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Abstract

Sub-surface-initiated spalling, which is the classical mode of failure in rolling element bearings is significantly influenced by the inhomogeneous and stochastic nature of the material microstructure. This microstructural disorder is one of the primary reasons for scatter in fatigue lives for a seemingly identical batch of bearings. In this study, a stochastic fatigue model that takes the material microstructure explicitly into account is used to investigate dispersion in spalling lives for rolling element bearings. Material microstructures are generated stochastically using the process of Voronoi tessellation. Input parameters to the fatigue model are obtained from torsional fatigue tests. Spalling lives are found to follow a three-parameter Weibull distribution more closely compared with the conventionally used two-parameter Weibull distribution. The stress-life results generated using the model are found to correlate well with the Lundberg-Palmgren theory. Based on parametric studies, a new statistical life equation for bearing life is proposed which is similar in structure to the Lundberg-Palmgren equation with a modification term. Parameters in the life equation are functions of torsional fatigue parameters for the material.

Keywords

sub-surface-initiated spalling rolling contact fatigue bearing life Weibull distribution

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Statistical numerical modelling of sub-surface initiated spalling in bearing contacts

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