Details
| Original language | English |
|---|---|
| Article number | 109 |
| Journal | Lubricants |
| Volume | 7 |
| Issue number | 12 |
| Publication status | Published - 6 Dec 2019 |
Abstract
Rolling bearings are frequently used machine elements in mechanical assemblies to connect rotating parts. Resource efficiency and reliability enhancement are considered to be important factors of rolling bearing development. One of the ways to meet these requirements is the tailored forming (TF) technology, which enables the functionalization of several metal layer composites in a single component. The so-called hybrid machine elements can be produced by co-extrusion of aluminum and steel and subsequent die forging, heat treatment, and machining. The TF rolling bearings made by this process can provide optimized characteristics that use aluminum to reduce weight and steel for a highly loaded contact zone between a rolling element and a bearing raceway. To evaluate the applicability and the potential of this technology, theoretical investigations are presented in this paper. The stress distribution under fully flooded conditions, caused by an external load in the contact between a rolling element and the TF outer ring of an angular contact ball bearing, is analyzed statically with the finite element method. The fatigue life of the TF component can be calculated for different external axial loads and manufacturing parameters, such as steel-to-aluminum volume ratios and osculation. As a damage model, the Ioannides and Harris fatigue model and the Dang Van multiaxial fatigue criterion were used. The results show that the fatigue life has high sensitivity to the steel-to-aluminum volume ratio. For the hybrid component with a steel layer thickness of 3 mm, 90 percent of the fatigue life of pure 100Cr6 steel bearing bushings is reached. In this FE model, residual stresses due to machining processes can be regarded as an initial state, which can increase the fatigue life of this TF machine component.
Keywords
- Bearing bushing, Fatigue life calculation, Hybrid bearing, Rolling contact fatigue, Tailored forming
ASJC Scopus subject areas
- Engineering(all)
- Mechanical Engineering
- Materials Science(all)
- Surfaces, Coatings and Films
Sustainable Development Goals
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In: Lubricants, Vol. 7, No. 12, 109, 06.12.2019.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Simulation of a steel-aluminum composite material subjected to rolling contact fatigue
AU - Hwang, Jae Il
AU - Coors, Timm
AU - Pape, Florian
AU - Poll, Gerhard
N1 - Funding Information: Funding: This research was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation), grant number 252662854. Funding Information: Acknowledgments: The results presented in this paper were obtained within the Collaborative Research Centre 1153 for the subproject C3 of the project “Process chain to produce hybrid high performance components by tailored forming”. The authors would like to thank the German Research Foundation (DFG) for the financial and organizational support of this project.
PY - 2019/12/6
Y1 - 2019/12/6
N2 - Rolling bearings are frequently used machine elements in mechanical assemblies to connect rotating parts. Resource efficiency and reliability enhancement are considered to be important factors of rolling bearing development. One of the ways to meet these requirements is the tailored forming (TF) technology, which enables the functionalization of several metal layer composites in a single component. The so-called hybrid machine elements can be produced by co-extrusion of aluminum and steel and subsequent die forging, heat treatment, and machining. The TF rolling bearings made by this process can provide optimized characteristics that use aluminum to reduce weight and steel for a highly loaded contact zone between a rolling element and a bearing raceway. To evaluate the applicability and the potential of this technology, theoretical investigations are presented in this paper. The stress distribution under fully flooded conditions, caused by an external load in the contact between a rolling element and the TF outer ring of an angular contact ball bearing, is analyzed statically with the finite element method. The fatigue life of the TF component can be calculated for different external axial loads and manufacturing parameters, such as steel-to-aluminum volume ratios and osculation. As a damage model, the Ioannides and Harris fatigue model and the Dang Van multiaxial fatigue criterion were used. The results show that the fatigue life has high sensitivity to the steel-to-aluminum volume ratio. For the hybrid component with a steel layer thickness of 3 mm, 90 percent of the fatigue life of pure 100Cr6 steel bearing bushings is reached. In this FE model, residual stresses due to machining processes can be regarded as an initial state, which can increase the fatigue life of this TF machine component.
AB - Rolling bearings are frequently used machine elements in mechanical assemblies to connect rotating parts. Resource efficiency and reliability enhancement are considered to be important factors of rolling bearing development. One of the ways to meet these requirements is the tailored forming (TF) technology, which enables the functionalization of several metal layer composites in a single component. The so-called hybrid machine elements can be produced by co-extrusion of aluminum and steel and subsequent die forging, heat treatment, and machining. The TF rolling bearings made by this process can provide optimized characteristics that use aluminum to reduce weight and steel for a highly loaded contact zone between a rolling element and a bearing raceway. To evaluate the applicability and the potential of this technology, theoretical investigations are presented in this paper. The stress distribution under fully flooded conditions, caused by an external load in the contact between a rolling element and the TF outer ring of an angular contact ball bearing, is analyzed statically with the finite element method. The fatigue life of the TF component can be calculated for different external axial loads and manufacturing parameters, such as steel-to-aluminum volume ratios and osculation. As a damage model, the Ioannides and Harris fatigue model and the Dang Van multiaxial fatigue criterion were used. The results show that the fatigue life has high sensitivity to the steel-to-aluminum volume ratio. For the hybrid component with a steel layer thickness of 3 mm, 90 percent of the fatigue life of pure 100Cr6 steel bearing bushings is reached. In this FE model, residual stresses due to machining processes can be regarded as an initial state, which can increase the fatigue life of this TF machine component.
KW - Bearing bushing
KW - Fatigue life calculation
KW - Hybrid bearing
KW - Rolling contact fatigue
KW - Tailored forming
UR - http://www.scopus.com/inward/record.url?scp=85079764196&partnerID=8YFLogxK
U2 - 10.3390/LUBRICANTS7120109
DO - 10.3390/LUBRICANTS7120109
M3 - Article
AN - SCOPUS:85079764196
VL - 7
JO - Lubricants
JF - Lubricants
SN - 2075-4442
IS - 12
M1 - 109
ER -