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Xiao-feng Qin, Da-le Sun, Li-yang Xie
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Lester E. Alban
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Book Chapter
Analysis of Critical Stress for Subsurface Rolling Contact Fatigue Damage Assessment Under Roll/Slide Contact
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001807
EISBN: 978-1-62708-241-9
... Abstract Rolling contact fatigue is responsible for a large number of industrial equipment failures. It is also one of the main failure modes of components subjected to rolling contact loading such as bearings, cams, and gears. To better understand such failures, an investigation was conducted...
Abstract
Rolling contact fatigue is responsible for a large number of industrial equipment failures. It is also one of the main failure modes of components subjected to rolling contact loading such as bearings, cams, and gears. To better understand such failures, an investigation was conducted to assess the role of friction in subsurface fatigue cracking in rolling-sliding contact applications. Based on the results of stress calculations and x-ray diffraction testing of steel samples, friction contributes to subsurface damage primary through its effect on the distribution of orthogonal shear stress. Although friction influences other stress components, the effect is relatively insignificant by comparison. It is thus more appropriate to select orthogonal shear stress as the critical stress when assessing subsurface rolling contact fatigue in rolling-sliding systems.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0047968
EISBN: 978-1-62708-225-9
... when the bearing was not rotating or during installation. It was concluded that the bearings had failed in rolling-contact fatigue. The noise was eliminated and the preload was reduced to 30 lb by using a different spring washer as a corrective measure. Computers Loads (forces) Noise Service...
Abstract
The radial-contact ball bearings (type 440C stainless steel and hardened) supporting a computer microdrum were removed for examination as they became noisy. Two sizes of bearings were used for the microdrum and a spring washer that applied a 50 lb axial load on the smaller bearing was installed in contact with the inner ring for accurate positioning of the microdrum. The particles contained in residue achieved after cleaning of the grease on bearings with a petroleum solvent were attracted by a magnet and detected under a SEM (SEM) to be flaked off particles from the outer raceway surface. Smearing, true-brinelling marks, and evidence of flaking caused by the shifting of the contact area (toward one side) under axial load, was revealed by SEM investigation of one side of the outer-ring raceway. The true-brinelling marks on the raceways were found to be caused by excessive loading when the bearing was not rotating or during installation. It was concluded that the bearings had failed in rolling-contact fatigue. The noise was eliminated and the preload was reduced to 30 lb by using a different spring washer as a corrective measure.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003563
EISBN: 978-1-62708-180-1
... Abstract A major cause of failure in components subjected to rolling or rolling/sliding contacts is contact fatigue. This article focuses on the rolling contact fatigue (RCF) performance and failure modes of overlay coatings such as those deposited by physical vapor deposition, chemical vapor...
Abstract
A major cause of failure in components subjected to rolling or rolling/sliding contacts is contact fatigue. This article focuses on the rolling contact fatigue (RCF) performance and failure modes of overlay coatings such as those deposited by physical vapor deposition, chemical vapor deposition, and thermal spraying (TS). It provides a background to RCF in bearing steels in order to develop an understanding of failure modes in overlay coatings. The article describes the underpinning failure mechanisms of TiN and diamond-like carbon coatings. It presents an insight into the design considerations of coating-substrate material properties, coating thickness, and coating processes to combat RCF failure in TS coatings.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003564
EISBN: 978-1-62708-180-1
... Abstract Rolling-contact fatigue (RCF) is a surface damage process due to the repeated application of stresses when the surfaces of two bodies roll on each other. This article briefly describes the various surface cracks caused by manufacturing processing faults or blunt impact loads on ceramic...
Abstract
Rolling-contact fatigue (RCF) is a surface damage process due to the repeated application of stresses when the surfaces of two bodies roll on each other. This article briefly describes the various surface cracks caused by manufacturing processing faults or blunt impact loads on ceramic balls surfaces. It discusses the propagation of fatigue cracks involved in rolling contacts. The characteristics of various types of RCF test machines are summarized. The article concludes with a discussion on the various failure modes of silicon nitride in rolling contact. These include the spalling fatigue failure, the delamination failure, and the rolling-contact wear.
Book Chapter
Rolling Contact Fatigue Failure of a Spiral Bevel Gear and Pinion Set
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.conag.c9001500
EISBN: 978-1-62708-221-1
.... The primary failure was associated with the 4820H NiMo alloy steel pinion, and thus the gear was not examined. The mode of failure was rolling contact fatigue, and the cause of failure improper engineering design. The pattern of continual overload was restricted to a specific concentrated area situated...
Abstract
A ‘worn-out’ spiral bevel gear and pinion set was submitted for examination and evaluation. This was a spiral bevel drive set with the gear attached to a differential. The assembled unit was driving a new, large, experimental farm tractor in normal plowing and tilling operations. The primary failure was associated with the 4820H NiMo alloy steel pinion, and thus the gear was not examined. The mode of failure was rolling contact fatigue, and the cause of failure improper engineering design. The pattern of continual overload was restricted to a specific concentrated area situated diagonally across the profile of the loaded side, which was consistent on every tooth.
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006792
EISBN: 978-1-62708-295-2
... Abstract Rolling-contact fatigue (RCF) is a common failure mode in components subjected to rolling or rolling-sliding contact. This article provides a basic understanding of RCF and a broad overview of materials and manufacturing techniques commonly used in industry to improve component life...
