The role of a single surface asperity in rolling contact fatigue

The effect of contact loading of single surface irregularities, i.e. asperities, as an underlying mechanism for surface initiated rolling contact fatigue was investigated numerically using FEM. Spalls in the teeth flanks of driving gear wheels were investigated for typical spalling crack initiation properties. The spalling entry angle was documented and some spalls with a convex entry tip were found. The residual surface stresses of the used teeth, with spalls, were measured with the hole drilling technique. The gear contact close to the rolling circle was modelled as two rolling cylinders. A single asperity was introduced into the contact surface of one of them. Due to the presence of the asperity a three dimensional contact model was required. The material description included J2-plasticity with isotropic and linear hardening. The simulation included residual stresses from material heat treatment. The first roll cycle introduced plastic deformation which altered the residual stresses. Thus, the stress results were captured during a second roll cycle. The most important result was that asperities will serve as local stress raisers in the contact surfaces. The computed stress cycle at the asperity was compared to stress cycles that gave ring/cone cracks at point loaded experiments. The principal stress trajectory into the material was compared to the cross-section profiles of the spalling entry and ring/cone crack. The surface stress profile at the asperity was compared to the convex surface profiles of the spalling tip and ring/cone crack. The asperity deformation and change in residual surface stresses from moderate plastic deformation during rolling were estimated.