Physics-Based Modeling of Rolling/Sliding Contact Fatigue Life

Physics based modeling is required for an accurate prediction of bearing life. The key challenge of developing an accurate prediction model is the development of a multi-scale physics model that accounts for the kinematics and dynamics of bearing operation, material microstructure from latest bearing manufacturing processes, surface finish and residual stress of the final components, and the thermomechanical stress. Sentient developed multiscale physics-based models over several years to predict the fatigue behavior of mechanical components such as bearings at the microstructural level. In Phase I, Sentient demonstrated the approach to predict rolling contact fatigue life at a coupon level.  Under Phase II, Sentient will demonstrate the modeling prediction on a component level at different bearing configurations, surface finishes, loading conditions, lubrication and more. Multiple set of tools at multiple temporal and spatial scales will be used to perform the simulations and to predict the bearing fatigue life. Model capabilities will be enhanced to account the effect of thermomechanical stresses.    In Phase II, Sentient will partner with Rolls-Royce (RR), The University of Akron (UA), and Napoleon Engineering Services (NES) to validate the DC model on rolling element bearings under operating conditions of limited lubrication. Multiple bearing case studies with different bearing configurations (ball and roller bearing), materials (M50, M50 NiL, 52100), surface finishes, and operating conditions will be tested and simulated under rolling contact fatigue life. Bearing Analysis Tool (BAT) will be used to conduct multibody dynamic simulation of rolling element bearings to generate time histories of the component motions and contact details of deep groove ball bearing and cylindrical roller bearing. There are four main technical objectives to be achieved in Phase II.