Rolling Contact Fatigue (RCF) is a phenomenon that occurs in mechanical components relating to rolling/sliding contact, such as railways, gears, and bearings. [2] It is the result of the process of fatigue due to rolling/sliding contact. [2] [3] The RCF process begins with cyclic loading of the material, which results in fatigue damage that can be observed in crack-like flaws, like white etching cracks. [2] These flaws can grow into larger cracks under further loading, potentially leading to fractures. [2] [4]
In railways, for example, when the train wheel rolls on the rail, creating a small contact patch that leads to very high contact pressure between the rail and wheel. [2] Over time, the repeated passing of wheels with high contact pressures can cause the formation of crack-like flaws that becomes small cracks. [2] These cracks can grow and sometimes join, leading to either surface spalling or rail break, which can cause serious accidents, including derailments. [2] [4]
RCF is a major concern for railways worldwide and can take various forms depending on the location of the crack and its appearance. [2] It is also a significant cause of failure in components subjected to rolling or rolling/sliding contacts, such as rolling-contact bearings, gears, and cam/tappet arrangements. [5] The alternating stress field in RCF can lead to material removal, varying from micro- and macro-pitting in conventional bearing steels to delamination in hybrid ceramics and overlay coatings. [5]
In the case of bodies capable of rolling, there is a particular type of friction, in which the sliding phenomenon, typical of dynamic friction, does not occur, but there is also a force that opposes the motion, which also excludes the case of static friction. This type of friction is called rolling friction. Now we want to observe in detail what happens to a wheel that rolls on a horizontal plane. Initially the wheel is immobile and the forces acting on it are the weight force and the normal force given by the response to the weight of the floor.
At this point the wheel is set in motion, causing a displacement at the point of application of the normal force which is now applied in front of the center of the wheel, at a distance b, which is equal to the value of the rolling friction coefficient. The opposition to the motion is caused by the separation of the normal force and the weight force at the exact moment in which the rolling starts, so the value of the torque given by the rolling friction force isWhat happens in detail at the microscopic level between the wheel and the supporting surface is described in Figure, where it is possible to observe what is the behavior of the reaction forces of the deformed plane acting on an immobile wheel.
Rolling the wheel continuously causes imperceptible deformations of the plane and, once passed to a subsequent point, the plane returns to its initial state. In the compression phase the plane opposes the motion of the wheel, while in the decompression phase it provides a positive contribution to the motion.
The force of rolling friction depends, therefore, on the small deformations suffered by the supporting surface and by the wheel itself, and can be expressed as , where it is possible to express b in relation to the sliding friction coefficient as , with r being the wheel radius.Testing for RCF involves several methods, each designed to simulate the conditions that cause RCF in a controlled environment. Here are some of the methods used:
Triple disc rolling contact fatigue (RCF) Rig is a specialised testing apparatus used in the field of tribology and materials science to evaluate the fatigue resistance and durability of materials subjected to rolling contact. [8] This rig is designed for simulating the conditions encountered in various mechanical systems, such as rolling bearings, gears, and other components exposed to repeated rolling and sliding motions. The rig typically consists of three discs or rollers arranged in a specific configuration. [9] These discs can represent the interacting components of interest, such as a rolling bearing. The rig also allows precise control over the loading conditions, including the magnitude of the load, contact pressure, and contact geometry. [10] [11]
PCS Instruments Micro-pitting Rig (MPR) is a specialised testing instrument used in the field of tribology and mechanical engineering to study micro-pitting, a type of surface damage that occurs in lubricated rolling and sliding contact systems. The MPR is designed to simulate real-world operating conditions by subjecting test specimens, often gears or rolling bearings, to controlled rolling and sliding contact under lubricated conditions. [12]Friction is the force resisting the relative motion of solid surfaces, fluid layers, and material elements sliding against each other. Types of friction include dry, fluid, lubricated, skin, and internal -- an incomplete list. The study of the processes involved is called tribology, and has a history of more than 2000 years.
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races.
Fluid bearings are bearings in which the load is supported by a thin layer of rapidly moving pressurized liquid or gas between the bearing surfaces. Since there is no contact between the moving parts, there is no sliding friction, allowing fluid bearings to have lower friction, wear and vibration than many other types of bearings. Thus, it is possible for some fluid bearings to have near-zero wear if operated correctly.
A bearing is a machine element that constrains relative motion to only the desired motion and reduces friction between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are classified broadly according to the type of operation, the motions allowed, or the directions of the loads (forces) applied to the parts.
Lubrication is the process or technique of using a lubricant to reduce friction and wear and tear in a contact between two surfaces. The study of lubrication is a discipline in the field of tribology.
Wear is the damaging, gradual removal or deformation of material at solid surfaces. Causes of wear can be mechanical or chemical. The study of wear and related processes is referred to as tribology.
