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Rolling–sliding contact fatigue of surfaces with sinusoidal roughness.pdf
International Journal of Fatigue 90 (2016) 57–68
Contents lists available at ScienceDirect
International Journal of Fatigue
journal homepage: /locate/ijfatigue
Rolling–sliding contact fatigue of surfaces with sinusoidal roughness
Wei Pu a, Dong Zhu a,?, Jiaxu Wang a,b, Q. Jane Wang b,c
a School of Aeronautics and Astronautics, Sichuan University, Chengdu 610065, China b State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400044, China c Center for Surface Engineering and Tribology, Northwestern University, Evanston, IL 60208, USA
article info
Article history: Received 22 December 2015 Received in revised form 7 March 2016 Accepted 8 April 2016 Available online 18 April 2016
Keywords: Rolling–sliding contact Elastohydrodynamic lubrication (EHL) Mixed EHL Contact fatigue Contact fatigue life prediction
abstract
Surfaces of mechanical components under combined rolling and sliding motions may be subjected to accelerated contact fatigue failure due to increased number of microscopic stress cycles and pressure peak heights caused by rough-surface asperity contacts. Available rolling contact fatigue (RCF) theories were developed mainly for rolling element bearings, for which the effect of sliding is usually insigni?cant. In various types of gears, however, considerable sliding exist in the critical tooth contact area below the pitch line, where excessive wear and severe pitting failures originate. Ignorance of sliding is most likely the reason why the conventional RCF models often overestimate gear fatigue life. This paper studies the effect of sliding motion on the contact fatigue life of surfaces with sinusoidal roughness that mimicks the topography from certain manufacturing processes. A set of simple equations for stress cycle counting is derived. Mixed elastohydrodynamic lubrication simulations are executed with the considerations of normal loading and frictional shear. Relative fatigue life evaluations based on a subsurface stress analysi
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