NONLINEAR SOLUTIONS LLC, Surface Engineering

Problem: Calculate the elastic-plastic deformation and fatigue of a surface dented roller bearing

Solution:

Developed a finite element model shown in Figure 1 using:

Semi-Infinite half-space model of the bearing surface
Infinite elements on the half-space outer boundaries to reduce the number of elements
A rigid indenter to create a spherical dent defect on the bearing surface

Surface engineering nonlinear material behavior rolling contact simulation shown in Figure 2:

Residual circular dent diameter deformation of 24.07 um on the surface after rigid indenter normal force removal
Deformation after 1 simulated rolling contact over the dent
Elastic-plastic strains were calculated to determine that fatigue failure would occurr near the dent shoulder
Crack initaition angle of 70 degrees from horizontal was determined by finding the plane with the highest shear amplitude

Figure 1. Semi-infinite half-Space model approx. of the bearing surface

Figure 2. Surface engineering nonlinear material behavior/fatigue

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