Details
| Originalsprache | Englisch |
|---|---|
| Aufsatznummer | 119027 |
| Fachzeitschrift | Journal of Materials Processing Technology |
| Jahrgang | 344 |
| Frühes Online-Datum | 12 Aug. 2025 |
| Publikationsstatus | Veröffentlicht - Okt. 2025 |
Abstract
The durability of highly loaded rolling-sliding contacts, such as those in rolling bearings, is critically determined by subsurface microstructure and residual stresses engineered during manufacturing. This study systematically investigates the interplay between thermal and mechanical process parameters during deep rolling, using bearing inner rings as a representative example, to identify optimal conditions for maximizing fatigue life. By isolating the effects of process temperature (20–400 °C) and deep rolling pressure (200–400 bar), we demonstrate that moderate mechanical loading at room temperature can more than double bearing life through beneficial compressive residual stresses, while excessive pressure or thermal input above 200 °C sharply reduces durability. Notably, we reveal a previously unrecognized mechanism of hidden thermal degradation that limits lifetime, even when conventional hardness or microstructural metrics remain unchanged. These results define a process window for residual stress engineering in bearing steels and provide generic guidelines for hybrid manufacturing of rolling-sliding components subjected to severe tribological loading. The findings advance fundamental understanding of process-induced fatigue mechanisms and offer a framework for the rational design of subsurface-optimized, durable, and sustainable machine elements.
ASJC Scopus Sachgebiete
- Werkstoffwissenschaften (insg.)
- Keramische und Verbundwerkstoffe
- Informatik (insg.)
- Angewandte Informatik
- Ingenieurwesen (insg.)
- Wirtschaftsingenieurwesen und Fertigungstechnik
- Werkstoffwissenschaften (insg.)
- Metalle und Legierungen
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in: Journal of Materials Processing Technology, Jahrgang 344, 119027, 10.2025.
Publikation: Beitrag in Fachzeitschrift › Artikel › Forschung › Peer-Review
}
TY - JOUR
T1 - Residual stress engineering for highly loaded rolling-sliding contacts
T2 - Finding the sweet spot for maximum durability by hard turning and deep rolling
AU - Dechant, Simon
AU - Nordmeyer, Henke
AU - Pape, Florian
AU - Breidenstein, Bernd
AU - Poll, Gerhard
AU - Marian, Max
N1 - Publisher Copyright: © 2025 The Authors
PY - 2025/10
Y1 - 2025/10
N2 - The durability of highly loaded rolling-sliding contacts, such as those in rolling bearings, is critically determined by subsurface microstructure and residual stresses engineered during manufacturing. This study systematically investigates the interplay between thermal and mechanical process parameters during deep rolling, using bearing inner rings as a representative example, to identify optimal conditions for maximizing fatigue life. By isolating the effects of process temperature (20–400 °C) and deep rolling pressure (200–400 bar), we demonstrate that moderate mechanical loading at room temperature can more than double bearing life through beneficial compressive residual stresses, while excessive pressure or thermal input above 200 °C sharply reduces durability. Notably, we reveal a previously unrecognized mechanism of hidden thermal degradation that limits lifetime, even when conventional hardness or microstructural metrics remain unchanged. These results define a process window for residual stress engineering in bearing steels and provide generic guidelines for hybrid manufacturing of rolling-sliding components subjected to severe tribological loading. The findings advance fundamental understanding of process-induced fatigue mechanisms and offer a framework for the rational design of subsurface-optimized, durable, and sustainable machine elements.
AB - The durability of highly loaded rolling-sliding contacts, such as those in rolling bearings, is critically determined by subsurface microstructure and residual stresses engineered during manufacturing. This study systematically investigates the interplay between thermal and mechanical process parameters during deep rolling, using bearing inner rings as a representative example, to identify optimal conditions for maximizing fatigue life. By isolating the effects of process temperature (20–400 °C) and deep rolling pressure (200–400 bar), we demonstrate that moderate mechanical loading at room temperature can more than double bearing life through beneficial compressive residual stresses, while excessive pressure or thermal input above 200 °C sharply reduces durability. Notably, we reveal a previously unrecognized mechanism of hidden thermal degradation that limits lifetime, even when conventional hardness or microstructural metrics remain unchanged. These results define a process window for residual stress engineering in bearing steels and provide generic guidelines for hybrid manufacturing of rolling-sliding components subjected to severe tribological loading. The findings advance fundamental understanding of process-induced fatigue mechanisms and offer a framework for the rational design of subsurface-optimized, durable, and sustainable machine elements.
KW - Deep rolling
KW - Fatigue life
KW - Hard turning
KW - Machine elements
KW - Rolling contact fatigue
KW - Subsurface
UR - http://www.scopus.com/inward/record.url?scp=105013569037&partnerID=8YFLogxK
U2 - 10.1016/j.jmatprotec.2025.119027
DO - 10.1016/j.jmatprotec.2025.119027
M3 - Article
AN - SCOPUS:105013569037
VL - 344
JO - Journal of Materials Processing Technology
JF - Journal of Materials Processing Technology
SN - 0924-0136
M1 - 119027
ER -