Analysis of non-uniform abrasion evolution for cylindrical roller bearings

In this paper, the effects of non-uniform loading on the performances and abrasion evolution of cylindrical roller bearings are explored and analyzed both theoretically and experimentally. The elasto-hydrodynamic lubrication phase of roller bearings is modeled and the lubricant film thickness is calculated. A comprehensive calculation method is subsequently proposed to analyze non-uniform contact loading distribution due to the combined radial and moment loads. Furthermore, increased metallic contact due to the breakdown of the lubricant film during the abrasive wear phase is investigated, and the contact deformation and stress distributions are analyzed accordingly. A test rig is designed and built to experimentally investigate these influences under different loading conditions. The experimental results demonstrate that the wear and deformations of the bearing raceway surfaces can be significantly promoted by the non-uniform loading due to the sliding motions between asperities of the bearing contact surfaces. Polishing wear of the bearing surfaces, such as surface induced cracks and material delamination, is expected when the bearing is further exposed to long-term non-uniform loading. Numerical simulation results are also obtained and analyzed to investigate the effects of material flexibility on the bearing responses, which show that the material flexibility can reduce bearing responses.