FE-simulation of the effects of machining-induced residual stress profile on rolling contact of hard machined components

Y. B. Guo, Mark E. Barkey

Research output: Contribution to journalArticlepeer-review

40 Scopus citations

Abstract

Compared with grinding, hard turning may induce a relatively deep compressive residual stress. However, the interactions between the residual stress profile and applied load and their effects on rolling contact stresses and strains are poorly understood, and are difficult to measure using the current experimental techniques due to the small-scale of the phenomena. A new 2-D finite element simulation model of bearing rolling contact has been developed, for the first time, to incorporate the machining-induced residual stress profile instead of only surface residual stresses. Three cases using the simulation model were assessed: (a) measured residual stress by hard turning, (b) measured residual stress by grinding, and (c) free of residual stress. It was found that distinct residual stress patterns hardly affect neither the magnitudes nor the locations of peak stresses and strains below the surface. However, they have a significant influence on surface deformations. The slope and depth of a compressive residual stress profile are key factors for rolling contact fatigue damage, which was substantiated by the available experimental data. Equivalent plastic strain could be a parameter to characterize the relative fatigue damage. The magnitudes of machining-induced residual stress are reduced in rolling contact. The predicted residual stress pattern and magnitude agree with the test data in general. In addition, rolling contact is more sensitive to normal load and residual stress pattern than tangential load.

Original languageEnglish (US)
Pages (from-to)371-388
Number of pages18
JournalInternational Journal of Mechanical Sciences
Volume46
Issue number3
DOIs
StatePublished - Mar 2004
Externally publishedYes

All Science Journal Classification (ASJC) codes

  • Civil and Structural Engineering
  • Materials Science(all)
  • Condensed Matter Physics
  • Mechanics of Materials
  • Mechanical Engineering

Keywords

  • Finite element analysis
  • Grinding
  • Hard turning
  • Residual stress
  • Rolling contact

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