Effects of altering surface integrity by electrolytic etching on fatigue performance in rolling contact

•A methodology for altering surface integrity by electrolytic etching is presented.•The effects of electrolytic etching on the fatigue parameters vary with the loading.•Electrolytic etching can enhance fatigue performance significantly.•The optimal layer removal depends on surface integrity and loading conditions.•The fatigue tests confirm the findings of this study.

A methodology is presented for altering the surface integrity of a machined surface using electrolytic etching. Fatigue parameters are computed to investigate the impact of surface layer removal by electrolytic etching. Generally, surface layer removal reduces crack initiation life. However, it reduces crack propagation life for specimens machined by new tools, while increasing it for specimens machined by worn tools. Consequently, surface layer removal reduces fatigue life when a new tool is used, and increases it when a worn tool is used. Rolling contact fatigue tests substantiate that the fatigue performance of machined surfaces can be significantly enhanced by removing an optimal thickness of the surface layer.