Furthermore, numerical simulation of this type of damage is currently impossible, both due to the lack of available experimental data and the extremely high number of cycles required for simulation. To enable the study of very high cycle loadings, we have designed an ultrasonic fatigue device capable of reproducing a loading path analogous to that of a bearing on an indented surface, with locally multiaxial and non-proportional loading. This parallel between the two loading paths was established using finite element numerical simulations. The experimental device thus allows simulating the equivalent of several decades of usage, or billions of cycles, in just a few tens of hours. This study has therefore established numerous connections between rolling contact fatigue and ultrasonic fatigue. In particular, it has provided an explanation for the phenomenon of crack initiation site transitions, which shift from the surface to the material’s depth in the context of very high cycle fatigue. Furthermore, an in-depth analysis of local microstructural refinement was conducted, revealing a direct link with fatigue initiation in the very high cycle regime. This refinement phenomenon was explained and attributed to the same underlying cause in both bearing fatigue and ultrasonic fatigue: cross-slip of dislocations
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Bonetto, Alexis. "Etude de l'indentation et de la fatigue des contacts roulants." Thesis, Lyon, 2020. http://www.theses.fr/2020LYSEI030.
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La fatigue de surface est aujourd'hui la principale cause de défaillances des roulements. Ce type de fatigue peut se développer du simple fait de la rugosité des surfaces mais est exacerbée par la présence de défauts de surface tels que les indents. La gestion de la pollution des lubrifiants, à l'origine de l'indentation des surfaces, est très coûteuse et ne peut être parfaite puisque la pollution est à la fois présente dans les huiles neuves, générée de manière continue par les systèmes lubrifiés et introduite lors des opérations sur le système. En conséquence, les huiles charrient systématiquement des particules d'origines variées qui sont amenées dans les contacts par les systèmes de lubrification. Au passage entre les surfaces, les particules sont écrasées et indentent les surfaces, créant ainsi des défauts qui seront les sites privilégiés d'amorçage de fatigue au cours des cycles de fonctionnement suivants. Ne pouvant se prémunir de l'indentation des surfaces, une bonne compréhension des mécanismes d'indentation et de fatigue sur indent est nécessaire pour garantir la fiabilité des roulements ainsi que pour réduire les coûts liés à leur maintenance. Au cours de cette thèse, un modèle éléments finis « couplé Euler-Lagrange » est développé pour reproduire le processus d’indentation réel des roulements et en étudier les effets. Dans un second temps, la fatigue des surfaces est étudiée par l’emploi de critères de fatigue issus de la littérature dans le cadre d’un contact sec. Enfin, l’effet du lubrifiant est ajouté par la mise en place d’un solveur multigrilles permettant la résolution du problème EHD transitoireSurface fatigue is currently the main cause of rolling element bearings failures. This type of fatigue can appear due to the presence of surface asperities but is exacerbated by the presence of surface defects such as dents. Handling the contamination of the lubricants that causes the denting of the surfaces is expensive and imperfect since the particles are not only already present in brand new oil but also generated during the operation of the system. Consequently, the lubricant carts particles of various nature into the contact. As they pass through the contact, the particles are crushed and dent the bearing surfaces, creating surface defects that will turn into initiation site for fatigue phenomena. As it is impossible to avoid debris denting, a better understanding of the denting and fatigue mechanisms is required to guarantee the reliability of the components and reduce their maintenance costs. During this PhD, a “coupled Euler-Lagrange” finite element model has been developed to reproduce the realistic debris denting process and study its effects. Then, the surface fatigue of dented surfaces was investigated using fatigue criteria in dry contact conditions. Finally, the effect of the lubricant on the dented surface was introduced using a multigrid solver for the transient EHL problem
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Potier, Karl. "Effets des faibles oscillations sur la dégradation de contacts roulants avec glissement de composants aéronautiques." Thesis, Université Paris-Saclay (ComUE), 2018. http://www.theses.fr/2018SACLC035.
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Ces travaux de thèse concernent l’étude des effets des oscillations de faibles amplitudes sur la durée de vie en fatigue de contact pour des composants d’actionneurs de vol. Des outils théoriques et expérimentaux ont pour cela été employés.Un modèle semi-analytique de contact rugueux élasto-plastique a été codé puis utilisé. Celui-ci, couplé au modèle de Dang Van, a permis de réaliser une étude théorique de l’influence du sens de passage de contacts sur la durée de vie en fatigue. Une comparaison en fatigue entre mouvements continus et mouvements oscillants a ainsi pu être faite.Un banc bi-disque a été spécifiquement développé chez UTAS pour pouvoir réaliser des essais de fatigue de roulement aussi bien en mouvements continus qu’en mouvements oscillants. Des essais de lubrification ont été réalisés sur des éprouvettes en XD15NW et en CX13VD afin de caractériser le phénomène de faux effet Brinell. Des essais de fatigue en lubrification optimale ont finalement été réalisés sur les éprouvettes en XD15NW en mouvements continus et en mouvements oscillants, les résultats ont été comparés et mis en vis-à-vis avec ceux de l’analyse théoriqueThis PhD thesis is a study of small reciprocating motions effects on contact fatigue life of flight actuator components. Theoretical and practical tools are used for this purpose.A semi-analytical elasto-plastic rough contact code has been implemented and, then, used. This code, associated with Dang Van model, allowed us to perform a theoretical study of rolling direction effect on fatigue life. A comparison has been made between continuous motions and reciprocating motions.A twin-disc test bench has been specifically design at UTAS to allow us to perform rolling fatigue tests with continuous motions or with reciprocating motions. Lubrications tests have been done on XD15NW and CX13VD samples in order to study false brinelling phenomenon. Finally, fatigue tests in ideal lubrication conditions have been done on XD15NW samples with continuous motions and with reciprocating motions, results have been cross-checked each other and cross-checked with theoretical results
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Berthe, Laure. "Durée de vie des contacts rugueux roulants." Thesis, Lyon, INSA, 2014. http://www.theses.fr/2014ISAL0097/document.
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La tenue des surfaces des contacts rugueux roulants est un problème crucial l’évaluation de la durée de vie des mécanismes. Cette durée de vie est conditionnée dès les premiers cycles par le rodage puis par les mécanismes de fatigue des surfaces. Le rodage est défini par le temps nécessaire à l’accommodation géométrique des surfaces rugueuses entre elles, à l’interface du contact. La charge transmise sur une faible aire de contact par rapport à l’aire apparente, crée des pressions importantes qui induisent de fortes contraintes en couche superficielle et des déformations plastiques de la microgéométrie. Cette plastification a lieu dans les tous premiers cycles puis la surface se stabilise, c’est le rodage. La répétition cyclique des sollicitations au cours du fonctionnement conduit enfin à l’endommagement du matériau et des avaries en surface telles que des micro-écailles. Après une étude bibliographique sur le contact roulant rugueux et les dispositifs expérimentaux existants, la difficulté de ce type d’analyse est mise en évidence. Elle consiste à effectuer un suivi en continu de l’évolution de l’état de surface du contact à une échelle suffisamment fine et précise. Une micromachine bi-disque a été développée afin de réaliser ce suivi quasi "in-situ" à l’échelle des rugosités permettant d’identifier les mécanismes de rodage et de dégradation. Un protocole expérimental précis permet de mesurer les surfaces antagonistes dans les premiers cycles correspondant au rodage. Les surfaces vierges mesurées sont utilisées comme paramètre d’entrée d’une simulation numérique du contact rugueux d’une sphère sur un plan. La déformée de surface numériquement obtenue à l’état stabilisé est comparée à celle mesurée expérimentalement à la fin du rodage. La très bonne superposition de ces résultats permet de valider cette méthode et les résultats numériques tels que les contraintes résiduelles et déformations plastiques. Les surfaces à l’état stabilisé obtenues, sont exploitées à travers différents critères de fatigue multiaxiaux. Les résultats numériques sont également comparés aux observations expérimentales pour déterminer le critère le plus adapté à cette analyse et permettant d’expliquer la formation de fissures et d’avaries de surfacesThe surface life of rolling rough contacts is an important problem in the evaluation of the life expectancy of a machine. This life span is conditioned by the first cycles of the running-in process and then by the surface fatigue. The running-in period is defined by the time necessary for the rough surfaces to accommodate. The real area of contact is small compared with the apparent area, hence the load creates important pressures which lead to important stresses in the superficial layer and to plastic deformation of the microgeometry. The plastic deformation takes place over the first cycles then the surface stabilizes, this is the end of running-in process. The repeated cyclic loading finally leads to material damage below the surface and to surface micropitting. After a bibliographical study on the rough rolling contact and the existing experimental test machines, the difficulty of analysing the roughness evolution is pointed out. It requires a precise, continuous monitoring of the contact surface evolution on a small enough scale. A two-disk micro-machine was developed to perform this almost "in situ" monitoring at the roughnesses scale, allowing one to identify the mechanisms of running-in and surface degradation. An accurate experimental protocol allows one to measure the opposing surfaces in the first cycles corresponding to the running-in period. The initial surfaces are used as entrance parameters for a numerical simulation of the rough contact of a sphere on a plane. The deformed surface numerically obtained in the stabilized state is compared with the measured one at the end of the running-in period. The very good agreement between these results allows one to validate this method and the numerical results such as the residual stresses and the plastic deformation. Different multiaxial fatigue criteria are applied to the numerical results obtained in the stabilized state. The results are compared to the experimental observations to determine the criterion that is the most suited for this analysis and allows one to explain the crack formation and surfaces damage
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Le, Marion. "Influence des liserés de carbures induits par la nitruration gazeuse sur les mécanismes de fissuration de fatigue de contacts roulants." Thesis, Lyon, INSA, 2015. http://www.theses.fr/2015ISAL0102/document.
