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Compressive Residual Stresses Effect on Fatigue

Life of Rolling Bearings

Conference Paper January 2007

DOI: 10.1115/IMECE2007-43561

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2007 ASME International Mechanical Engineering Congress and Exposition
COMPRESSIVE RESIDUAL STRESSES EFFECT ON FATIGUE LIFE OF ROLLING BEARINGS
Spiridon S. Cretu Marcelin I. Benchea
Technical University of Iasi, Technical University of Iasi,
ROMANIA ROMANIA
ABSTRACT
The fatigue life tests carried out on two groups of ball
bearings confirm the positive influence of the compressive
residual stresses induced by a previous loading in the elastic-
plastic domain.
The values of residual stresses are numerically
evaluated by employing a three-dimensional strain
deformation analysis model. The model is developed in the
frame of the incremental theory of plasticity by using the von
Mises yield criterion and Prandtl-Reuss equations. To consider
the material behaviour the Ramberg-Osgood stress-strain
equation is involved and a nonlinear equation is considered to
model the influence of the retained austenite. To attain the final
load of each loading cycle the two bodies are brought into
contact incrementally, so that for each new load increment the
new pressure distribution is obtained as the solution of a
constrained system of equation. Conjugate gradients method in
conjunction with discrete convolution fast Fourier transform
is used to solve the huge system of equations.
Both the new contact geometry and residual stresses
distributions, are further considered as initial values for the
next loading cycle, the incremental technique being reiterated.
The cyclic evaluation process of both plastic strains and
residual stresses is performed until the material shakedowns.
Comparisons of the computed residual stresses and
deformed profiles with corresponding measured values reveal a
good agreement and validate the analysis model.
The von Mises equivalent stress, able to include both
elastic and residual stresses, is considered in Ioannides-Harris
rolling contact fatigue model to obtain theoretical lives of the
ball bearings groups. The theoretical analysis reveals also
greater fatigue lives for the ball bearings groups with induced
residual stresses than the fatigue lives of the group without
induced residual stresses.
Proceedings of IMECE07
November 11-15, 2007, Seattle, Washington, USA
IMECE2007-43561
Ovidiu S. Cretu
Tribo-Consult, Olympia,WA,
USA
1. INTRODUCTION
The majority of the researchers considers that the presence
of the compressive residual stresses has a beneficial influence
on the fatigue life of rolling contacts [1,2,3], but there are also
some contrary opinions [4].
In the experimental part of the study, the residual stresses
were induced by loading the deep-groove ball bearings into the
elastic-plastic domain.
Since the approaches of the cyclic elastic-plastic contact
problems by finite element methods are time consuming
[2,3,5], some semi-analytical methods have been recently
developed [6,7,8]. The incremental technique of plasticity
applied in two-dimensional elastic-plastic contact problems
proved to be accurate and more faster than the finite element
method [1,2,6,8], but also than the semi-analytical methods
[6,8].
Starting from the two-dimensional formulation presented
in [9,10], an improved three-dimensional strain deformation
analysis model has been developed to obtain the residual
stresses distribution.
The rolling contact fatigue model developed in [11,12]
involving the von Mises equivalent stress, capable to include
both elastic and residual stresses,[13], is considered to estimate
the theoretical lives of the tested groups.
NOMENCLATURE
[ ]
A tensor revealing the stress increments by strain
[B ] tensor revealing the strainincrements by stress
A proportionality constant
B - material constant
E Youngs modulus
H ' - equivalent plasticity modulus
L - fatigue life
1 Copyright 2007 by ASME
 Lref - relative fatigue life -the radial load on each bearing was established a level
N parameter of strain hardening able to induce a maximum Hertz pressure 0 = 3.35GPa ;
Ra - arithmetic average of roughness -rotational velocity of the inner ring n = 1500rev / min . ;
S deviatoric stress tensor -oil lubrication ables to attain the value = 4.8 for the
c stress criterion exponent lubrication parameter;
e Weibull slope -the ball bearing endurance tests were run until all rolling
bearings failed.
V volume of material where > u The Weibull distribution function was hypothesized as
Vref - volume of material where ref > u describing the distribution of fatigue lives and the maximum
likelihood method was used to estimate the parameters of each
- half-axes ratio of the contact ellipse distribution group. Estimators referring to the fatigue lives L10
- Kroneckers tensor and Lm corresponding to 10% and median failures, as well as
- strain tensor
to the shape factor e are presented in Table 1.
e - strain intensity
d - strain increment tensor Table 1. The estimators of the parameters L10, Lm and e.
- lubrication parameter
- Poissons ratio Fatigue lives
- stress tensor Prestressing (relative values) Shape
d - stress increment tensor Group stress P factor,
e
E - initial value of the yield limit (GPa ) L10 Lm
e - stress intensity BB-1 0 86 193 2.44
H - maximum Hertz pressure BB-2 4.5 135 717 1.27

ref - stress used for reference life computation The fatigue life tests provide evidence for the positive
u - fatigue limit influence of the compressive residual stresses induced by a
previous loading in the elastic-plastic domain.
To obtain a theoretical formulation of the experimental results
Superscripts the evolution of the residual stresses state on both the load
e elastic level and number of cycles was first needed, and
n iteration order correspondingly an elastic-plastic contact model has been
p plastic developed.

