A simulation study on predicting the distribution of rolling contact fatigue life
Abstract
We proposed and conducted a simulation study to investigate both the effect of residual stress and tool wear on the distribution of rolling contact fatigue life. Distributions of both crack initiation life and propagation life have been studied by introducing normally distributed randomness in residual stress. Simulation results show that lognormal distribution is the most suitable distribution to describe the distribution of rolling contact fatigue life assuming the residual stress follows a normal distribution. Results are validated by comparing the simulation results with previous rolling contact fatigue test results. The simulation results showed good agreement on lower maximum Hertzian stress area on the average value for fatigue life with previous experimental results. Experimental investigation of the tool wear effect on rolling contact fatigue life has been performed on AISI 1045 steel. The fatigue lives for three levels of tool wear were investigated and compared. It has been shown experimentally that tool wear can introduce as large as 33 times of fatigue life differences between machined pieces. Comparison between predicted fatigue life and experimental fatigue life were investigated. However, due to the large variation in the experimental fatigue life results, we cannot make a firm conclusion on the accuracy of the predicted model.
Degree
M.S.
Advisors
Wan, Purdue University.
Subject Area
Industrial engineering
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