Tribology is the science and engineering of understanding friction, lubrication and wear phenomena for interacting surfaces in relative motion. It is highly interdisciplinary, drawing on many academic fields, including physics, chemistry, materials science, mathematics, biology and engineering. The fundamental objects of study in tribology are tribosystems, which are physical systems of contacting surfaces. Subfields of tribology include biotribology, nanotribology and space tribology. It is also related to other areas such as the coupling of corrosion and tribology in tribocorrosion and the contact mechanics of how surfaces in contact deform. Approximately 20% of the total energy expenditure of the world is due to the impact of friction and wear in the transportation, manufacturing, power generation, and residential sectors.
A plain bearing, or more commonly sliding contact bearing and slide bearing, is the simplest type of bearing, comprising just a bearing surface and no rolling elements. Therefore, the part of the shaft in contact with the bearing slides over the bearing surface. The simplest example of a plain bearing is a shaft rotating in a hole. A simple linear bearing can be a pair of flat surfaces designed to allow motion; e.g., a drawer and the slides it rests on or the ways on the bed of a lathe.
In mechanical engineering, a rolling-element bearing, also known as a rolling bearing, is a bearing which carries a load by placing rolling elements between two concentric, grooved rings called races. The relative motion of the races causes the rolling elements to roll with very little rolling resistance and with little sliding.
Rolling is a type of motion that combines rotation and translation of that object with respect to a surface, such that, if ideal conditions exist, the two are in contact with each other without sliding.
False brinelling is a bearing damage caused by fretting, with or without corrosion, that causes imprints that look similar to brinelling, but are caused by a different mechanism. False brinelling may occur in bearings which act under small oscillations or vibrations.
Rolling resistance, sometimes called rolling friction or rolling drag, is the force resisting the motion when a body rolls on a surface. It is mainly caused by non-elastic effects; that is, not all the energy needed for deformation of the wheel, roadbed, etc., is recovered when the pressure is removed. Two forms of this are hysteresis losses, and permanent (plastic) deformation of the object or the surface. Note that the slippage between the wheel and the surface also results in energy dissipation. Although some researchers have included this term in rolling resistance, some suggest that this dissipation term should be treated separately from rolling resistance because it is due to the applied torque to the wheel and the resultant slip between the wheel and ground, which is called slip loss or slip resistance. In addition, only the so-called slip resistance involves friction, therefore the name "rolling friction" is to an extent a misnomer.
Fretting refers to wear and sometimes corrosion damage of loaded surfaces in contact while they encounter small oscillatory movements tangential to the surface. Fretting is caused by adhesion of contact surface asperities, which are subsequently broken again by the small movement. This breaking causes wear debris to be formed.
A tribometer is an instrument that measures tribological quantities, such as coefficient of friction, friction force, and wear volume, between two surfaces in contact. It was invented by the 18th century Dutch scientist Musschenbroek
The stick–slip phenomenon, also known as the slip–stick phenomenon or simply stick–slip, is a type of motion exhibited by objects in contact sliding over one another. The motion of these objects is usually not perfectly smooth, but rather irregular, with brief accelerations (slips) interrupted by stops (sticks). Stick–slip motion is normally connected to friction, and may generate vibration (noise) or be associated with mechanical wear of the moving objects, and is thus often undesirable in mechanical devices. On the other hand, stick–slip motion can be useful in some situations, such as the movement of a bow across a string to create musical tones in a bowed string instrument.
Sliding is a type of motion between two surfaces in contact. This can be contrasted to rolling motion. Both types of motion may occur in bearings.
Dry lubricants or solid lubricants are materials that, despite being in the solid phase, are able to reduce friction between two surfaces sliding against each other without the need for a liquid oil medium.
Contact mechanics is the study of the deformation of solids that touch each other at one or more points. This can be divided into compressive and adhesive forces in the direction perpendicular to the interface, and frictional forces in the tangential direction. Frictional contact mechanics is the study of the deformation of bodies in the presence of frictional effects, whereas frictionless contact mechanics assumes the absence of such effects.
In fluid mechanics, the Reynolds equation is a partial differential equation governing the pressure distribution of thin viscous fluid films. It was first derived by Osborne Reynolds in 1886. The classical Reynolds Equation can be used to describe the pressure distribution in nearly any type of fluid film bearing; a bearing type in which the bounding bodies are fully separated by a thin layer of liquid or gas.
White etching cracks (WEC), or white structure flaking or brittle flaking, is a type of rolling contact fatigue (RCF) damage that can occur in bearing steels under certain conditions, such as hydrogen embrittlement, high stress, inadequate lubrication, and high temperature. WEC is characterised by the presence of white areas of microstructural alteration in the material, which can lead to the formation of small cracks that can grow and propagate over time, eventually leading to premature failure of the bearing. WEC has been observed in a variety of applications, including wind turbine gearboxes, automotive engines, and other heavy machinery. The exact mechanism of WEC formation is still a subject of research, but it is believed to be related to a combination of microstructural changes, such as phase transformations and grain boundary degradation, and cyclic loading.