Experimental analysis and modelling of c-crack propagation in silicon nitride ball bearing element under rolling contact fatigue

• Published in: Tribology international Vol. 126; pp. 386 - 401
• Main Authors: Nazir, Mian Hammad, Khan, Zulfiqar Ahmad, Saeed, Adil
• Format: Journal Article
• Language: English
• Published: Kidlington Elsevier Ltd 01.10.2018; Elsevier BV
• Subjects: Ball bearing; Ball bearings; c-crack propagation; Ceramics; Computer simulation; Crack initiation; Crack propagation; Durability; Experiments; Failure mechanisms; Fatigue cracks; Fatigue failure; Finite element method; Fracture mechanics; Fracture toughness; Materials fatigue; Mathematical analysis; Mathematical models; Modelling; Monte-Carlo simulation; Predictions; Rolling; Rolling contact; Rolling contact fatigue; Silicon nitride; Stress intensity factors; Three dimensional analysis; Finite element method; Ball bearing; Rolling contact fatigue; c-crack propagation; Monte-Carlo simulation; Silicon nitride
• ISSN: 0301-679X; 1879-2464
• DOI: 10.1016/j.triboint.2018.04.030

A comprehensive model for predicting fatigue failure probability of surface c-shaped cracks in silicon nitride ball bearing elements under rolling contact fatigue (RCF) has been presented in this paper. Firstly, three-dimensional finite element analysis (FEA) is used to determine the stress intensity factors (SIFs) along the front of crack by using fracture mechanics approach. Then the propagation uncertainty of c-crack is evaluated by using surrogate models built upon highly accurate finite element modelling for equivalent stress intensity factors. Finally, the Monte Carlo Simulations combined with surrogate models are used to predict the failure probability of rolling ball bearing element. Simulation results reveal that it is possible to reduce the failure probability of ball bearing element up to 95% by reducing the maximum crack size and enhancing the fracture toughness of the ball material. The modelling results have been verified by experimental studies showing that the current predictions of c-crack fatigue failures were consistent with the experimental results. Fatigues crack initiation and propagation is a significant failure mechanism within ceramic ball bearing elements. It presents design and durability challenges for both manufacturers and users. A three-fold approach, to simulate fatigue propagation of c-shaped crack in rolling contact ceramic bearing element presented in this paper, is novel and will solve major durability issues within ceramic ball bearing elements subject to rolling contact fatigue. In the present work,•A fatigue failure model for surface c-shaped cracks in silicon nitride ball bearing under rolling contact is presented.•Firstly, three-dimensional FEA is used to determine the stress intensity factors (SIFs) along the front of crack.•Then the propagation uncertainty of c-crack is evaluated by using surrogate models built upon highly accurate FEA analysis.•Finally, the Monte Carlo Simulations combined with surrogate models predict the failure probability of rolling ball bearing.•The modelling results have been verified by experimental studies showing good agreement with the experimental results.