A 3D efficient finite element model to simulate rolling contact fatigue under high loading conditions

The objectives of this investigation were to develop a 3D efficient elastic-plastic finite element model to characterize the rolling contact fatigue behavior of through hardened steel at high loads (∼5 GPa) and to corroborate analytical and experimental results. The efficient FE model developed for this investigation was coupled with the continuum damage mechanics to simulate rolling contact fatigue (RCF). The new computationally efficient approach developed uses Delaunay mesh to reduce the number of elements without compromising the accuracy of stress distribution induced during a rolling contact pass. In order to validate the newly developed approach, the results obtained from the current 3D model for line contact were corroborated to previously published results. The fatigue lives obtained from the new model are consistent with the previously published model predictions and empirical observations. In order to simulate the RCF for high load conditions, the increase in the contact width observed in the experiments and consequently the decrease in the contact pressure with loading cycles were implemented in the model. Furthermore, the damage evolution law was modified to incorporate the compressive residual stresses induced by the plastic deformation. The L10 life and the scatter in the fatigue lives obtained from the model correlated well with the experimental results. As a part of this investigation, a Thrust Bearing Test Apparatus (TBTA) was designed and developed to simulate RCF. RCF experiments were conducted on through hardened AISI 52100 steel flat specimens at high contact stress levels (5 GPa) to induce plastic deformation. The results demonstrated that the contact width increased as the cycles increased due to plastic strain accumulation. The results from FE model corroborate well with experimental results obtained from TBTA. •A 3D elastic-plastic FE model based on the damage mechanics was developed to simulate rolling contact fatigue at high loads.•Experiments depict that contact width increased during fatigue cycles due to plastic deformation accumulation.•This increase causes to reduce the contact pressure distribution.•Moreover, the compressive residual stresses induced by plastic strain increase with cycles.•These evolutions were employed in the 3D efficient FE model to predict RCF lives at high loads and compared with experiments.