PSI - Issue 57

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ScienceDirect Structural Integrity Procedia 00 (2022) 000 – 000 Structural Integrity Procedia 00 (2022) 000 – 000

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Structural Integrity 57 (2024) 191–198

© 2024 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 the scientific committee of the Fatigue Design 2023 organizers This methodology is based on the correlation between rolling contact fatigue tests performed on a twin-disc machine, which reproduced the contact between rolling elements and rings, and finite element calculations taking into account the geometry of the specimens and the gradient of mechanical characteristics. © 2023 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 the scientific committee of the Fatigue Design 2023 organizers Keywords: Rolling Contact Fatigue; Induction Hardening; Abstract Large dimension bearings and gears are generally made of surface hardened steels after induction heating or case hardening steels. Unlike case hardened steels, induction surface hardened steels show a drastic reduction of material properties (hardness, endurance limit…) between the treated layer and the core called “metallurgical slope of the transition zone”. The combination between the use of conventional hardened depth dimensioning methods (depth greater than 2 times the maximum shear stress depth) and a severe metallurgical slope allows the existence of an unconventional location of fatigue cracks initiation leading to early failure. There is no current method for sizing this phenomenon. In collaboration with users and manufacturers of slewing bearings, Cetim is thus developing a simplified sizing methodology which aims to set up easy to use design rules. This methodology is based on the correlation between rolling contact fatigue tests performed on a twin-disc machine, which reproduced the contact between rolling elements and rings, and finite element calculations taking into account the geometry of the specimens and the gradient of mechanical characteristics. © 2023 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 the scientific committee of the Fatigue Design 2023 organizers Keywords: Rolling Contact Fatigue; Induction Hardening; Fatigue Design 2023 (FatDes 2023) Rolling contact fatigue design of induction hardened steels: experimental methodology Guillaume THOQUENNE a , Luc AMAR a , Philippe AMUZUGA a , Albin PONCEAU b * a Cetim, 52 avenue Félix Louat b Rollix Defontaine Abstract Large dimension bearings and gears are generally made of surface hardened steels after induction heating or case hardening steels. Unlike case hardened steels, induction surface hardened steels show a drastic reduction of material properties (hardness, endurance limit…) between the treated layer and the core called “metallurgical slope of the transition zone”. The combination between the use of conventional hardened depth dimensioning methods (depth greater than 2 times the maximum shear stress depth) and a severe metallurgical slope allows the existence of an unconventional location of fatigue cracks initiation leading to early failure. There is no current method for sizing this phenomenon. In collaboration with users and manufacturers of slewing bearings, Cetim is thus developing a simplified sizing methodology which aims to set up easy to use design rules. Fatigue Design 2023 (FatDes 2023) Rolling contact fatigue design of induction hardened steels: experimental methodology Guillaume THOQUENNE a , Luc AMAR a , Philippe AMUZUGA a , Albin PONCEAU b * a Cetim, 52 avenue Félix Louat b Rollix Defontaine 1. Overview of the project The first part of the project is to reproduce the fatigue phenomenon on the Cetim rolling contact fatigue test bench, which means to considerer small sample in comparison of the industrial components. We therefore have to design the specimen’s geometry and the characteristics of the induction hardening heat treatment, taking into account two opposite-factors: Plasticity and fatigue. This article presents the numerical methodology used to design the specimens and the first test results which validate this design. 1. Overview of the project The first part of the project is to reproduce the fatigue phenomenon on the Cetim rolling contact fatigue test bench, which means to considerer small sample in comparison of the industrial components. We therefore have to design the specimen’s geometry and the characteristics of the induction hardening heat treatment, taking into account two opposite-factors: Plasticity and fatigue. This article presents the numerical methodology used to design the specimens and the first test results which validate this design.

* Corresponding author. Tel.: +33 681911345 E-mail address: Guillaume.thoquenne@cetim.fr * Corresponding author. Tel.: +33 681911345 E-mail address: Guillaume.thoquenne@cetim.fr

2452-3216 © 2024 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 the scientific committee of the Fatigue Design 2023 organizers 10.1016/j.prostr.2024.03.022 2452-3216 © 2023 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 the scientific committee of the Fatigue Design 2023 organizers 2452-3216 © 2023 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 the scientific committee of the Fatigue Design 2023 organizers