CONTACT STRESS

FATIGUE
Presented by

Purvesh K. Nanavaty
ME (Mat.Tech.)
Sem II

Guided by
Dr.Vandana Rao
 Contents
 Introduction
 Fundamentals of CSF
 Subsurface –origin fatigue
 Surface –origin fatigue
 Subcase-origin fatigue (“Spalling” fatigue)
 Cavitation fatigue
 Conclusion
 References



 introduction
 Fatigue :- phenomenon that results from
cyclic slip under repetitive load
applications for many thousands &
millions of cycles.
 Certain type of metal removal –or wear-
that are not caused directly by sliding
action
 Fatigue that produces cavities, or pits , in
either of two surfaces in contact
primarily by rolling and/or sliding
action, or –---- in case of cavitation
fatigue---in a metal surface in contact
with liquid.
  The difference…
 Instead of causing gross fractures of
parts, only fragments of the surface are
removed at least initially. Then lost
gradually results in pits & cavities in the
surfaces.



Behaviour of pits / cavities
 Frequently acts as a stress concentrations
 If metal removed from the cavities is very
hard & brittle –readily crushed-
fragmented cause abrasive wear
 Some start as microscopic in size &
remain as throughout the life of the
part
 Some start as microscopic but gradually
becomes large.
 Start as large & then rapidly become
even larger.

Contact stress fatigue / pitting
fatigue are observed with.
 Various Mechanisms involved with rolling
and/ or sliding type. as Pure rolling is
never possible, in fact there is some
degree of sliding due to elastic
deflection –of the part under load
 Bearings, gears, cams, pumps, impeller,
propellers ….
 One or both mating surfaces under
compressive load on point or line
contact.
 Instantaneous contact area bearing high
amount of compressive & shear
Subsurface-origin Fatigue
 Most common in antifriction, or rolling
element bearings –ball & roller
bearings, needle bearings, roller cams
 Various types of inclusions inherent in the
steels randomly distributed.
 Hard, angular, brittle often “stress
raisers”
 Max shear stress is located at short
distance below the surface
 Result in a high stress conc. Crack
initiation, propagation, surrounding
metal removal
 Re occurrence at various points of
surface.
Stress distribution in contacting surfaces due to rolling,
sliding, and combined effect
 Gear tooth section
Ge a r-t o o t h s e c t io n . Ro llin g -
c o n t a c t f a t ig u e . Cra c k o rig in
s u b s u rf a c e . P ro g re s s io n w a s
p a ra lle l t o
s u rfa c e a n d in w a rd a w a y f ro m
s u rfa c e . N o t e t c h e d . 6 0 ×
Ge a r-t o o t h s e c t io n . Ro llin g -
c o n t a c t f a t ig u e . Cra c k o rig in
s u b s u rf a c e . P ro g re s s io n w a s
p a ra lle l
w it h s u rf a c e , in w a rd , a n d
f in a lly t o t h e s u rfa c e t o fo rm a
la rg e p it o r s p a ll. N o t e t c h e d .
60×
Fracture surface of a hardened steel connecting rod.
Arrows indicate large
inclusions from which fatigue cracking initiated
Fracture surface of a hardened steel valve spring that
failed in torsional fatigue.
Arrow indicates fracture origin at a subsurface
nonmetallic inclusion.
Fracture surface of a carburized-and-hardened steel roller. As a
result of banded
alloy segregation, circumferential fatigue fracture initiated at
a subsurface origin near the
case/core interface (arrow).
 Surface -origin fatigue
 Pure rolling / meshing (In case of gears)
is never possible because of difference
in the driver/driven relative surface
velocities.
 Sliding at the interface.
 Difference in the sliding causing “drag”
usually of slow surface speed driven
member clockwise or counter
clockwise.
 Negative sliding- rolling & sliding are in
opposite directions
 Positive sliding- rolling & sliding are in
same directions
Rolling /sliding action in gear
teeth.
 Dedendum (the region below the pitch
line) of all gear teeth are in negative
sliding. -origin of surface –potential
source of surface origin pitting.

Gear with arrow-shaped
surface-origin pit
 Macropitting

 Macro pitting is a general term that

includes spalling and other forms of
macro scale damage caused by contact
fatigue. Macro pitting of bearing
raceways or gear teeth is generally due
to contact fatigue, which occurs from
localized plastic deformation, crack
initiation, and finally macro pitting from
crack propagation in and near the
contact surface
Fractograph showing the advanced stages of
point-surface-origin macropitting
fatigue of a bearing raceway in which the
origin is still visible
 Micropitting

 Micropitting is the preferred term for

peeling fatigue, which is defined as
microscale spalling fatigue. It is
damage of….
 rolling/sliding contact metal surfaces by
the formation of a Micropitting damage
is a gradual type of surface fatigue
damage that is a complex function of
surface topography and its interaction
with the lubricant.
Gear with micropitting
(frosting) failure
 Subcase –origin Fatigue
 Damage to case-hardened rolling /sliding
surfaces - gear teeth and roller
mechanism
 Very large pieces are suddenly lost from
the surface & extensive damage may
result.

Sub case –origin fatigue

 Sub case fatigue

cracking. The
micrographs show
etched cross
sections of
 (a) a carburized
cylindrical test
specimen (1.9×)
and (b) a carburized
gear tooth
 Sub case fatigue, also
known as case
crushing
 (c ) how the stress and
strength gradients
combine to cause
the weakest
Pinion with several very large cavities where metal from
the surface down to the
depth of the case has fallen out due to sub case fatigue
Cavitation pitting Fatigue
 Serious problem in Marine propellers,
diesel engine cylinder liners, pump
impellers, hydraulic pumps &
equipments, turbines.
 Those parts that vibrate & come in
contact with liquids.
 Liquid metal interface.
 Pit size range from pin head to golf ball
size



 Applied shear stress and material shear strength as a
function of depthrepresenting types of fatigue damage

 (a) No damage.
 (b) Subsurface-
origin, macro
pitting fatigue.
 (c) Micropitting
or surface-
origin
macropitting
fatigue. (d)
Subcase
fatigue.
SUMMARY
REFERANCES
ASM HAND BOOK VOL. 11.


FAILURE ANALYSIS & PREVENTION

 UNDERSTANDING HOW COMPONENTS

FAIL- DONALD J.WULPI
THANK YOU