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La nitruration gazeuse est utilisée par les fabricants d’engrenages pour traiter la surface des dentures. En effet, l’augmentation de la dureté et l’introduction de contraintes résiduelles de compression contribuent à retarder voire inhiber l’initiation et la propagation des fissures superficielles de fatigue de contact. Cependant la majorité des aciers alliés présentent des réseaux de précipités de carbures dans la couche nitrurée. Ceux-ci ont la particularité de se retrouver aux joints de grains relativement parallèles à la surface, ce qui leurs ont attribué les surnoms de «liserés de carbures». Associés à une phase dure et fragile, ces carbures constituent des zones d’hétérogénéités. Par ailleurs, la norme pour la qualité des matériaux d’engrenages autorise une large gamme de tailles de grains, conduisant à diverses microstructures pour les couches nitrurées des aciers alliés. En effet, la morphologie des réseaux de carbures après nitruration dépend entre autres de la taille de grain de l’acier. De par le manque de travaux sur l’impact réel de ces précipités sur la fatigue de contact, la présente étude propose des analyses d’essais. Les essais consistent à reproduire de l’écaillage initié en surface sur des éprouvettes dont les couches nitrurées, issues d’un seul traitement thermochimique, présentent les mêmes propriétés mécaniques (dureté et contraintes résiduelles) mais différentes propriétés microstructurales (tailles de grains et morphologies de carbures). Les analyses ont permis de proposer des mécanismes d’initiation de micro-fissures induites en proche surface sous les conditions d’essai appliquées. Les sites d’initiation dépendent de la taille de grain de l’acier et peuvent en particulier s’établir au niveau des carbures intergranulaires. L’étude des réseaux de fissures couplée à l’analyse des contraintes résiduelles a permis d’établir des scénarii de propagation des fissures dans les couches nitrurées. Sous les conditions de contact appliquées, l’apparition de déformation plastique entraîne, par accommodation des variations de volume, la relaxation des contraintes résiduelles compressives initialement présentes dans le matériau, aux profondeurs les moins sollicitées. Ces contraintes étant moins compressives, elles libèrent les micro-fissures déjà présentes en proche surface. Dès lors, la propagation au travers des carbures qui s’apparentent à des sites privilégiés pour la croissance des fissures en cours de fatigue est possible. En particulier, ces précipités entraînent les fissures vers le cœur lorsqu’ils sont en forte densité dans les couches nitrurées, tandis que l’endommagement reste superficiel lorsque l’éloignement entre les précipités est trop important. Enfin, la continuité et la longueur des carbures augmentent localement la vitesse de propagation des fissures. Ceci se traduit par l’apparition plus rapide de l’écaillage initié en surface pour les couches nitrurées de microstructures grossièresGas nitriding is a thermochemical surface treatment widely used by gear manufacturers to improve the rolling contact fatigue endurance of their components. Indeed, increasing the hardness and introducing compressive residual stresses to the geartooth surfaces inhibit or delay crack initiation and propagation. However, most of the alloyed steel nitrided layers show the presence of intergranular carbide networks. The precipitation of these carbides specifically occurs at parallel grain boundaries during the treatment and, being a carbon-rich phase, they are associated to tough and fragile heterogeneities. Besides, standards for gear material quality recommend a broad range of steel grain sizes which lead to various possible microstructures on gear components after nitriding. Indeed, the intergranular carbide network morphology depends on the steel grain size. Since there is no evidence regarding the real effect of the carbides on rolling contact fatigue, this work presents experimental investigations carried out on a twin-disc machine. The tests consist in reproducing surface-initiated pitting on specimens whose nitrided layers, obtained by a unique thermochemical surface treatment, display similar mechanical properties (hardness and compressive residual stresses) but different microstructures (grain sizes and carbide network morphologies). The first analysis resulted in suggesting the micro-crack nucleation mechanisms. In this study, the test conditions were chosen to induce these micro-cracks near the disc surfaces. For a given contact stress field, nucleation sites depend on the steel grain size and can take place at intergranular carbides. Investigations of crack networks led on cross sections and 3D observations by means of high energy X-ray computed tomography, coupled with compressive residual stress evolution analysis, help the authors proposing the rolling contact fatigue crack propagation scenarios in nitrided layers. When contact shear stresses locally exceed the material micro-yield shear stress limit, micro-deformations arise and add compressive residual stresses to the treated layers. To accommodate these volume variations the compressive residual stresses, initially induced by nitriding, release at depths where contact stresses are lower. The pre-existing residual stresses being less compressive, micro-cracks near the surface can propagate through the carbides that act as preferential crack growth sites. When the nitrided layers display high carbide density, the intergranular precipitates drag the cracks toward the core, whereas rolling contact fatigue failures are limited to the near surface when the distance between the precipitates is too important. Finally, the length and the continuity of the carbides, linked to the steel grain size, locally increase the crack propagation speed. This gives rise to a lower endurance to surface-initiated pitting in coarse microstructures
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Graux, Nicolas. "Caractérisation et modélisation des propriétés à la fatigue à grand nombre de cycles des aciers cémentés à partir d'essais d'auto-échauffement sous sollicitations cycliques." Thesis, Brest, 2017. http://www.theses.fr/2017BRES0104.
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Le dimensionnement en fatigue à grand nombre de cycles d'un contact roulant entre des éléments ayant subi un traitement thermochimique de cémentation s'avère rapidement complexe.D'une part le traitement de cémentation apporte une hétérogénéité de propriété dans les couches supérieures de la pièce qui dépend du protocole utilisé. D'autre part le chargement de contact roulant est un chargement complexe dont le mode de défaillance en fatigue s'initie en sous-couche.Afin de limiter le temps de la caractérisation des champs de propriétés en fatigue, l'utilisation des mesures d'auto-échauffement sous sollicitation cyclique ainsi que leur interprétation par un modèle probabiliste à deux échelles est proposé. Néanmoins de par l'hétérogénéité du matériau et de par la particularité du chargement il peut s'avérer délicat d'appliquer une telle méthode d'évaluation. ll est alors proposé d'explorer ces deux difficultés de manière séparé.Pour prendre en compte l'hétérogénéité matériaux, un protocole d'analyse de courbe d'auto-échauffement basé sur une variante d'un modèle probabiliste à deux échelles et sur les mesures de taux de carbone a été proposé. Les paramètres du modèle ont été identifiés sur une classe d'acier via des mesures d'auto-échauffement réalisées sur des éprouvettes représentatives de l'hétérogénéité du au traitement de cémentation. Enfin le modèle a été validé par comparaison avec des points de fatigue expérimentaux.En ce qui concerne le chargement de contact roulant, les difficultés pour réaliser une mesure d'auto-échauffement ont mené à effectuer une première campagne de mesure sur le cas intermédiaire du contact répété. A l'aide d'un modèle analytique simple, l'évolution du champ de température a pu être reliée à un terme source de chaleur moyen dont le lien avec les mécanismes de fatigue reste à démontrer. Finalement, des prototypes de machine de contact roulant dédiés aux mesures d'auto-échauffement ont été proposés. Les mesures réalisées sur ces dernières et leur interprétation laissent à penser qu'il sera possible d'identifier des propriétés de fatigue à partir de mesure d'auto-échauffementThe rolling contact fatigue prediction between two carburizing part quickly becomes complex.On one hand, the carburizing treatment give heterogeneous properties in surface layer depending on the treatment protocol. On the other hand, the rolling contact load is a complex load with a fatigue initiation in the sub-layer. To limit the duration of the field fatigue properties characterization, self-heating measurements under cycle load are used and their interpretation by a probabilistic two scales model is proposed. Nevertheless applying this fatigue evaluation method on heterogeneous material and for rolling contact load can be difficult. ln first approach those difficulties are split.To take into account the material heterogeneity, an analysis based on a variation of one probabilistic two scales model and on carbon rate measurement is proposed. Model parameters are identified on one steel class with self-heating measurement made on specimens representative of carburizing material heterogeneity. Finally the model is validated by comparison with experimental fatigue point.Making self-heating measurement for rolling contact load is complex. Consequently a first self-heating measurement campaign is made on the intermediary case of repeated contact. With a simple analytic model, the temperature field evolution can be linked to a mean heat source whose link with fatigue mechanism must be proven. Finally, rolling contact machine prototypes are proposed. Self-heating measurement made on those prototypes and their interpretation suggest that it will be possible to identify fatigue properties with self-heating measurement
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Soua, Brahim. "Étude de l'usure et de l'endommagement du roulement ferroviaire avec des modèles d'essieux non-rigides." Phd thesis, Ecole Nationale des Ponts et Chaussées, 1997. http://tel.archives-ouvertes.fr/tel-00529512.
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L'étude ferroviaire présentée dans ce mémoire traite de trois types de dégradations de profils des roues et des rails en service. Comme tous les solides devant assurer une liaison par contact, les roues et les rails ferroviaires sont affectés par des dégradations telles que l'usure et la fatigue. Dans un premier temps, on s'intéresse à l'usure régulière des profils des roues et des rails. Ce type d'usure influence en particulier la stabilité des véhicules, donc le confort et la sécurité. Nous exposons notre modèle de simulation numérique de l'usure transverse des profils ; sa validation étant assurée par des applications à des profils mesurés sur le réseau S.N.C.F. Nous abordons ensuite le phénomène d'usure irrégulière longitudinale des roues à grande vitesse. Nous traitons cette partie avec de nouvelles hypothèses sur un mécanisme d'apparition d'ondulations. L'origine de ce phénomène est due au couplage, à travers le contact, de la dynamique transversale des bogies et de la torsion de l'axe des essieux. En nous appuyant sur deux modèles de simulations numériques, nous montrons la validité des hypothèses et nous mettons en évidence le mécanisme d'usure irrégulière longitudinale des roues. La dernière partie est consacrée à la fatigue des rails soumis au contact roulant, on y étudie une forme particulière appelée le Head Checking. Une première phase, basée sur l'étude des efforts de contact dus au comportement en courbes de certains véhicules ferroviaires, nous permet d'isoler les caractéristiques du système véhicule-voie les plus contraignantes. Une seconde étape consiste à étudier les conditions d'amorçage des fissures par deux approches : le critère de Dang Van et la mécanique de l'endommagement. Les résultats obtenus nous permettent de proposer des dispositions qui semblent appropriées à la lutte contre le Head Checking.