Abstract
Rolling-contact fatigue (RCF) is a common failure mode in components subjected to rolling or rolling-sliding contact. This article provides a basic understanding of RCF and a broad overview of materials and manufacturing techniques commonly used in industry to improve component life. A brief discussion on coatings to improve surface-initiated fatigue and wear is included, due to the similarity to RCF and the increasing criticality of this failure mode. The article presents a working knowledge of Hertzian contact theory, describes the life prediction of rolling-element bearings, and provides information on physics and testing of rolling-contact fatigue. Processes commonly used to produce bearings for demanding applications are also covered.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0047975
EISBN: 978-1-62708-225-9
... by contact fatigue mechanism (flaking) activated by the subsurface nonmetallic inclusions. Aircraft components Bearing races Flaking Transmissions (sutomotive) Bearing steel Fatigue fracture Rolling-contact wear The pilot of an aircraft reported illumination of the transmission oil-pressure...
Abstract
An aircraft was grounded when illumination of the transmission oil-pressure light and an accompanying drop in pressure on the oil-pressure gage was reported by the pilot. No discrepancy in the bearing assemblies and related components was revealed by teardown analysis of the transmission. The center bearing of the transmission input-shaft ball-bearing stack had a broken cage and one ball was found to have been split into several pieces. Several scored balls and flaking damage in the raceways of the inner and outer rings was observed. The origin (area in rectangle) was oriented axially in the raceway and was flanked by areas of markedly different-textured flaking damage. Stringers of nonmetallic inclusions were revealed at the origin during metallographic examination of a section parallel to the axially oriented origin. Thus it was concluded that the failure was caused by contact fatigue mechanism (flaking) activated by the subsurface nonmetallic inclusions.
Image
Gear-tooth section. Rolling-contact fatigue. Crack origin subsurface. Progr...
Available to PurchasePublished: 01 January 2002
Fig. 23 Gear-tooth section. Rolling-contact fatigue. Crack origin subsurface. Progression was parallel to surface and inward away from surface. Not etched. 60×
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Image
Gear-tooth section. Rolling-contact fatigue. Crack origin subsurface. Progr...
Available to PurchasePublished: 01 January 2002
Fig. 24 Gear-tooth section. Rolling-contact fatigue. Crack origin subsurface. Progression was parallel with surface, inward, and finally to the surface to form a large pit or spall. Not etched. 60×
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Image
Gear-tooth section. Rolling-contact fatigue distinguished by subsurface she...
Available to PurchasePublished: 01 January 2002
Fig. 25 Gear-tooth section. Rolling-contact fatigue distinguished by subsurface shear parallel to surface. Note the undisturbed black oxides at the surface, indicating no surface-material movement. Not etched. 125×
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Image
Published: 01 January 2002
Image
Gear-tooth section. Rolling-contact fatigue. Crack origin subsurface. Progr...
Available to PurchasePublished: 01 January 2002
Fig. 4 Gear-tooth section. Rolling-contact fatigue. Crack origin subsurface. Progression was parallel to surface and inward away from surface. Not etched. 60×
More
Image
Gear-tooth section. Rolling-contact fatigue. Crack origin subsurface. Progr...
Available to PurchasePublished: 01 January 2002
Fig. 5 Gear-tooth section. Rolling-contact fatigue. Crack origin subsurface. Progression was parallel with surface, inward, and finally to the surface to form a large pit or spall. Not etched. 60×
More
Image
Gear-tooth section. Rolling-contact fatigue distinguished by subsurface she...
Available to PurchasePublished: 01 January 2002
Fig. 6 Gear-tooth section. Rolling-contact fatigue distinguished by subsurface shear parallel to surface. Note the undisturbed black oxides at the surface, indicating no surface-material movement. Not etched. 125×
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Image
Morphology of cracks leading to rolling-contact fatigue failure of PVD (TiN...
Available to PurchasePublished: 01 January 2002
Fig. 9 Morphology of cracks leading to rolling-contact fatigue failure of PVD (TiN) coatings. (a) Crack parallel to the interface leading to spalled area for hard substrate (60 HRC) TiN coating. (b) Cracks parallel to the coating-substrate interface for hard substrate (60 HRC) TiN coating. (c
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Image
Rolling-contact fatigue failure modes of thermal spray cermet and ceramic c...
Available to PurchasePublished: 01 January 2002
Fig. 10 Rolling-contact fatigue failure modes of thermal spray cermet and ceramic coatings. Source: Ref 84
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Image
Gear-tooth section. Rolling-contact fatigue distinguished by subsurface she...
Available to PurchasePublished: 15 January 2021
Fig. 8 Gear-tooth section. Rolling-contact fatigue distinguished by subsurface shear parallel to surface. Note the undisturbed black oxides at the surface, indicating no surface-material movement. Not etched. Source: Ref 30
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Image
Results of rolling contact fatigue test: ( a ) varies of friction coefficie...
Available to Purchase
in Analysis of Critical Stress for Subsurface Rolling Contact Fatigue Damage Assessment Under Roll/Slide Contact
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 6 Results of rolling contact fatigue test: ( a ) varies of friction coefficient with the test time,; and ( b ) FWHM along the radii of test samples)
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Image
Gear tooth section. Rolling-contact fatigue distinguished by subsurface she...
Available to Purchase
in Failure Analysis of Gears and Reducers
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 26 Gear tooth section. Rolling-contact fatigue distinguished by subsurface shear parallel to surface. Note the undisturbed black oxides at the surface, indicating no surface-material movement. Not etched. Original magnification: 125×. Source: Ref 1
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Image
Section showing race surface. Extensive rolling contact fatigue has occurre...
Available to Purchase
in Failure of Coal Crushing Plant Taper Bearing
> ASM Failure Analysis Case Histories: Failure Modes and Mechanisms
Published: 01 June 2019
Fig. 2 Section showing race surface. Extensive rolling contact fatigue has occurred due to the overload condition.
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