Numerical modeling of sub-surface initiated spalling in rolling contacts

A 3D finite element model was developed to investigate the influence of microstructure topology on the stochastic nature of rolling contact fatigue. Grains of the material microstructure are modeled with random Voronoi tessellations. Continuum damage mechanics and mesh partitioning are implemented to capture the initiation and propagation phases of fatigue damage that lead to spalling. Simulated fatigue spalling is shown to progress similarly to experimental observations of rolling contact fatigue. The fatigue lives obtained with the model exhibit scatter on par with empirical measures and are fit well by 2 and 3-parameter Weibull distributions.

► Rolling contact fatigue is studied using a 3D finite element model of steel microstructure.
► Damage mechanics theory is applied to model the gradual material degradation.
► A novel integration algorithm is proposed to expedite the simulations.
► The subsurface initiated failure propagates similarly to experimental observations.
► Fatigue life scatter is effected by the 3D internal topology and is within empirical bounds.