Subscripts 3. ELASTIC-PLASTIC MODEL

i, j, k, l - components The increment of the total strain is assumed to be a sum of the
elastic and plastic strain increments :
2. FATIGUE LIVE RESULTS
Two groups of 6308-type deep groove ball bearings were
d = d e + d p (1)
selected, each group containing 24 bearings manufactured Hookes law provides the differential of elastic strain tensor:
from the same steel charge and using the same production
series.
d ije =
1
E
[
(1 + ) d ij d kk ij ] (2)
One ball bearings group was the reference group while the The differential of plastic strain tensor is:
second one had been previously preloaded at a load level
3 d ep
corresponding to elastic-plastic domain. The preload force was d p = S (3)
applied 200 loading cycles on each ball bearing at a level to 2 e
attain the value H = 4.5GPa for the elastic Hertz In the elastic-plastic domain the link between the intensity of
pressure at the contact achieved between the inner ring and the the stress tensor and the intensity of the strain tensor is assured
most loaded ball. To produce micro-structural changes which by the Ramberg-Osgoods equation:

are visible by light microscopy more than one million loading N

cycles are required [14]. e = e + e (4)

Both ball bearings groups were fatigue tested in the same E B
working conditions: The differential of the strain tensor becomes:

2 Copyright 2007 by ASME

 d ij =
1
E
[
(1 + )d ij ij d kk + 3 S d e
2 H e
] (5)
Versus the previous incremental algorithms [9,10], the
increments of residual stresses are evaluated in this approach:
E
BN d R( n +1) =
1 + 1 +
(d kk )
p n +1
ij + (d ij )
p n +1

where : H =
N ( e )
N 1

d xxR
( n +1)
= d xxR
*( n +1)
d zzR
*( n +1)
(14)
Differentiating the intensity of the stress tensor, the increments
1
of the total strain are obtained, as follows:

[ ] d yyR = d *(yyRn +1) d zzR
( n +1) *( n +1)
d ij = (1 + )d ij ij d kk +
1 (15)
E
1
(6) In the third step, the residual stresses increments are added to
9 S ij 1
[S kk dS kk + (1 kl ) kl d kl ] the stresses increments:
4 e2 H d ( n +1) = d ( n +1) + d R( n +1) (16)
In the matrix notation: Finally, for the involved point, the stress and strain tensors are:
d = [B ] d and d = [ A] d , [A] = [B ] ( n +1) = ( n ) + d ( n +1)
1
(7) (17)
( n +1) ( n +1)
p = p + d p
( n)
(18)
4. INCREMENTAL ALGHORITHM The evaluation process, of both plastic strains and residual
The algorithm starts from a sufficiently low load level to stresses, is performed in all points of the loaded half-space.
induce in the entire half-space an elastic stresses state. The As long as the load attains its final value, the integration
pressure distribution is numerically obtained as the solution of of the plastic strains provides the plastic displacements and
the linear algebraic system formed with Boussinesqs equation changes of the contact geometry.
written in all mesh points of the candidate contact area, [15]. Both, the new contact geometry and residual stresses
The conjugate gradients method in conjunction with the distributions, are further considered as initial values for the
discrete convolution fast Fourier transform is involved to solve next loading cycle, the incremental technique being reiterated.
the linear system,[7]. The cyclic incremental technique continues till material
To attain the final load, the two bodies are brought into shakedowns.
contact incrementally, and for each new load increment the
new pressure distribution is obtained as the solution of a 5. COMPARATIVE SIMULATIONS
constrained system of equations. For each load level the The results obtained with the incremental technique have
internal stresses state is found by using the superposition been compared with results provided either by the finite
principle and the von Mises yield condition is checked. At a element method or by more sophisticated semi-analytical
certain load increment order, n + 1, the yield condition is codes. In this respect, the case of an elastic-plastic body in
fulfilled in a number of points inside the stressed volume and contact with a rigid punch, recently analyzed by Jacq and
the plastic deformation takes place. For each of these points the Nelias, [6], as well as by Wang and Keer, [8], has been
stress and strain tensors are obtained in three steps. In the first considered.
step, the increment of the stress tensor is evaluated as a
difference between the successive order components while the
increment of the total deformation tensor is evaluated by
equation (2), (compatibility technique):
d ( n +1) = (n +1) (n ) (8)
1
[
d ( n +1) = (1 + ) d ( n +1) d ( n +1)
E
] (9)

In the second step, the increment of the stress tensor is

recalculated involving equation (7):
[ ]
d ( n +1) = A( n ) d ( n +1) (10)
The increments of the elastic and plastic strains are founded:

(d )e ( n +1)
ij =
1
E
[
(1 + ) d ij( n +1) d kk( n +1) ij ] (11)

(d )p ( n +1)
= d ( n +1) (d e )
( n +1)
(12)
Fig. 1: Distribution of residual displacement along the contact
axis

