Influence of manufacturing processes on fatigue life and acoustic behavior of deep groove ball bearing

Abstract

This study examines the effects of three manufacturing routes—grinding and superfinishing (GR), hard turning and superfinishing (HT), and a sequential combination of hard turning, deep rolling (DR), and superfinishing (DR)—on the surface integrity, noise characteristics, and fatigue life of deep groove ball bearing inner rings. The experimental results revealed notable differences in both mechanical and functional performance among the processes. The DR specimens exhibited the highest compressive residual stresses, reaching approximately −1100 MPa at a depth of 150 μm, indicating a deeper compressive stress zone compared to the GR and HT specimens. Nevertheless, acoustic measurements showed that DR bearings generated the highest noise levels (NLs) in the L-band, primarily due to roundness deviations introduced by the DR process, whereas GR bearings demonstrated the lowest NLs. Fatigue testing indicated that HT bearings achieved the longest service life, while DR bearings exhibited the shortest fatigue life despite their favorable residual stress profile. Progressive wear and sudden failure were observed at critical wear levels, mainly caused by surface defects such as pitting and spalling. Overall, the findings highlight the complex trade-offs between surface integrity, acoustic performance, and fatigue durability in bearing raceway manufacturing processes.