An acoustic emission in-Situ measuring system for the investigation of white layer effect on rolling contact fatigue

Dale Schwach, Y. B. Guo

Research output: Contribution to conferencePaperpeer-review

Abstract

Hard turning has begun to compete with grinding in manufacturing various mechanical components because of the significant potential technical and economical benefits for improving fatigue life. However under certain cutting conditions, a phase-transformed white layer (WL) may form on the machined surface that could drastically affect a component's service life. The presence of WL causes great concerns in machining industry just because the WL effects on component performance such as fatigue life are yet to be understood. Therefore the significant benefits of hard turning would not be realized fully unless this issue is solved. A novel real-time acoustic emission (AE) based rolling contact fatigue (RCF) testing system was presented to study the WL effects on component life. AISI 52100 bearing steels were machined to generate two distinct surfaces: free of white layer (NOWL) and with WL. The real life loading of contact pressures and rolling speeds was applied to the test specimens. The applied load throughout the experiment was in-process monitored using a load cell which enabling the record of a Hertzian pressure history during rolling contact. It was found that the RCF testing system is simple and inexpensive, but very sensitive to fatigue crack initiation and propagation. Compared with AE count rate, AE parameters such as energy, RMS, and amplitude are more sensitive to fatigue crack initiation and propagation in rolling contact. The NOWL samples are more resistive to fatigue crack initiation/propagation and therefore have a longer life when compared to the WL samples with equivalent surface finish. The WL samples have shorter life or at most comparable with the NOWL samples with relative rough surface finish.

Original languageEnglish (US)
Pages887-894
Number of pages8
DOIs
StatePublished - 2004
Externally publishedYes
Event2004 ASME International Mechanical Engineering Congress and Exposition, IMECE 2004 - Anaheim, CA, United States
Duration: Nov 13 2004Nov 19 2004

Conference

Conference2004 ASME International Mechanical Engineering Congress and Exposition, IMECE 2004
Country/TerritoryUnited States
CityAnaheim, CA
Period11/13/0411/19/04

All Science Journal Classification (ASJC) codes

  • Engineering(all)

Keywords

  • Acoustic emission
  • Fatigue
  • Hard machining
  • Rolling contact
  • White layer

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