Abstract. This paper describes a methodology for assessing critical stress ranges arising in automotive plain bearings during engine operations. An industry-produced and run simulation program provides information on oil film pressure and overall bearing deformation during accelerated performance tests. This code performs an elasto-hydrodynamic lubrication analysis accounting for the compliance of the housing and journal. Finite element analyses of a multilayer bearing are performed to assess the conditions responsible for possible fatigue damage over the bearing lining. The residual stresses arising from the forming and fitting process are first assessed. The stress analyses over the engine cycle show the intensity and distribution of cyclic tensile and compressive stresses in the bearing. The location of maximum stress range is found to be consistent with the damage observed in accelerated fatigue tests. Critical zones are identified in the lining for possible fatigue crack initiation and growth studies.
Multi-layered bearing systems used in the automotive industry show shielding and antishielding effects that reduce or amplify the crack driving force under large scale yielding conditions. Using finite element analysis, it is shown that shielding in such systems results in path deflection and bifurcation despite the absence of mixed-mode loading. As the crack approaches a stiff layer, the tangential strains measured around a blunted crack tip model show a maximum corresponding to the direction of crack propagation. The distribution of such strains indicates the effect of shielding and the likelihood of the tip to deflect or bifurcate. The suitability of bi-layer and tri-layer bearing architectures is assessed through crack path and respective crack driving force predictions.
Experimentally observed crack deflection events in multi-layered material systems, occurring even under pure mode-I loading, are here simulated and explained through elasto-plastic finite element modelling. The crack tip opening displacement is adopted as the crack driving force and estimated along crack paths whose deflection is predicted using the maximum tangential strain criterion. Shielding conditions that promote deflection and bifurcation are evaluated. It is shown that, under conditions of extended plasticity, CTOD evolution as a crack approaches an interface can reveal crack shielding and amplification, and that crack deflection and growth can be assessed from the variation of tangential strains around the crack tip.
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