Production-Related Surface and Subsurface Properties and Fatigue Life of Hybrid Roller Bearing Components

Breidenstein, Bernd; Denkena, Berend; Krödel, Alexander; Prasanthan, Vannila; Poll, Gerhard; Pape, Florian; Coors, Timm

doi:10.3390/met10101339

Cited by 5 publications

(6 citation statements)

References 31 publications

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“…Precision hard turning offers better fatigue life due to the low surface roughness, as well as the residual stress state, which is compressive and maximum at the subsurface depth. The residual stress distributions are of considerable importance; several investigations have reported that compressive residual stresses induced by the manufacturing process can extend the fatigue life of bearings up to 2.5 times [ 20 , 23 , 37 ]. Low surface roughness and subsurface residual stresses are the key parameters for extending bearing fatigue life.…”

Section: Resultsmentioning

confidence: 99%

Investigation of Surface Integrity Induced by Various Finishing Processes of AISI 52100 Bearing Rings

2022

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Surface integrity induced by finishing processes significantly affects the functional performance of machined components. In this work, three kinds of finishing processes, i.e., precision hard turning, conventional grinding, and sequential grinding and honing, were used for the finish machining of AISI 52100 bearing steel rings. The surface integrity induced by these finishing processes was studied via SEM investigations and residual stress measurements. To investigate rolling contact fatigue performance, contact fatigue tests were performed on a twin-disc testing machine. As the main results, the SEM observations show that precision hard turning and grinding introduce microstructural alterations. Indeed, in precision hard turning, a fine white layer (<1 μm) is observed on the top surface, followed by a thermally affected zone in the subsurface, and in grinding only, a white layer with 5 μm thickness is observed. However, no microstructural changes are found after sequential grinding and honing processes. White layers induced by precision hard turning and grinding possess compressive residual stresses. Grinding and sequential grinding and honing processes generate similar residual stress distributions, which are maximum and compressive at the machined surface and tensile at the subsurface depth of 15 μm. Precision hard turning generates a “hook”-shaped residual stress profile with maximum compressive value at the subsurface depth and thus contributes as a prenominal factor to the obtainment of the longest fatigue life with respect to other finishing processes. Due to the high quality of surface roughness (Ra = 0.05 μm), honing post grinding improves the fatigue life of bearing rings by 2.6 times in comparison with grinding. Subsurface compressive residual stresses, as well as low surface roughness, are key parameters for extending bearing fatigue life.

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Section: Resultsmentioning

confidence: 99%

Investigation of Surface Integrity Induced by Various Finishing Processes of AISI 52100 Bearing Rings

2022

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“…Hard turning cycles have been widely used for many decades in the real industry for the production of critical components after quenching [ 1 ]. Hard turning can be employed for surface finishing [ 2 ] or in combination with grinding [ 3 ]. The surface state after hard turning is different as compared with hard turning [ 4 ].…”

Section: Introductionmentioning

confidence: 99%

Study of Residual Stresses and Austenite Gradients in the Surface after Hard Turning as a Function of Flank Wear and Cutting Speed

et al. 2023

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This paper investigates the influence of cutting speed and flank wear on the depth profile of residual stresses, as well as the fraction of retained austenite after hard turning of quenched bearing steel 100Cr6. Residual stress and retained austenite profiles were studied for the white layer, heat-affected zone thickness, and XRD sensing depth. It was found that the influence of flank wear on the white layer and heat-affected zone thickness predominates. On the other hand, residual stresses are affected the cutting speed and the superimposing contribution of flank wear. Moreover, these aspects also alter microhardness in the affected regions. The study also demonstrates that information concerning residual stresses and the austenite fraction is integrated into the white layer, and the heat-affected zone in the surface is produced by the insert of low flank wear since the XRD sensing depth is more than the thickness of the white layer. On the other hand, the pure contribution of the white layer or the heat-affected zone to residual stress and the austenite fraction can be investigated when the affected surface region is thick enough.

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“…Increasing demands on components’ functionality has led to novel concepts for their manufacturing, together with the application of progressive materials [ 1 , 2 , 3 ]. The high tempered steels undergo the conventional quenching process when a component is rapidly cooled down from a high temperature, followed by tempering in the furnace at an elevated temperature.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Surface State after Turning of High Tempered Bearing Steel

et al. 2022

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This paper investigates surface state after turning of the high tempered bearing steel 100Cr6 with a hardness of 40 HRC. White layer (WL) thickness and its microhardness, as well as surface roughness, are investigated as a function of tool flank wear VB as well as cutting speed vc. The mechanical and thermal load of the machined surface were analysed in order to provide a deeper insight into their superimposing contribution. Cutting energy expressed in terms of cutting force was analyses as that consumed for chip formation Fγ and consumed in the flank wear land Fα. It was found that the mechanical energy expressed in terms of the shear components of the Fα grows with VB, converts to the heat and strongly affects the thickness of the re-hardened layer. Furthermore, the superimposing contribution of the heat generation and its duration in the VB region should also be taken into account. It was also found that the influence of VB predominates over the variable cutting speed.

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Production-Related Surface and Subsurface Properties and Fatigue Life of Hybrid Roller Bearing Components

Cited by 5 publications

References 31 publications

Investigation of Surface Integrity Induced by Various Finishing Processes of AISI 52100 Bearing Rings

Investigation of Surface Integrity Induced by Various Finishing Processes of AISI 52100 Bearing Rings

Study of Residual Stresses and Austenite Gradients in the Surface after Hard Turning as a Function of Flank Wear and Cutting Speed

Analysis of Surface State after Turning of High Tempered Bearing Steel

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