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Smith, Lindsey. "Rolling contact fatigue in wheel-rail contact." Thesis, University of Newcastle Upon Tyne, 2007. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.438385.
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Hadfield, Mark. "Rolling contact fatigue of ceramics." Thesis, Brunel University, 1993. http://bura.brunel.ac.uk/handle/2438/6622.
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Ceramic/ceramic and ceramic/steel contacts under lubricated rolling conditions are studied. This work is of interest to ball bearing manufacturers as the use of ceramics in the design of these components has some advantages over traditional bearing-steel materials. Low density and increased stiffness are the mechanical properties which gas-turbine and machine tool manufacturers are most likely to realise. Much research over the past two decades on material structure, quality control and manufacturing techniques has produced a material which can seriously challenge bearing steel in ball-bearing design. This is especially the case for hybrid ball-bearings, ie ceramic balls with steel bearing races which are now used as standard components. The purpose of this study is to examine the rolling contact fatigue failure modes of ceramics. This study concentrates on silicon nitride as this material has most potential for use by industry. The primary reason for studying ceramic balls is because of interest in ball-bearing applications, hence a modified four-ball machine is employed which correctly models ball motions and precisely defines ball load. Experimental and theoretical kinematic analysis of ball motion during modified four ball machine tests is presented. The kinematic analysis reveals that in practice, lower ball tracking exists at high speeds. Test conditions of lubricated contacts under high compressive stress show delamination type failures. Delamination failures are classified in terms of propagation and initiation from scanning electron microscope observations. Residual stresses are measured on delaminated surfaces, which implies plastic deformation of the ceramic. Also, chemical analysis implies that disruption of silicon, nitrogen and oxygen levels may take place on delaminated surfaces. Experiments illustrating various fatigue failure modes using artificially pre-cracked ceramic balls in contact with a steel upper ball are presented.
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Nemeyuko, Médiateur. "Fatigue de contact de roulement." Electronic Thesis or Diss., Université de Lorraine, 2023. http://docnum.univ-lorraine.fr/ulprive/DDOC_T_2023_0030_NEMEYUKO.pdf.
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Dans ce travail, un modèle bidimensionnel par éléments finis est utilisé pour simuler la réponse mécanique d'une roue ferroviaire roulant sur un rail. Le matériau (acier pour roue) est élastoplastique avec une loi de comportement de Chaboche-Lemaitre combinant l'écrouissage isotrope et l'écrouissage cinématique non linéaire. Les contraintes et les déformations locales dans la zone près de la surface de contact roue-rail sont calculées en fonction de la charge par essieu, du coefficient de frottement et de la force centrifuge. A l'interface roue-rail, les forces tangentielles dues au frottement sont prises en compte. On suppose que le contact roue-rail est situé entre le boudin de la roue et le congé de roulement du rail pour des valeurs relativement faibles du coefficient de frottement (µ ≤ 0.05) pendant la phase de traction et entre la bande de roulement de la roue et le champignon du rail pour des valeurs relativement élevées du coefficient de frottement (0.1 ≤ µ ≤ 0.4) pendant la phase de freinage. En première approximation, on suppose que le contact roue-rail est similaire à un contact entre un cylindre et un plan, qui est linéique; ensuite on suppose que ce contact est similaire à un contact entre deux cylindres à axes perpendiculaires, qui est elliptique. Les écarts entre les résultats obtenus dans le cas linéique et ceux obtenus dans le cas elliptique ont été analysés. Pour valider le modèle numérique du contact roue-rail, on compare les évolutions des contraintes normales et de cisaillement obtenues analytiquement par la théorie du contact de Hertz (en élasticité plane) dans Matlab et celles obtenues numériquement sous Abaqus. La quantification de l'endommagement par fatigue de contact de roulement est réalisée en utilisant le critère de fatigue multiaxiale modifié de Jiang-Sehitoglu et le calcul de la durée de vie d'une roue ferroviaire N_f est effectuée à l'aide de la relation entre le paramètre de fatigue maximum FP_max et la loi de Smith-Watson-Topper sur un plan critique où s'amorce une fissure de fatigue. Le diagramme d'accommodation a été construit en considérant une roue ferroviaire sans défaut dans le cas d'un contact roue-rail linéique et le cas d'un contact roue-rail elliptique. La fatigue de contact de roulement d'une roue ferroviaire a été étudiée par la technique de sous modélisation. Un défaut géométrique est inséré dans la section de la roue ferroviaire afin d'étudier son effet, notamment celui de sa forme, sur la fatigue de contact de roulement. Ce défaut est situé à une profondeur où se situe la valeur maximale de la contrainte de cisaillement tau_max. Les résultats obtenus dans le cas sans défaut, dans le cas d'un défaut circulaire et dans le cas d'un défaut elliptique ont été comparés. L'influence des paramètres du matériau sur la fatigue de contact de roulement d'une roue ferroviaire dans le cas sans défaut et dans le cas avec un défaut circulaire a été étudiée. L'influence de la force centrifuge a été étudiée dans le cas sans défautIn this work, a two-dimensional finite element model is used to simulate the mechanical response of a wheel rolling on a rail. The material (wheel steel) is elastoplastic with a Chaboche-Lemaitre behavior law combining isotropic and nonlinear kinematic strain hardening. The local stresses and strains in the area near the wheel-rail surface are calculated as a function of axle load, friction coefficient, and centrifugal force. At the wheel-rail interface, tangential forces due to friction are taken into account. It is assumed that the wheel-rail contact is located between the wheel flange and the rail gauge corner for relatively low values of the friction coefficient (µ ≤ 0.05) during the traction phase and between the wheel tread and the rail head for relatively high values of the friction coefficient (0.1 ≤ µ ≤ 0.4) during the braking phase. As a first approximation, we assume that the wheel-rail contact is similar to a contact between a cylinder and a plane, which is linear; then we assume that this contact is similar to a contact between two cylinders with perpendicular axes, which is elliptical. The differences between the results obtained in the linear case and those obtained in the elliptical case are studied. To validate the numerical model of the wheel-rail contact, the evolution of the normal and shear stresses obtained analytically by the Hertz contact theory (plane elasticity) in Matlab and those obtained numerically in Abaqus are compared. The quantification of rolling contact fatigue damage is performed using the modified Jiang-Sehitoglu multiaxial fatigue criterion and the calculation of the life of a railway wheel N_f is performed using the relationship between the maximum fatigue parameter FP_max and the Smith-Watson-Topper law on a critical plane where a fatigue crack initiates. The shakedown map was constructed considering a defect-free wheel in the case of a linear wheel-rail contact and in the case of elliptical wheel-rail contact. The rolling contact fatigue of a railway wheel has been studied by the sub-modeling technique. A geometric defect is inserted in the railway wheel section to study its effect, particularly the effect of its shape, on rolling contact fatigue. This defect is located at a depth where the maximum value of the shear stress tau_max is located. The results obtained in the case without defect, in the case of a circular defect, and in the case of an elliptical defect were compared. The influence of the material parameters on the rolling contact fatigue of the railway wheel in the case without defect and in the case with a circular defect was studied. The influence of the centrifugal force was studied in the case without defect
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Alfredsson, Bo. "A study on contact fatigue mechanisms." Doctoral thesis, Stockholm, 2000. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-3028.
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Wang, W. "Rolling contact fatigue of silicon nitride." Thesis, Bournemouth University, 2010. http://eprints.bournemouth.ac.uk/17764/.
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Silicon Nitride has traditionally been used as rolling contact bearing material owing to its superior performance compared to bearing steels. Its successful application as a bearing element has led to the development of Silicon Nitride in other rolling contact applications in the automotive industry and the power industry. However, a major limitation of its wider application is its high material and machining cost, especially the cost associated with the finishing process. In the present study, a low cost sintered and reaction-bonded Silicon Nitride is used to study the surface machining effects on its rolling contact fatigue performance. Studies have been carried out to link the surface strengths of Silicon Nitride derived from half-rod and C-Sphere flexure strength specimens to the rolling contact lives of Silicon Nitride rod and ball specimens. The rolling contact fatigue tests were carried out on ball-on-rod and modified four-ball machines. Three types of surface with coarse, fine and RCF-conventional finishing conditions were examined. Flexure strength tests on half-rod and C-Sphere showed an increasing surface strength from specimens with coarse, fine to RCF-conventionally machined conditions. During rolling contact fatigue tests of as-machined specimens, no failures were observed on either ball-on-rod or four-ball tests after 100 million stress cycles. However, a trend of decreasing wear volumes was measured on the contact path of rods and balls with coarse, fine and RCF-conventional conditions. In four-ball tests, spall failures were observed on pre-cracked specimens. There was a trend of increasing rolling contact fatigue lifetime from pre-cracked specimens with coarse, fine to RCF-conventional machining conditions. The study of Silicon Nitride machining was also carried out using an eccentric lapping machine to investigate the effect of eccentricity on the finishing rate of hot isostatically-pressed and sintered and reaction-bonded Silicon Nitride. The eccentricity had no significant impact on finishing rate as concluded in this study. The effect of lubricant viscosity and chemistry on the rolling contact fatigue performance of Silicon Nitride was also studied. The result is inconclusive.
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Conner, Brett P. (Brett Page) 1975. "Contact fatigue : life prediction and palliatives." Thesis, Massachusetts Institute of Technology, 2002. http://hdl.handle.net/1721.1/16866.
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Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Materials Science and Engineering, 2002.Includes bibliographical references (p. 125-135).
This electronic version was submitted by the student author. The certified thesis is available in the Institute Archives and Special Collections.
