2D Spall Generation Simulation in a Rolling Element Bearing

摘要

Rolling element bearing prognosis is the process of forecasting the remaining operational life, future condition, or probability of failure of the bearing. One of the common reasons for rolling element bearings failure is the rolling contact fatigue (RCF). RCF occurs when two bodies roll/slide with respect to each other, producing alternating stresses over a very small volume beneath the contact surface. Complete understanding of the fatigue process is critical for estimation of the bearing remaining useful life and allows planning maintenance actions. In the current work, it is assumed that the spall generation, on the surface of the raceway, is a result of RCF. This process is modeled based on continuum damage mechanics with representation of material grain structure and later implemented using ABAQUS Finite Element software. Damage mechanics approach relates the accumulated microscopic failure mechanisms to a damage state variable. The material microstructure is represented with the Poisson-Voronoi tessellation, with an emphasis on the realistic features of the microstructure, e.g. grain size and material properties. The developed model can be incorporated into ABAQUS by using standard tools of the software, e.g. meshing, damage representation, etc. Different microstructures, with a variety of material properties and grain topologies, were constructed for simulation purposes. The geometry of the simulated spalls and the Weibull slopes of the fatigue lives are in good agreement with published theoretical and experimental data. It can be concluded that the assumptions and the simplifications of the current, convenient to use, RCF model yield a sufficiently accurate tool based on previous publications and experimental data.