3 Copyright 2007 by ASME

 1/ e
The distribution of the residual displacement u z along the
1
contact axis presented in fig.1, is quite similar with the ln
corresponding distribution obtained by Wang and Keer, ([ 8]- L= S

A * ( u ) .dV
c
(19)
figure 17), but with a more elaborate semi-analytical method.
For the same case, the distributions of the residual stresses V


[ ]
obtained by using the incremental technique are presented in
S = exp A L ( u ) dV
e c
fig.2 and fig.3. These distributions proved to be identical with (20)
V
those obtained by using both a semi-analytical method and the
finite element method, Jacq and Nelias ,([6]- figure 14 and
figure 16). What is concern in this study is not the absolute fatigue
life but the relative live, which is the life L divided by a
reference life , both of which refer to the same reliability:

( )
1/ e
ref u dV

c

V
Lref (ref ) = ref
V ( u ) dV
c (21)

The von Mises equivalent stress, capable to include both

elastic and residual stresses, is suitable to be the stress used
for reference life computation, Popinceanu, Diaconescu, Cretu,
[13].
The distributions of von Mises equivalent stresses for the
Fig. 2: Residual stress versus depth along the contact axis
case of the reference bearings group are presented in fig. 4 for
the x-o-z plane and in fig. 5 for the y-o-z plane. No residual
stresses have been considered in the von Mises equation.

Fig.3: Residual stresses profile at 2 microns far from the

contact axis.

6. THEORETICAL STUDY ON FATIGUE LIVES

To estimate the theoretical values of fatigue lives for each Fig. 4 : The von Mises stress distribution in the xoz plane
ball-bearing group, the Ioannides-Harris fatigue life model for the reference ball bearings
[11] was applied, with the depth weighting removed, as it was
suggested by Lubrecht, Jacobson and Ioannides, [12].
According to Ioannides and Harris the fatigue life L (millions
of stress cycles) and the related reliability S are calculated
from:

4 Copyright 2007 by ASME

 Fig. 5 : The von Mises stress distribution in the yoz plane
for the reference ball bearings
7. RESIDUAL STRESSES AND SHAKEDOWN
For the case of the preloaded ball bearings, the
distributions of the normal residual stresses achieved after the
1st, 2nd, 10th, 60th, 90th and 100 loading cycles are presented in
fig. 6 for the circumferential direction and in fig. 7 for the
axial direction.
Fig. 6: Depth distribution of the normal circumferential
residual stress
Fig. 7 : Depth distribution of the normal axial residual stress
The diagrams presented in fig. 6 and fig. 7 point out
that the shakedown process has been attained. After 100
loading cycles the residual stresses distributions are the same
with those attained at 90 loading cycles that suggests that the
residual stresses distribution have no evolution as long as the
number of cycles is greater than 90.
The residual stresses attained in the shakedown
process have been further considered to obtain the new von
Mises distributions, fig. 8 and fig. 9.
Fig. 8 : The von Mises stress distribution in the xoz plane
for the prestressed ball bearings
5 Copyright 2007 by ASME

Fig. 9 : The von Mises stress distribution in the yoz plane
for the prestressed ball bearings
On the basis of the equation (21), the theoretical analysis
reveals 3.09 greater fatigue life for the group with induced
residual stresses versus the fatigue life of the reference group.
8. CONCLUSIONS
Two groups of 6308-type deep-groove ball bearings were
subjected to rolling contact fatigue. Each group contained 24
bearings. One ball bearings group was the reference group
while the second one had been previously preloaded at a load
level high enough to induce compressive residual stresses into
a shallow layer beneath the working surface.
The ball bearing group with induced residual stresses
provided greater fatigue lives comparing with the fatigue lives
of the reference group.
The residual stresses resulting from the heavily
stressed contact of ball on the inner ring of deep-groove ball
bearing surface are numerically evaluated by a three-
dimensional strain deformation analysis model
To obtain the theoretical lives of the tested groups,
Ioannides-Harris model of rolling contact fatigue life and von
Mises stress have been used. The numerical analysis reveals
also greater fatigue lives for the group with induced residual
stresses than the fatigue lives of the reference group.
Both, the experimental work and the theoretical
analysis, validate the beneficial influence of the compressive
residual stresses induced by a previous contact loading in the
elastic-plastic domain.
REFERENCES
[1] Ko, C.N., Ioannides, E., 1988, The Associated Residual
Stresses and their Effect on the Fatigue Life of Rolling
Bearing: an FEM Analysis, Proc. 15th Leeds-Lyon Symp.,
Leeds, pp.199-207.
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[3] Muro, H., Tsushima, N., Nunome, K., 1973, Failure
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[4] Kepple, R.K., Mattson, R.L., 1970, Rolling Element
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[5] Jiang, Y., Xu, B., Sehitoglu, H., 2002, Three-
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[12] Lubrecht, A.A., Jacobson, B.O., Ioannides E., 1990,
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ASME J. Lubr. Technol., 92(1), pp. 54-58.
[15] Allwood, J., 2005, Survey and Performance Assessment
of Solution Method for Elastic Rough Contact Problems,
ASME J. Tribol., 127, pp. 10-23.
6 Copyright 2007 by ASME