Fretting fatigue is defined as damage resulting from small magnitude (0.5-50 microns) displacement between contacting bodies where at least one of the bodies has an applied bulk stress. The applicability and limits of a fracture mechanics based life prediction is explored. Comparisons are made against highly controlled experiments and less controlled but more realistic experiments using a novel dovetail attachment fixture. Surface engineering approaches are examined from a mechanics perspective. Using a new tool, depth sensing indentation, the mechanical properties of an aluminum bronze coating are determined. Fretting fatigue experiments are performed on specimens coated with aluminum bronze and on specimens treated with low plasticity burnishing. Low plasticity burnishing is a new method of introducing beneficial compressive residual stresses without significant cold work at the surface. A mechanics based approach to the selection of palliatives is addressed.
by Brett P. Conner.
Ph.D.
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Tamine, Tawfik. "Amorçage de fissures par fatigue-contact." Metz, 1994. http://docnum.univ-lorraine.fr/public/UPV-M/Theses/1994/Tamine.Tawfik.SMZ9418.pdf.
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La présente thèse est une contribution à la compréhension du phénomène d'écaillage provoque par la fatigue contact. Cette fatigue apparait en dessous d'une surface soumise à un chargement de contact quasi ponctuel, à partir d'une inclusion, site idéal pour l'amorçage de fissures. Souvent la direction d'amorçage et de propagation de fissures est associée à la répartition des contraintes résultant du chargement complexe. Pour mettre en évidence ce phénomène, nous avons entrepris: une étude bibliographique afin de recenser les différents travaux relatifs à la concentration des contraintes, aux critères d'amorçage et à la répartition des contraintes au voisinage d'un défaut. Une étude expérimentale simulant l'amorçage de fissures selon les trois modes de sollicitation. Un calcul aux éléments finis qui nous a permis de développer de nouveaux critères d'amorçage. Ces critères s'adaptent mieux aux résultats expérimentaux en comparaison avec ceux de la littératureThe present thesis is a contribution to the knowledge of the shelling process caused by a contact fatigue. This phenomenon appears under a surface submitted to a quasi punctual loading and initiates at an inclusion which is the most probable site for crack initiation. The direction of propagation is associated with the stress distribution resulting from a complex loading. To understand this phenomenon, we present : a bibliographical study to collect the different works related to stress concentration, crack initiation criteria and the stress distribution in the vicinity of a defect. An experimental study for the simulation of crack initiation under the three modes of loading. A finite element calculation from which we have derived new initiation criteria. We have shown that they best fit the experimental results by comparison with those given in the literature
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TAMINE, TAWFIK Pluvinage Guy. "AMORCAGE DE FISSURES PAR FATIGUE CONTACT /." [S.l.] : [s.n.], 1994. ftp://ftp.scd.univ-metz.fr/pub/Theses/1994/Tamine.Tawfik.SMZ9418.pdf.
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Hannes, Dave. "Growth of cracks at rolling contact fatigue." Thesis, KTH, Hållfasthetslära (Avd.), 2008. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-33659.
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Rolling contact fatigue is a problem encountered with many machine elements.In the current report a numerical study has been performed in order to predictthe crack path and crack propagation cycles of a surface initiated rolling contactfatigue crack. The implementation of the contact problem is based on theasperity point load mechanism for rolling contact fatigue. The practical studiedproblem is gear contact. Different loading types and models are studied andcompared to an experimental spall profile. Good agreement has been observedconsidering short crack lengths with a distributed loading model using normalloads on the asperity and for the cylindrical contact and a tangential load on theasperity. Several different crack propagation criteria have been implemented inorder to verify the validity of the dominant mode I crack propagation assumption.Some general characteristics of rolling contact fatigue cracks have beenhighlighted. A quantitative parameter study of the implemented model hasbeen performed.Utmattning med rullande kontakter är ett ofta förekommande problem för många maskinelement. I den aktuella rapporten utfördes en numerisk studieför att förutsäga sprickvägen hos utmattningssprickor som initierats i ytan vidrullande kontakter. Implementeringen av kontaktproblemet bygger på asperitpunktlastmekanismen för rullande kontakter. Studien av kontaktproblemetär tillämpad till kugghjul. Olika belastningstyper och modeller studeradesoch jämfördes med profilen hos en experimentell spall. Bra överensstämmelseobserverades för korta spricklängder när en modell med fördelad belastninganvänds för en belastningstyp där en normalbelastning agerar på asperiten ochvid cylindriska kontakten och en tangentialbelastning införs på asperiten. Olikakriterier för spricktillväxt implementerades för att verifiera giltigheten av antagandetatt mode I spricktillväxt är dominant. Några generella kännetecken avutmattningssprickor med rullande kontakter framhävdes. En kvantitativ parameterstudie för den implementerade modellen utfördes.
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Hearle, Adrian Donald. "Deformation, shakedown and fatigue in rolling contact." Thesis, University of Cambridge, 1985. https://www.repository.cam.ac.uk/handle/1810/250858.
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Ahmed, Rehan. "Rolling contact fatigue of thermal spray coatings." Thesis, Brunel University, 1998. http://bura.brunel.ac.uk/handle/2438/5469.
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The practical advantages of thermal spray coatings like high deposition rates, low cost and tribological properties of high wear resistance have enabled these coatings to become an integral part of aircraft and automobile industry. Recent advancements in thermal spraying techniques like high particle speed and temperature call for new applications for these coatings. This experimental study addresses the Rolling Contact Fatigue performance of thermal spray coatings deposited by a variety of techniques like High Velocity Oxy-Fuel (HVOF), Detonation Gun (D-Gun) and Plasma spraying. RCF tests were conducted using a modified four ball machine in conventional steel ball bearing and hybrid ceramic bearing configurations. Tribological conditions during the RCF tests were varied by changing the test lubricant and the lubrication mechanism, contact load and shape of the drive coated rolling element to vary the roll/slip ratio. RCF tests were analyzed on the basis of the performance, coating failures using surface and subsurface observations, and residual stress studies. Experimental and theoretical studies of the ball kinematics have also been included. These tests revealed that the performance of the coated rolling elements was dependent upon the coating and the substrate properties. The coating thickness, substrate hardness, tribological conditions during the test, coating and substrate material as well as the coating process and the substrate preparation significantly affect the coating performance and the failure modes. Three different failure modes of these coatings have been discussed along with the changes in the near surface residual stress behaviour of the coated rolling elements.
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Alwahdi, Farag Abdullah Mohamed. "Wear and rolling contact fatigue of ductile materials." Thesis, University of Sheffield, 2004. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.421003.
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Carroll, Robert Ian. "Surface metallurgy and rolling contact fatigue of rail." Thesis, University of Sheffield, 2006. http://etheses.whiterose.ac.uk/14639/.
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This thesis presents the results of an investigation into the effect of surface metallurgy on the rolling contact fatigue behaviour of rail. The investigation has used laboratory based rolling/sliding twin disc testing of samples with a surface metallurgical feature simulated on them. The samples used in laboratory testing have been compared with samples of rail removed from track. Two surface metallurgical features have been investigated: decarburisation and white etching layer. Decarburisation is the loss of carbon from the surface of the rail due to oxidation at high temperatures, resulting in a softer layer at the surface (180HV compared to 250HV bulk). The decarburised layer has been simulated in this research by heat treating discs in a laboratory furnace with an air atmosphere. The results show that by increasing the depth of decarburisation the growth rate of cracks within the sample, along with the wear rate, increases. At the maximum depth of decarburisation allowed on rail by the standard (O.5mm) there was little difference in the wear or rolling contact fatigue behaviour with or without decarburisation. White etching layer (WEL) forms on the surface of rail due to the action of the wheels and is a very hard layer (>850HV) up to 250mm deep. White etching layer has been simulated in two ways: spot welding and gross sliding of the discs. The results have shown that cracks initiate preferentially at weak spots at the surface, such as the interface between the WEL and pearlite or along proeutectoid ferrite boundaries. It has been found that the growth of cracks below the surface depends on the strain history of the subsurface pearlite. The results indicate that white etching layer is detrimental to rail life through either the promotion of rolling contact fatigue and/or wear.
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Vouaillat, Guillaume. "Analyse de la fatigue de contact d'engrenages aéronautiques." Thesis, Lyon, 2020. http://www.theses.fr/2020LYSEI035.
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Le micro-écaillage est une défaillance en fatigue de contact qui intervient sur les composants de transmissions mécaniques tels que les roulements et les engrenages. Le plus souvent, il est le résultat d’un manque de lubrification ou d’un écart avec les spécifications d’état de surfaces. La conséquence est alors l’apparition de sur-contraintes dans le matériau qui évoluent vers des arrachements microscopiques de matière. Ces derniers sont appelés micro-écailles et peuvent éventuellement amener à des dysfonctionnements de la transmission dans laquelle les pièces impactées sont en jeu. La littérature a alors mené de nombreuses études à ce sujet mais manque de travaux liant dans la même analyse, la représentation de l’état de surface à l’origine de la défaillance d’une part et la simulation d’un état microstructural du matériau sollicité qui rentre en compte dans les mécanismes de création de la fatigue de contact, d’autre part. Les travaux de cette thèse présentent donc d’abord, un modèle regroupant ces deux caractéristiques, construit à partir des outils et théories de la littérature. Une étude paramétrique est alors conduite et permet d’estimer l’influence de plusieurs paramètres de contact (glissement, frottement, pressions, rugosité) sur les résultats de trois critères en fatigue de contact. La mise en place d’un critère complémentaire est alors nécessaire pour apporter des précisions là où les premiers critères semblent insuffisants. A partir de l’étude des contraintes de cisaillement au niveau des joints de grains du matériau, la prise en compte de l’historique complet de la sollicitation est possible. Elle permet notamment de proposer une durée de vie avant initiation des microfissures et d’identifier dans le cas du glissement, des cycles locaux complémentaires de sollicitation. Ces derniers résultent des passages répétés des pics rugueux en surface du matériau. Finalement, une comparaison avec une application expérimentale sur composant denture d’engrenages apporte des éléments d’identification des zones à risque vis-à-vis du micro-écaillage dans les applications concernéesGears and rolling elements that are parts of transmissions are sometimes subjected to rolling contact fatigue failures as micro-pitting. It usually results from a lubrication loss or an uncontrolled surface finishing. First layers of the material are consequently overstressed. Microscopic material wrenching then occurs and is called micro-pitting. Such transmission parts failures may potentially lead to the whole system dysfunction. Several studies have already been performed in the literature concerning this topic. However, few of them take into account both surface roughness and material microstructure analyses which impact rolling contact fatigue mechanisms. Thus, a model with those characteristics is developed from literature theories and tools and presented in this thesis. A parametrical study is then conducted so as to estimate the influence of specific contact parameters (among sliding, friction, pressure and roughness) on three fatigue criteria results. However the use of an additional criterion is necessary in order to give more accurate conclusions. Intergranular shear stresses are subsequently studied and make the analysis of the complete stress history possible. Moreover, a life expectancy to micro-cracks nucleation is computed. An identification of sliding-linked local shear stress oscillations which result from successive rough peaks passing over the material surface is also made. Finally, numerical results are compared to an experimental investigation conducted on FZG-type gears. The most at risk areas regarding micropitting in the relevant applications are thus identified among the addendum, the dedendum and the pitch
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Sato, Meiji. "Wear and rolling contact fatigue of rail steels." The Ohio State University, 1991. http://rave.ohiolink.edu/etdc/view?acc_num=osu1335372747.
