New Stress-Based Fatigue Life Models for Ball and Roller Bearings

ABSTRACT

New stress-based life models are introduced to define “dynamic stress capacity” in rolling bearings for the first time. The generalized stress capacity equations are formulated, for both point and line contacts, in terms of distinct geometrical and materials parameters while the empirical constants are now material independent. Life equations are first developed for individual rolling element to race contacts and then statistically combined to estimate lives of both races, rolling elements, and, finally, the whole bearings for both ball and roller bearings. An estimate of the empirical constant for the ball bearing equation is derived by regression analysis of available experimental data. The applicable constant for roller bearings is then derived by relating the ball and roller bearing constants to the fundamental subsurface fatigue hypothesis applicable to both point and line contacts. For AISI 52100 bearing steel at room temperature, life predictions with the new stress-based equations are in complete agreement with those currently provided by widely used load-based formulations, where the empirical constant contains the elastic properties of AISI 52100 bearing steel. In addition to these life equations based on the magnitude and depth of maximum orthogonal subsurface shear stress and the volume of material stressed, a new model that eliminates life dependence on the depth of maximum orthogonal shear stress and relates life to only the subsurface maximum shear stress and the stressed volume is presented. Though the predicted life estimates with the currently used and newly introduced life models are comparable in the contact stress range of 2 to 3 GPa, the new model provides significantly higher lives at low contact stresses.

KEYWORDS:

• Rolling element bearing
• rolling element bearing fatigue
• dynamic load capacity
• dynamic stress capacity
• rolling bearing life prediction
• ADORE

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Acknowledgments

Work reported in this article was sponsored by the United States Air Force under Small Business Innovation Research (SBIR) Phase I (Contract #FA8650-13-M-2406) and Phase II (Contract #FA8650-15-C-2534) contracts awarded to PKG Inc. The Air Force Technical Contract Monitors were Captain Justin Mason, Captain Ryan Kolesar and Jeremy Nickell.