Theoretical investigations on the fatigue behavior of a tailored forming steel-aluminium bearing component

Coors, Timm; Hwang, Jae-Il; Pape, Florian; Poll, Gerhard

doi:10.1063/1.5112554

Cited by 5 publications

(7 citation statements)

References 8 publications

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“…However, the equivalent stress from a greater depth of h > 3 mm below the surface of the contact point is low enough to apply the lighter aluminium base material. Further investigations can be found in [16,17]. These theoretical findings will be verified by future fatigue bench tests.…”

Section: Fatigue Lifetime Model For a Hybrid Bearing Bushing Under Romentioning

confidence: 61%

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Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing

Behrens

Maier

Poll

et al. 2020

Prod. Eng. Res. Devel.

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This contribution deals with the numerical investigations to develop a novel process chain for hybrid solid components using Tailored Forming. For manufacturing a hybrid bearing bushing, co-extrusion is the first step to produce hybrid semi-finished workpieces followed by a die forging process, machining processes and hardening. Combining aluminium with steel, compounds with wear-resistant functional surfaces and reduced weight are realised. Numerical simulations are a decisive part of the process chain design, for example to determine suitable process parameters for the co-extrusion process and to predict the thickness of intermetallic phases in the joining zone using a macroscopic phenomenological model. A numerical design including a tool analysis of the die forging process was carried out taking the experimentally determined material properties and the temperature profile after inductive heating into account. Additionally, the damage and fatigue behaviour of the polycrystalline material of the joining zone are modelled at the microstructure level. Moreover, a new discretization scheme, namely the virtual element method, which is more efficient at grain level, is developed regarding a crystal plasticity framework. Numerical simulations are used to develop inductive heating strategies for the forming process and for the design of the inductive hardening of the functional surface at the end of the process chain. In order to investigate the performance of this hybrid machine element under application-oriented conditions, a contact simulation is linked with a statistical damage model to calculate the bearing fatigue. In this study, a general overview of the individual process steps is given and results of the respective models are presented.

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Section: Fatigue Lifetime Model For a Hybrid Bearing Bushing Under Romentioning

confidence: 61%

“…Parts of the authors have investigated steel-steel components produced by tailored forming. Aluminium-steel components have not been investigated so far, besides [16,17].…”

Section: State Of the Artmentioning

confidence: 99%

Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing

Behrens

Maier

Poll

et al. 2020

Prod. Eng. Res. Devel.

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“…Previous investigations [25,26] have shown that the performance of tailored forming machine elements, in particular their fatigue life, is dependent on the layer height of the cladding material. The cladding height h is defined as the radial distance between the rolling element/shaft contact point at one end, and the cladding layer/base material interface at the other, see Figure 1 (right).…”

Section: Bearing Fatigue Life Of Tailored Forming Machine Elementsmentioning

confidence: 99%

Numerical Simulation and Experimental Validation of the Cladding Material Distribution of Hybrid Semi-Finished Products Produced by Deposition Welding and Cross-Wedge Rolling

Kruse

Mildebrath

Budde

et al. 2020

Metals

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The service life of rolling contacts is dependent on many factors. The choice of materials in particular has a major influence on when, for example, a ball bearing may fail. Within an exemplary process chain for the production of hybrid high-performance components through tailored forming, hybrid solid components made of at least two different steel alloys are investigated. The aim is to create parts that have improved properties compared to monolithic parts of the same geometry. In order to achieve this, several materials are joined prior to a forming operation. In this work, hybrid shafts created by either plasma (PTA) or laser metal deposition (LMD-W) welding are formed via cross-wedge rolling (CWR) to investigate the resulting thickness of the material deposited in the area of the bearing seat. Additionally, finite element analysis (FEA) simulations of the CWR process are compared with experimental CWR results to validate the coating thickness estimation done via simulation. This allows for more accurate predictions of the cladding material geometry after CWR, and the desired welding seam geometry can be selected by calculating the cladding thickness via CWR simulation.

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“…Process chain for the manufacture of a hybrid angular ball bearing bushing via tailored forming based on[10].…”

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confidence: 99%

“…x FOR PEER REVIEW 6 of Different residual stress depth profiles measured by X-ray diffractometry (black circles) and extrapolated profiles (red lines): (a) after hard turning and subsequent deep rolling, (b) after hard turning based on[10].…”

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confidence: 99%

Simulation of a Steel-Aluminum Composite Material Subjected to Rolling Contact Fatigue

et al. 2019

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Rolling bearings are frequently used machine elements in mechanical assemblies to connect rotating parts. Resource efficiency and reliability enhancement are considered to be important factors of rolling bearing development. One of the ways to meet these requirements is the tailored forming (TF) technology, which enables the functionalization of several metal layer composites in a single component. The so-called hybrid machine elements can be produced by co-extrusion of aluminum and steel and subsequent die forging, heat treatment, and machining. The TF rolling bearings made by this process can provide optimized characteristics that use aluminum to reduce weight and steel for a highly loaded contact zone between a rolling element and a bearing raceway. To evaluate the applicability and the potential of this technology, theoretical investigations are presented in this paper. The stress distribution under fully flooded conditions, caused by an external load in the contact between a rolling element and the TF outer ring of an angular contact ball bearing, is analyzed statically with the finite element method. The fatigue life of the TF component can be calculated for different external axial loads and manufacturing parameters, such as steel-to-aluminum volume ratios and osculation. As a damage model, the Ioannides and Harris fatigue model and the Dang Van multiaxial fatigue criterion were used. The results show that the fatigue life has high sensitivity to the steel-to-aluminum volume ratio. For the hybrid component with a steel layer thickness of 3 mm, 90 percent of the fatigue life of pure 100Cr6 steel bearing bushings is reached. In this FE model, residual stresses due to machining processes can be regarded as an initial state, which can increase the fatigue life of this TF machine component.

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Theoretical investigations on the fatigue behavior of a tailored forming steel-aluminium bearing component

Cited by 5 publications

References 8 publications

Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing

Numerical investigations regarding a novel process chain for the production of a hybrid bearing bushing

Numerical Simulation and Experimental Validation of the Cladding Material Distribution of Hybrid Semi-Finished Products Produced by Deposition Welding and Cross-Wedge Rolling

Simulation of a Steel-Aluminum Composite Material Subjected to Rolling Contact Fatigue

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