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Quiney, Zak. "Rolling contact fatigue detection via high frequency acoustic emission." Thesis, Swansea University, 2013. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.678470.
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Qiu, Xiaonong. "Rolling contact fatigue behavior of three eutectoid rail steels /." Full text open access at:, 1987. http://content.ohsu.edu/u?/etd,153.
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Kim, Tae Hyun. "Fatigue of surface engineered steel in rolling-sliding contact." Thesis, Imperial College London, 1999. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.325019.
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Yang, Yulin. "Evaluation of rolling contact fatigue resistance for coated components." Thesis, University of Hull, 2003. http://hydra.hull.ac.uk/resources/hull:8534.
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The thesis reviews and studies current evaluation mechanisms, techniques and machines for testing rolling contact fatigue failure resistance and load capacity of coated components. The thesis investigates both normal and accelerated rolling contact fatigue evaluation test mechanisms and their models, and evaluation test technique principles suitable to the appraisal of coated bearing components. A major contribution of the thesis is the design and development of a new rolling contact fatigue evaluation test machine for coated components. Tests of the rolling contact fatigue of coated bearing raceways under the oil lubricant, grease lubricant and no lubricant conditions, applying the new rolling contact fatigue evaluation mechanisms, evaluation technique principles and the new test machine, have been performed. The accelerated rolling contact fatigue tests of the coated bearing raceways use SiC powder in the oil lubricant. The new rolling contact fatigue test machine has been found suitable for evaluating the rolling contact fatigue resistance of components with superhard coatings. The accelerated rolling contact fatigue test method has been shown to give comparable rolling contact fatigue test results to those obtained in a normal rolling contact fatigue test, while being much faster. In the fatigue test, the cyclic maximum shear stress produces an initial fatigue crack near the substrate surface of the test bearing raceways. The observed phenomena are consistent with theory, although the location of the initial crack is much closer to the surface than would be predicted by a 'static' Hertzian analysis. Insufficient traction forces on the contact surface between the rolling elements of a test coated bearing makes gross skidding occur, leading to rapid wear, over-heating and final failure of the test coated bearing. The LSO fatigue life of the test coated bearing raceway tends to decrease with increase of the coating thickness and coating hardness of the test coated bearing raceway.
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Fish, Gareth. "The effect of emulsion chemistry on rolling contact fatigue." Thesis, Imperial College London, 1990. http://hdl.handle.net/10044/1/46297.
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Alshahrany, Shaya. "Rolling contact fatigue in heavily loaded gear transmission contacts." Thesis, Cardiff University, 2015. http://orca.cf.ac.uk/90422/.
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This thesis examines the influence of asperities such as found on the teeth of gears and discs, and failure mechanisms associated with rough surface Elastohydrodynamic Lubrication (EHL). The principal outcomes of the research provide a good insight into fatigue life, residual stress effects, damage prediction and surface contact failures. In particular, the study is intended to provide understanding into the residual stress distribution resulting from plastic deformation of surface asperities in the running in process. The residual stress is then added to the asperity elastic stress distribution and examined in detail to see the effects on fatigue damage and fatigue life. So, a theoretical model has been developed to assist design against the residual stress effect and surface contact fatigue, such as micropitting. The technique used in the study starts with developing an elastic plastic model of the rough surface by using the Abaqus Finite Element analysis software package. This is a nonlinear problem and ranges of applied loads have been applied to the as-manufactured surfaces causing the asperity features to experience varying degrees of plastic deformation. The pre and post running roughness profiles are studied in order to assess the level of plastic deformation actually occurring at significant surface asperity features by aligning the pre and post running profiles. This results in a new technique that has helped to identify the level of plastic deformation occurring in the practice, and also to make a comparison with FEA contact analysis for the same asperity features to identify the appropriate residual stress field. The residual stress field associated with the plastic deformation was extracted and evaluated. The extracted residual stress field was transferred to a form that facilitated IV inclusion in stress evaluation code to obtain the stress history for the material subject to loading in an EHL contact. The research carried out considers surface fatigue analysis with and without a residual stress field, so as to establish the influence of asperity plastic deformation on the fatigue properties of the surface. All the work is based on numerical simulation of surface fatigue failure in EHL situations and carried out numerically. The procedure can be applied quickly and gives the opportunity to apply several models and investigate the influence of all the model parameters on material deformation and fatigue life.
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Fu, Hanwei. "Microstructural alterations in bearing steels under rolling contact fatigue." Thesis, University of Cambridge, 2017. https://www.repository.cam.ac.uk/handle/1810/270311.
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The formation of microstructural alterations in bearing steels under rolling contact fatigue (RCF) is systematically studied. A literature review summarizes current understanding in this field, leading to the key to the formation of these microstructural features being carbon redistribution as a consequence of cyclic rolling contact. In this context, a novel theory is postulated to describe the migration of carbon caused by gliding dislocations. The theory combines the Cottrell atmosphere theory with the Orowan equation and is capable of quantifying the dislocation-assisted carbon flux. Based on the proposed theory, models are suggested for different types of microstructural alterations formed in rolling contact fatigued bearings – dark etching regions (DERs), white etching bands (WEBs) and white etching areas (WEAs). Very good agreement is obtained between the predications made by the models and the experimental data from both this research and the literature. Moreover, the models consider the effects of contact pressure, temperature, rotational speed and number of cycles, and thus can be applied for universal RCF testing conditions. The reproduced microstructural features are also characterized using advanced characterization techniques such as scanning electron microscopy (SEM), transmission electron microscopy (TEM) and atom probe tomography (APT), with the observation validating the postulated formation mechanisms. It is demonstrated that DERs, WEBs and WEAs follow the same principle during formation – strain induced carbon redistribution. This is the first time that these microstructural alterations are quantitatively described using a unified theory. The achievements obtained from this research can be far reaching. It not only leads to great progress in understanding the phenomenology of RCF in bearing steels, but also can be further extended to other scenarios with similar phenomena such as severe plastic deformation and hydrogen embrittlement.
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Ghaffari, Gharehbagh Mir Ali. "Multi-scale modeling and simulation of rolling contact fatigue." Diss., University of Iowa, 2016. https://ir.uiowa.edu/etd/2082.
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In this thesis, a hierarchical multiscale method was developed to predict rolling contact fatigue lives of mechanical systems. In the proposed multiscale method, the molecular modeling and simulation of lubricant was conducted to investigate the friction between rolling contact surfaces. The calculated friction coefficient was passed to the continuum model of rolling contact components to predict fatigue lives.
Molecular dynamics modeling and simulation of thin film lubrication and lubricated contact surfaces were carried out to investigate mechanisms of hydrodynamic lubrication at nano-scale first. Although various lubricant alkane chains were considered in the molecular model, the chain length of eight united molecules were mainly employed in this thesis. In addition, the effects of temperature and nano-particles (debris) on the friction forces were discussed. It was found that the existing of nano-particles (debris) could increase the friction force between contact surfaces with hydrodynamic lubrication.
In the continuum model of the developed multiscale method, finite element analysis was employed to predict rolling contact fatigue life of rolling contact components, including bearing and gear-tooth. Specifically, the fatigue crack initiation of bearing was studied, and then the fatigue crack initiation and propagation in gear-tooth. In addition, the enhancement of gear-tooth fatigue life by using composite patches was discussed as well. It should be noted that the friction coefficient used in the continuum model was calculated in the molecular model. It is one-way message passing in the developed multiscale method.
Another continuum method was studied and developed in this thesis to provide alternate methods for the continuum model in the proposed multiscale framework. Peridynamics method has advantages in modeling and simulation of discontinuities, including cracks, over the conventional finite element methods. The applications of Peridynamics in predicting fatigue crack initiation and propagation lives were discussed in this thesis.
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Bulusu, Prashant. "Rolling contact fatigue predictions based on elastic-plastic finite element stress analysis and multiaxial fatigue /." abstract and full text PDF (free order & download UNR users only), 2006. http://0-gateway.proquest.com.innopac.library.unr.edu/openurl?url_ver=Z39.88-2004&rft_val_fmt=info:ofi/fmt:kev:mtx:dissertation&res_dat=xri:pqdiss&rft_dat=xri:pqdiss:1437664.
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Thesis (M.S.)--University of Nevada, Reno, 2006."August, 2006." Includes bibliographical references (leaves 38-45). Library also has microfilm. Ann Arbor, Mich. : ProQuest Information and Learning Company, [2006]. 1 microfilm reel ; 35 mm. Online version available on the World Wide Web.
