PSI - Issue 66

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2025) 000 – 000 ScienceDirect Structural Integrity Procedia 00 (2025) 000 – 000

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Procedia Structural Integrity 66 (2024) 55–70 8th International Conference on Crack Paths Crack path prediction on integrated raceways under RCF Ramdane Boukellif a *, Sven Hilleke a , Jörg Litzba a , Waldemar Riesen a a Airbus Helicopters Technik GmbH, Flugplatzstrasse, Calden 34379, Germany 8th International Conference on Crack Paths Crack path prediction on integrated raceways under RCF Ramdane Boukellif a *, Sven Hilleke a , Jörg Litzba a , Waldemar Riesen a a Airbus Helicopters Technik GmbH, Flugplatzstrasse, Calden 34379, Germany

Abstract The prediction of crack paths on integrated raceways under rolling contact fatigue (RCF) in case-hardened components is in the focus of this research. In addition to the rolling contact, the residual stresses and the complex load situation were taken into account. Using a basic parametric study, the following possible influencing parameters on the crack growth and on the crack path were investigated: initial crack length/ depth, contact pressure and coefficient of friction between the crack surfaces. The crack growth simulations were carried out using the FE program ABAQUS and the crack propagation simulation program ADAPCRACK3D. Using the sub-model technique, the fracture mechanical investigations are based on the theory of linear elastic fracture mechanics. Using the MVCCI method, the stress intensity factors (SIFs) and are calculated. Crack paths in the hollow shaft and in the outer ring of the bearing were predicted and compared with the cracks that occurred at the same locations in the test. The results of the crack growth simulations showed good agreement with some test results. The prediction of the crack path after spalling in the outer ring matched very well with the crack path in the tests. Abstract The prediction of crack paths on integrated raceways under rolling contact fatigue (RCF) in case-hardened components is in the focus of this research. In addition to the rolling contact, the residual stresses and the complex load situation were taken into account. Using a basic parametric study, the following possible influencing parameters on the crack growth and on the crack path were investigated: initial crack length/ depth, contact pressure and coefficient of friction between the crack surfaces. The crack growth simulations were carried out using the FE program ABAQUS and the crack propagation simulation program ADAPCRACK3D. Using the sub-model technique, the fracture mechanical investigations are based on the theory of linear elastic fracture mechanics. Using the MVCCI method, the stress intensity factors (SIFs) and are calculated. Crack paths in the hollow shaft and in the outer ring of the bearing were predicted and compared with the cracks that occurred at the same locations in the test. The results of the crack growth simulations showed good agreement with some test results. The prediction of the crack path after spalling in the outer ring matched very well with the crack path in the tests. © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers Keywords: Crack path; RCF; integrated raceway; residual stress; body stress

Keywords: Crack path; RCF; integrated raceway; residual stress; body stress

* Corresponding author. Tel.: +49 5674 701 860. E-mail address: ramdane.boukellif@airbus.com

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers 2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers * Corresponding author. Tel.: +49 5674 701 860. E-mail address: ramdane.boukellif@airbus.com

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of CP 2024 Organizers 10.1016/j.prostr.2024.11.055