Functionalized subsurface zone for load-oriented fatigue behavior of hardened components
Final Report Abstract
The project investigates the influence of thermomechanical processes, specifically hard turnrolling, on the properties of the surface of hardened materials, particularly in rolling bearing inner rings, rotating bending specimens made of 100Cr6. Experimental investigations, and simulations revealed that workpiece temperatures during the deep rolling process have a significant influence on the residual stresses that develop in the material. To precisely control the temperature, induction heating was used, which allows for targeted heating of the material surface. The results show that a consistent surface temperature is crucial for process stability. Temperatures below 200 °C have no influence on the compressive residual stresses. Above this range, however, they decrease significantly, leading to reduced mechanical strength. The mechanical load during machining, especially during deep rolling, generates different stress states depending on the temperature. The residual stresses in the axial direction exhibit different effects, which are caused by mechanical restrictions during heating. Tests with different tool configurations and cutting speeds have shown that cutting speed and cooling lubricants in particular influence tool life and workpiece quality. The induced residual stresses remain stable, which indicates a permanent improvement in the material properties. If the deep rolling temperature exceeds 200 °C, the lifetime decreases. This is caused by temperature-related changes in the subsurface, which accelerate material fatigue.
Publications
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Einfluss des Eigenspannungszustandes auf das Ermüdungslebensdauerverhalten von Wälzlagern, Herbstsitzung FA Eigenspannungen (2023) 18. Oktober 2023, Hamburg, Deutschland
Dechant, S. & Nordmeyer, H.
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Einfluss hoher Lasten auf das Ermüdungslebensdauerverhalten von Wälzlagern. Gleit- und Wälzlagerungen 2023, 279-300. VDI Verlag.
Dechant, S.; Poll, G.; Rüth, L.; Foko Foko, F. & Koch, O.
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Energiedispersive Messung der Eigenspannungen nach dem Festwalzen – Analyse des Mikro- und Makrokontakts, Arbeitstreffen "Energiedispersive Röntgenbeugung" (2023), 03. Mai 2023, Kassel, Deutschland
Breidenstein, B., Gerdes, L. & Nordmeyer, H.
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Funktionalisierte Randzone für belastungsorientiertes Ermüdungsverhalten gehärteter Bauteile, Frühjahrssitzung FA Eigenspannungen (2023) 28. März 2023, Berlin, Deutschland
Breidenstein, B., Poll, G., Pape, F., Dechant, S. & Nordmeyer, H.
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Influence of high loads on the fatigue life behavior of rolling bearings, 77th STLE Annual Meeting & Exhibition (2023) 21-25 May 2023, Long Beach, California (USA)
Dechant, S. & Nordmeyer, H.
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Eigenspannungen beim Festwalzen von gehärtetem Stahl bei erhöhter Temperatur, Frühjahrssitzung FA Eigenspannungen (2024) 20. März 2024, Wolfsburg, Deutschland
Breidenstein, B. & Nordmeyer, H.
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Fatigue life analysis of deep rolled bearing inner rings. Procedia CIRP, 123, 13-17.
Breidenstein, Bernd; Poll, Gerhard; Pape, Florian; Bergmann, Benjamin; Dechant, Simon & Nordmeyer, Henke
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Influence of deep rolling process at various temperatures on the fatigue life of rolling bearings, Bearing World Journal Vol. 8 (2024), S. 77-83
Dechant, S., Nordmeyer, H., Pape, F., Breidenstein, B., Marian, O. & Poll, G.
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Influence of Turning and Deep Rolling Processes on Bearing Fatigue Life, 11th European Conference on Residual Stresses (ECRS), Prague, Czech Republic
Dechant, S., Nordmeyer, H., Pape, F., Breidenstein, B., Marian, O. & Poll, G.
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Numerical Simulation Approach of Deep Rolling of AISI 52100 at Elevated Temperature. Procedia CIRP, 121, 7-12.
Breidenstein, Bernd; Bergmann, Benjamin; Heikebrügge, Steffen & Nordmeyer, Henke