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Webster, Martin Nicholas. "Measurement and contact analysis of engineering surfaces." Thesis, Imperial College London, 1986. http://hdl.handle.net/10044/1/38184.
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Nowell, D. "An analysis of fretting fatigue." Thesis, University of Oxford, 1988. http://ora.ox.ac.uk/objects/uuid:61c9f75d-7c81-4280-9997-91f6e79543fb.
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This thesis describes a series of fretting fatigue experiments carried out under closely controlled conditions of partial slip. These experiments confirm the existence of a size effect whereby the fretting fatigue life of an aluminium alloy is shown to vary with contact size. The configuration chosen, of cylindrical fretting pads contacting a plane specimen is amenable to classical stress analysis and the surface tractions between the contacting bodies are derived. The effects of tension in the specimen, finite specimen thickness, differing elastic constants, and surface roughness are all investigated and incorporated into the analysis where appropriate. A technique is then developed to calculate stress intensity factors for plane cracks growing under the contact load at an arbitrary angle to the free surface. The analysis is then applied to the experimental results and three possible explanations for the size effect are proposed, based on statistical effects, crack arrest, and crack initiation. These are examined in the light of the experimental evidence and it is proposed that the variation of fatigue life with contact size is due to an increase in the amount of fretting damage above a threshold level for crack initiation. A composite parameter is chosen to characterise the severity of fretting conditions and this is shown to describe the experimental results accurately. Finally, the use of this parameter in design calculations is discussed.
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Dahlberg, Johan. "On the asperity point load mechanism for rolling contact fatigue." Doctoral thesis, Stockholm : Hållfasthetslära, Kungliga Tekniska högskolan, 2007. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-4569.
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Stewart, Simon Hardie. "The rolling contact fatigue of post-treated thermal spray coatings." Thesis, Heriot-Watt University, 2005. http://hdl.handle.net/10399/234.
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Iida, Yusuke. "The effects of magnetic fields on rolling contact fatigue wear." Thesis, Brunel University, 2007. http://bura.brunel.ac.uk/handle/2438/7405.
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The thesis describes the effects of the magnetic field in rolling contact tests of steel by using a two-disc machine and the investigation of its mechanism from contact stress analysis by using FEM and the agnetisation of a ferromagnetic substance. In the tests, two contact kinematic conditions, that is pure rolling and 10% rolling with sliding together with 1.1 and OAT [Tesla] of horizontal static magnetic fields created by permanent magnets were pplied. The results of optical and scanning electron microscopy observations show that finer wear particles and smoother worn surfaces are produced in the presence of the magnetic field. For the generation of the finer wear particles, it is considered necessary that the subsurface crack initiation point is moved towards the surface due to the magnetic field. Wear amounts of the discs are lowered III the magnetic fields under the pure rolling conditions. However, at 100/0 rolling with sliding, the wear amounts are increased in the magnetic fields even though finer particles and smoother surfaces are observed. Both tendencies are unified by calculating the number of cycles required to generate wear particles, which are reduced due to the magnetic field's presence. For these mechanisms, it is considered that domain walls near the contact region are caught by dislocations when the specimen is agnetised and part of the energy for magnetisation activates the dislocation movement resulting in crack initiation.
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Green, Richard. "A study of fretting fatigue incorporating sharp corner contact geometry." Thesis, Sheffield Hallam University, 2003. http://shura.shu.ac.uk/19720/.
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Fretting fatigue occurs when components are in contact and subjected to cyclic loads or vibrations. The following research programme investigates the fretting fatigue phenomenon using a specific flat contact geometry encompassing sharp comers. The pressure distribution at the contact interface is fundamentally important in the understanding of fretting fatigue problems. In the case of sharp comer contacts, the analysis of the pressure distribution results in an infinite gradient occurring at the edges of the contact. The infinite gradients generate deformation singularities and closed form solutions are not available for this contact geometry. The specific contact pressure generates friction forces, which affect the nucleation and growth of dominant fretting cracks by influencing the stress distributions in the region of the contact. The current research programme presents a method of analysing flat contacts containing sharp comers. The method includes the development of a finite element solution capable of accurately predicting the friction force behaviour observed in fretting fatigue. The subsequent numerically determined stress distributions in the contact region are then used to generate a multiaxial stress concentration factor, which provide the basis for a fretting fatigue life prediction method. Furthermore, the research programme investigates the phenomenological effects observed during fretting fatigue. The study investigates friction behaviour and its effects on the initiation of fretting cracks and fretting fatigue lives.
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Hanzal, Robert J. F. "Rolling contact fatigue failures in silicon nitride and their detection." Thesis, University of Southampton, 2013. https://eprints.soton.ac.uk/361698/.
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The project investigates the feasibility of using sensor-based detection and processing systems to provide a reliable means of monitoring rolling contact fatigue (RCF) wear failures of silicon nitride in hybrid bearings. To fulfil this investigation, a decision was made early in the project to perform a series of hybrid rolling wear tests using a twin disc machine modified for use on hybrid bearing elements. The initial part of the thesis reviews the current understanding of the general wear mechanisms and RCF with a specific focus to determine the appropriate methods for their detection in hybrid bearings. The study focusses on vibration, electrostatic and acoustic emission (AE) techniques and reviews their associated sensing technologies currently deployed with a view of adapting them for use in hybrids. To provide a basis for the adaptation, an understanding of the current sensor data enhancement and feature extraction methods is presented based on a literature review. The second part describes the test equipment, its modifications and instrumentation required to capture and process the vibration, electrostatic and AE signals generated in hybrid elements. These were identified in an initial feasibility test performed on a standard twin disc machine. After a detailed description of the resulting equipment, the thesis describes the calibration tests aimed to provide base data for the development of the signal processing methods. The development of the signal processing techniques is described in detail for each of the sensor types. Time synchronous averaging (TSA) technique is used to identify the location of the signal sources along the surfaces of the specimens and the signals are enhanced by additional filtering techniques. The next part of the thesis describes the main hybrid rolling wear tests; it details the selection of the run parameters and the samples seeded with surface cracks to cover a variety of situations, the method of execution of each test run, and the techniques to analyse the results. The research establishes that two RCF fault types are produced in the silicon nitride rolling element reflecting essentially different mechanisms in their distinct and separate development; i) cracks, progressing into depth and denoted in this study as C-/Ring crack Complex (CRC) and ii) Flaking, progressing primarily on the surface by spalls. Additionally and not reported in the literature, an advanced stage of the CRC fault type composed of multiple and extensive c-cracks is interpreted as the result of in duced sliding in these runs. In general, having reached an advanced stage, both CRC and Flaking faults produce significant wear in the steel counterface through abrasion, plastic deformation or 3-body abrasion in at least three possible ways, all of which are described in details.
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Evans, M. H. "White structure flaking failure in bearings under rolling contact fatigue." Thesis, University of Southampton, 2013. https://eprints.soton.ac.uk/355966/.
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White structure flaking (WSF) as a premature wear failure mode in steel rolling element bearings is caused by white etching cracks (WECs) and perhaps butterflies formed in the ~1 mm zone beneath the contact surface under rolling contact fatigue (RCF). WECs are branching crack systems typically several millimetres in length that have a microstructural change called ‘white etching area’ (WEA) associated with the crack. Butterflies are smaller cracks initiating at material defects and impurities that form WEA wings that revolve around their initiators. Hydrogen diffusion into the bearing steel during service and transient operating conditions have been suggested as drivers of white etching features (butterflies, WEA and WECs). However the initiation and propagation mechanisms as well as the thresholds for WEC formation are not well understood. This is due to the difficulties of creating WECs repeatedly under laboratory conditions and the lack of a method established for mapping WECs in detail or 3 dimensions as typically only limited metallographic analyses are conducted over several cross-sections. A series of RCF tests have been conducted in this study to investigate the formation drivers and formation mechanisms of WECs using a two-roller RCF machine. WECs were successfully created in hydrogen charged 100Cr6 martensitic steel rollers under low-moderate concentrations of diffusible hydrogen (~1 ppm) and service realistic loading conditions (Pmax 1.5 – 2 GPa). However, only butterflies were formed under transient conditions with non-hydrogen charged rollers. One such butterfly was analysed in detail to further understanding of crack formation mechanisms and carbide dissolution as part of the WEA microstructural change. Based on the evidence obtained from the SEM, FIB tomography and STEM/TEM analysis, a void/cavity coalescence theory for initial butterfly crack formation and iron chromium carbide dissolution as part of the WEA formation mechanism is proposed. Metallography was extensively used in this project to view cross-sections of the wear zones subject to RCF. A metallographic serial sectioning technique was established to quantitatively map wear zones for the first time. Mapping WECs in their entirety and 3D modelling revealed the 3-dimensional morphology and orientation of WECs and maximised detection of possible WEC initiators. This study has for the first time quantitatively investigated the influence of diffusible hydrogen, load and rolling cycles on white etching feature formation and the thresholds of formation. The hydrogen charged tests showed that the formation of butterflies was independent of the concentration of diffusible hydrogen with the test parameters used, but dependent on contact pressure and number of rolling cycles up to a threshold. WEC formation thresholds were found at certain values of the concentration of diffusible hydrogen, contact pressure and number of rolling cycles. Extensive serial sectioning and 3D modelling of WECs also demonstrated that the orientation of WECs differed depending on the sectioning direction. It was found that the vast majority of WECs were contained in the subsurface wear zone and did not make any connection with the surface, thus dismissing surface initiation. The WECs often interacted with inclusions that were judged to be crack initiators and evidence was found that butterfly cracks could propagate to form WECs. The white etching features initiated predominately at short sulfide type inclusions, small globular manganese sulfide oxide inclusions and small globular oxide inclusions. Therefore strong evidence was observed for a subsurface initiation mechanism of WECs from non-metallic inclusions. A comparison of the WEC formations in the hydrogen charged two-roller tests was made with serial sectioning investigations of WEC formation in wind turbine gearbox bearings obtained from the field and those tested on a large-scale transient test rig (non-hydrogen charged). This was performed to understand if a difference in the WEC initiation and propagation mechanism occurs under the differing conditions. The comparison showed correlation between the WEC formation mechanisms as a high number of inclusions interacted with the WECs that were judged to be crack initiators and small/short sized inclusions predominated as the crack initiators. Therefore based on the serial sectioning analysis across various test specimens and bearings it is proposed that one mechanism of WEC formation is due to multiple linking of extended butterflies or small WECs in the subsurface to form larger WEC networks that eventually propagate to the surface resulting in WSF. The data also suggests that steel cleanliness standards analysing inclusion density (as opposed to maximum inclusion lengths) are more relevant in understanding butterfly/WEC initiation. However steel cleanliness standards used should record inclusions that are only a couple of micrometer’s in length/diameter.
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Udthala, Aparna. "Contact Fatigue of Spur Gear Operating Under Starved Lubrication Condition." Wright State University / OhioLINK, 2021. http://rave.ohiolink.edu/etdc/view?acc_num=wright1619554628009744.
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Li, Sheng. "Lubrication And Contact Fatigue Models For Roller And Gear Contacts." The Ohio State University, 2009. http://rave.ohiolink.edu/etdc/view?acc_num=osu1234822355.
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Balcombe, Robbie. "A study of rolling contact fatigue cracks in lubricated contacts." Thesis, Imperial College London, 2012. http://hdl.handle.net/10044/1/9848.
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A novel method for coupling fluid pressure and crack deformation for the purpose of analysing rolling contact fatigue (RCF) cracks in lubricated, hydrodynamic and elastohydrodynamic, contacts is presented. The model addresses some of the simplifying assumptions applied to existing models presented in the literature such as: (i) using an imposed fluid pressure gradient inside the crack, (ii) using an imposed fluid pressure at the crack mouth, and (iii) adopting a surface contact pressure, Hertzian or EHL, that does not account for the fluid flow in and out of the crack during loading. The model has been used to model the effect of lubricant/crack interaction in various RCF configurations as the rolling element passes over the pre-formed crack; which has direct application to bearings and rail/wheel contacts. The results of the simulations performed with the fully-coupled fluid/solid solver developed by the author suggest that the cracked component/lubricant interaction contributes significantly to accelerate the rate of surface breaking crack growth in rolling element bearings and wheel/rail type contacts. It is shown through simulations that the lubricant works as a catalyst inside the crack to convert the compressive contact load into a crack opening, tensile fatigue mechanism, through the effect of fluid pressurisation inside the crack. The results obtained using such a model suggest that the opening associated with the fluid action within the crack induces large mode I stress intensity factors. This has been shown to be the principal factor that promotes and influences the rate of rolling contact fatigue crack growth in lubricated contacts. In addition to the modelling work, an experimental method of analysing RCF cracks in real time has been developed. The technique is based on laser induced fluorescence that allows the penetration of the fluid within the crack to be observed. Though the method would require development to be used to provide results that could be used for quantitative comparisons with crack models, some encouraging preliminary results have been obtained: the technique has been shown to be suitable for measuring, at least qualitatively, the real time evolution of the film thickness in RCF cracks.
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Hannes, Dave. "On fatigue crack growth modelling of surface initiated rolling contact fatigue using the asperity point load mechanism." Doctoral thesis, KTH, Hållfasthetslära (Avd.), 2014. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-141151.
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Load transfer in applications or between machine components is generally achieved through contact. In case of recurrent high contact loads in combination with a rolling motion, i.e. with a relatively small amount of slip, the contact surface may eventually suffer from rolling contact fatigue (RCF). The damage consists then of cracks and craters or spalls, which can cause dysfunctionality of the application leading to inefficiency or increased maintenance costs. Ultimately the damage may cause total failure of the machine component. The damage process is still not fully understood due to the complexity of the problem. Different mechanisms have been suggested to explain initiation and propagation of RCF damage. The current work focused on crack growth modelling of surface initiated RCF in case hardened gear steel. The study was based on the asperity point load mechanism, which emphasizes the importance of the surface roughness in the damage process. Asperities on the contact surface act as stress raisers inducing locally high tensile surface stress when entering the contact. Improved understanding of the damage process and further validation of the asperity point load mechanism was achieved. In Paper A, the crack path of surface initiated RCF was simulated in the symmetry plane of the damage with the trajectory of the largest principal stress in the uncracked material. The mode I fracture mechanism was found applicable as well as linear elastic fracture mechanics (LEFM). The evolvement of the asperity contact parameters during the load cycle was determined through a finite element (FE) contact model based on an equivalent contact geometry. The predicted RCF crack path agreed with experimental spall profiles both in entry details as in overall shape. An experimental series was performed in Paper B to investigate the crack closure behaviour in presence of large negative minimum loads. The experimental results suggested a crack closure limit close to zero. The choice of the equivalent mixed-mode stress intensity factor range and especially the crack closure limit had a significant effect on the predicted RCF or spalling life. The two-dimensional crack growth model was further developed in Paper C and used to investigate the influence of asperity size, friction and residual surface stress on the simulated RCF damage. The simulations agreed qualitatively with experimental observations where reduced surface roughness, improved lubrication and compressive residual surface stress increased RCF resistance. In Paper D, a three-dimensional stationary crack was studied using an FE model and a simplified RCF load. A new crack geometry was proposed allowing the investigation of the spall opening angle of the typical vshaped damage. Crack arrest through crack closure was suggested as explaining mechanism. A qualitative study indicated increased spread of the surface damage with increased friction. The results also depended on the crack inclination angle. The different studies supported the asperity point load mechanism to explain not only fatigue initiation but also fatigue crack propagation.QC 20140210
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Flicek, Robert C. "Analysis of complete contacts subject to fatigue." Thesis, University of Oxford, 2015. http://ora.ox.ac.uk/objects/uuid:10c6e429-4e9e-45f0-a7a6-21823592043b.
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Engineering assemblies are very frequently subject to fretting fatigue, which is a damage process that results when very small slip displacements arise at nominally stationary frictional interfaces. Fretting accelerates the initiation and early propagation of fatigue cracks, thereby causing significant reductions in the fatigue performance of many critical engineering components. A majority of the previous research on fretting fatigue has focused on incomplete (i.e. smooth-edged) contacts, while complete (i.e. sharp-edged) contacts have received less attention. The aim of this thesis is to contribute to the theoretical understanding of complete contacts, especially when they are subject to fatigue conditions. This problem is addressed in two separate ways. First, because fretting failures almost invariably initiate from the edge of contact, a detailed understanding of the conditions in this region should enable more accurate assessments of fatigue performance to be made. Thus, an asymptotic analysis is presented, which provides an accurate description of the contact edge under many conditions. This is done by using the elasticity solution for a semi-infinite notch to represent the state of stress near the contact edge in an asymptotic sense. Attention is then placed on the fact that cyclically loaded frictional contacts tend toward a steady-state response in which less frictional slip (and energy dissipation) occurs than in the first few load cycles. To investigate this effect, a numerical sub-structuring procedure is described, which significantly reduces the number of degrees of freedom in finite element models of frictional contact. This reduced model is then used to calculate the shakedown limit, i.e. the amplitude of cyclic load above which frictional slip is guaranteed to persist in the steady state. The sensitivity of the steady-state solution to the initial residual displacement state is then investigated, and it is shown that initial conditions can have a large influence on the steady-state behaviour of complete contacts.
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Stephan, Pierre. "Influence de la rugosité en fatigue de contact : rôle du rodage." Phd thesis, Ecole Polytechnique X, 2009. http://pastel.archives-ouvertes.fr/pastel-00005313.
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Les paliers à roulements sont des pièces mécaniques utilisées dans de nombreux domaines. Leur durée de vie est un paramètre critique pour celle des assemblages dans lesquels ils sont montés. Des méthodes de calcul de la durée de vie des paliers à roulements existent mais ne prennent pas en compte certains paramètres importants tels que le gradient des propriétés mécaniques du matériau et des contraintes résiduelles. Les travaux menés par G. Thoquenne [1] en 2004 ont mis en place une méthode de prévision de durée de vie prenant en compte ces paramètres. Or celle-ci nécessite la connaissance de l'état après rodage du matériau en terme de contraintes résiduelles et de rugosité des surfaces en contact. L'objectif de la thèse présentée ici est de pouvoir prédire l'état après rodage du matériau en terme de rugosité et de contraintes résiduelles. Trois modèles numériques de simulation de la phase de rodage ont été développés sous Castem et Code Aster. Le modèle le plus performant pourra être utilisé en complément de la méthode de prévision de durée de vie. Une étude expérimentale comprenant des essais de rodage sur une machine bi-disque de fatigue de contact a été menée en parallèle pour valider ces modèles numériques. L'effet de la pression de contact, du taux de glissement et de la rugosité des galets en contact ont été particulièrement pris en compte.[1] Prévision des durées de vie en fatigue des roulements, G. Thoquenne, Manuscrit de thèse, école polytechnique, avril 2004.
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Kang, JeeHyun. "Mechanisms of microstructural damage during rolling contact fatigue of bearing steels." Thesis, University of Cambridge, 2014. https://www.repository.cam.ac.uk/handle/1810/245255.
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Bearings are employed in a number of applications under extremely demanding conditions. During long operation times, the material undergoes rolling contact fatigue where microstructural damage manifests as dark-etching regions and white-etching areas, which display different properties from the surrounding region. The aim of this study is to identify the mechanisms for such damage and to suggest models that can explain the influence of the initial microstructure and test conditions. In order to appraise the stress state in rolling contacts, two testing techniques were employed and it was examined if the testing methods could reproduce the same damage as in bearing operation. During ball-on-rod fatigue testing, microcracks were generated adjacent to inclusions and some were decorated with white-etching areas. Repetitive push tests showed a similar extent of subsurface hardening compared to the ball-on-rod tests, and allowed the strain per stress cycle to be measured. The microstructural alterations in a white-etching area were studied both on a macroscale and on an atomic-scale. The degree of stress concentration near a microcrack was calculated employing a nite element method. The microstructure, as well as the segregation behaviour of alloying elements in the white-etching area, were investigated by employing transmission electron microscopy and atom probe tomography. A nanocrystalline structure with scattered carbide particles was observed in the white-etching area. Carbon and silicon segregation was highly pronounced in some boundaries of dislocation cell structures. Models were suggested to account for the microstructural alterations during rolling contact fatigue. Carbide coarsening in dark-etching regions was modelled by considering how carbon di usion is assisted by dislocation glide. The predicted hardness evolution was consistent with experimental observation. The kinetics of carbide dissolution in white-etching areas was calculated by taking two processes into account: deformation accumulation and carbon diffusion. These models suggest that the microstructural changes during bearing operation can be controlled by tailoring the initial microstructure and managing the test conditions.
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Everitt, Carl-Magnus. "Initiation of rolling contact fatigue from asperities in elastohydrodynamic lubricated contacts." Licentiate thesis, KTH, Hållfasthetslära (Avd.), 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-222371.
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Rolling contacts are utilized in many technical applications, both in bearings and in the contact between gear teeth. These components are often highly loaded, which makes them susceptible to suffer from rolling contact fatigue. This work focuses on the rolling contact fatigue mechanism of pitting. In order to attain a better understanding of why pitting initiates and grows, detailed simulations of rolling contacts have been performed. In particular the contact between two gears in a truck retarder was here used as a case study. The investigated contact experienced elastohydrodynamic lubrication conditions since the load was high enough to causes the surfaces in contact to deform and the viscosity of the lubricant to increase significantly. In Paper A it was investigated if surface irregularities in the size of the surface roughness are large enough to cause surface initiated fatigue. The investigation focused on the pitch line since small surface initiated pits were found here even though there was no slip present. Since there were pits present at the pitch line, it is important that the theories of pitting can explain the development of pits also in the absence of slip. The conclusion of the work was that surface irregularities of the size of normal surface roughness are enough to cause surface initiated fatigue at the pitch line. In Paper B it was investigated why pits are more likely to initiate in the dedendum of pinion gears than in the addendum. In both areas slip is present but in different directions. In the dedendum the friction from slip is against the rolling direction which enhances the risk for pitting. The investigation was performed by studying the effect of the temperature rise in the contact caused by the slip. The conclusion drawn was that the temperature rise in the contact explained why pitting was more common in the dedendum than in the addendum.Rullande kontakter förekommer i många applikationer, till exempel i lager och mellan kugghjulständer. Både lager och kugghjul utsätts ofta för höga laster vilket gör att dess ytor löper stor risk att utmattas, vilket kallas rullande kontaktutmattning. Denna studie fokuserar på pitting, även kallat spalling, vilket är en typ av rullande kontaktutmattning där en utmattninsspricka växer fram som får delar av ytan att ramla av. För att få en bättre förståelse varför pittingskador uppkommer har noggranna simuleringar utförts av rullande kontakter. Kontakten mellan två tänder på kugghjul i en lastbilsretarder har används som underlag då många pittingskador påträffats på dem. För att minska friktionen och nötningen i kontakten mellan kuggtänderna användes smörjmedel. De höga lasterna lastbilsretardern utsattes för deformerade kuggarnas ytor elastiskt samtidigt de kraftigt ökade viskositeten hos smörjmedlet. Dessa förhållanden gör att kontakten kallas för elastohydrodynamiskt smord, vilket på engelska förkortas till EHL. I Artikel A undersöktes om små ytojämnheter kan orsaka ytinitierade pittingskador. Eftersom skadan påträffats i friktionslösa kontakter, så som vid rullcirkeln på de undersökta kugghjulen, är det viktigt att teorierna som förklarar uppkomsten inte är beroende av friktion. Undersökningen fokuserade därför på förhållandena vid rullcirkeln. Slutsatsen från arbetet var att små ytojämnheter, av samma storleksordning som ytojämnheterna på de undersökta kugghjulen, är tillräckligt stora för att orsaka utmattningsskador. I Artikel B undersöktes varför det är vanligare att pitts initieras i dedendum än addendum på drivande kugghjul. Kontakten på båda sidorna om rullcirkeln slirar svagt åt olika håll. Att kontakten slirar skapar friktion som är motriktad rullriktningen i dedendum vilket ökar risken för pittingskador. För att undersöka varför dessa förhållanden ökar risken för skador fördjupades analysen av kontakten genom att inkludera temperaturfältet. Simuleringarna visade att temperaturen ökar genom kontakten vilket orsakar en asymmetrisk spänningsfördelning. Denna asymmetriska spänningsfördelning gör att ytojämnheter i dedendum är troligare att orsaka skador än ytojämnheter i addendum.
QC 20180213
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Tyfour, Wa'il Radwan Ali. "Interaction between wear and rolling contact fatigue in pearlitic rail steels." Thesis, University of Leicester, 1995. http://hdl.handle.net/2381/34715.
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The work presented in this thesis is aimed at investigating the interaction between wear and rolling contact fatigue, which are two of the most serious forms of deterioration caused by the wheel on rail contact stresses. Wheel-rail contact conditions were simulated by a two disc contact using the LEROS (LEicester university ROlling-Sliding wear testing machine). Investigation of the wear behaviour of BS11 pearlitic rail steel showed that steady state wear behaviour is established after a certain number of rolling-sliding cycles. Contact surface failure by ratchetting (accumulation of unidirectional plastic strain) was found to be the dominant failure mechanism during the period leading to the steady state. This mechanism was confirmed by the drop in the wear rates when the direction of rolling-sliding; i.e. strain in the surface layer, was reversed at predetermined numbers of cycles. The effect of repeated rolling direction reversals on crack morphology, propagation and rolling contact fatigue (RCF) life of BS11 rail steel was also investigated. It was established that rolling direction reversal has a beneficial effect on RCF life. A new mechanism, the "variable crack face friction mechanism", was proposed to explain this effect. Interaction between wear and RCF fatigue was investigated through rolling-sliding experiments where specimens were run dry for certain number of cycles, to induce different levels of wear damage, before the fatigue performance was investigated. It was shown that initial dry cycles above a critical number causes sudden and significant deterioration in RCF life. This deterioration has been explained in terms of the role of the accumulation unidirectional plastic strain (ratchetting) in initiating and propagating the early cracks during the dry phase. A strong correlation was found between the total ratchetting strain induced during the dry phase and the deterioration in RCF life. An empirical relationship to estimate this deterioration was concluded.
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Frolish, Michael Fraser. "Design criteria for rolling contact fatigue resistance in back-up rolls." Thesis, University of Sheffield, 2002. http://etheses.whiterose.ac.uk/15083/.
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The demands placed on back-up rolls in hot strip mills have been investigated by a combination of literature and industrial studies. The tribological operating conditions have been established and the maximum local loads and pressure distributions at the work roll/back-up roll interface have been obtained by processing mill and roll schedule data using a computer program (commercial software developed by V AI Industries (UK) Ltd) and applying the theories of contact mechanics. After a study of the responses of the rolls to these demands and possible failure mechanisms, research has centred on surface initiated damage whereby cracks can propagate into the roll substrate potentially reaching the internal residual stress fields and leading to catastrophic failure. A proposed qualitative contact and fracture mechanics model, for the rolling contact fatigue and spalling failure, has been quantified theoretically using published methods for determining the stress intensity factors at the tips of pressurised and water lubricated, inclined rolling contact fatigue cracks. The predictions of the quantitative model in terms of crack directions and lengths have been validated by microscopic observation of the morphologies cracks produced in test discs used in the "SUROS" Rolling-Sliding Testing Machine and also in a sample of material spalled from a back-up roll. The quantitative failure model includes criteria for crack branching either upwards leading to micro spalling or downwards (potentially catastrophic) and the link between these two cases has been related quantitatively to the value of the mode I threshold for the roll material. After linking mechanics to microstructure and quantifying the interactions between wear and rolling contact fatigue in this case, practical quantitative recommendations have been made for the design of bainitic back-up roll materials, back-up roll redressing procedures and the surface roughness of both the work rolls and back-up rolls presented to the mill.
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Maslan, Mohamad Haidir. "Development of predictive finite element models for complete contact fretting fatigue." Thesis, University of Manchester, 2016. https://www.research.manchester.ac.uk/portal/en/theses/development-of-predictive-finite-element-models-for-complete-contact-fretting-fatigue(a4652a74-7429-4f2c-b022-578111608651).html.
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Nucleation and propagation of cracks under fretting conditions has been a subject of study for many years. An extensive experimental investigation to study these cracks was undertaken by Royal Aerospace Establishment (RAE Farnborough). Of particular interest to RAE was an Aluminium alloy (L65) developed for aerospace applications. Many researchers have studied fretting damage and fatigue cracks. Some have examined damage development due to wear, whilst others have analysed cracks under linear elastic fracture mechanics (LEFM) domain. To date, no attempt has been made to develop an integrated numerical model which incorporates all aspects of fretting fatigue i.e. nucleation, initial (or early) crack growth, and long crack propagation. The development of such a model is the principal aim of this work. It is expected that the integrated approach will provide the basis for a standard fretting fatigue analysis of other materials, components, and structures using the finite element method (FEM).This study uses the earlier experimental results with RAE as the reference for comparison. The approach followed is to implement the various stages of fretting in a commercial finite element code, ABAQUS. Unlike previously used simple FE models, both specimen (Aluminium alloy) and the fretting pad (steel) are modelled to simulate the real contact conditions including slip. Various predictive models for crack nucleation (based on damage) and propagation (based on fracture mechanics) are developed, tested, and implemented in ABAQUS. Results clearly show that these models together provide a good estimation tool for predicting total life in complete contact fretting fatigue. It is envisaged that the integrated model will be easily utilised for other materials, components, and structures subjected to fretting fatigue conditions with minimum experimental testing required.