Experimental and numerical rolling contact fatigue study on the 32CrMoV13 steel

The aim of this work is to study pure rolling contact fatigue in 32CrMoV13 quenching and tempering steel. The study involves both experimental and numerical work. The influence of the roughness and the residual stresses on the mechanisms and zones of cracking were studied. The results show a rapid reduction in roughness during the first minute of test but even so there will be specimen deterioration. The residual stress profile after rolling contact tests have high compression values in the surface and at a depth of approximately 240 μm, which is related with the Hertzian maximal shear stress. The numerical simulation of the Hertzian loading was used both to determine the elastic shakedown of the material and to apply a high-cycle multiaxial fatigue criterion. The three-dimensional finite element analysis used in the numerical calculation includes elastic-linear kinematic hardening plastic material and allows the introduction of an initial residual stress state. Taking into account the elastoplastic load induced by the Hertz pressure, low-cycle fatigue tests were used to characterize the mechanical properties of the material. In order to validate the numerical simulation, the results of the calculation after elastic shakedown were compared with the values measured by X-ray diffraction after rolling contact tests. The results showed a reasonable agreement between calculated and measured stresses. The Dang Van high-cycle multiaxial fatigue criterion showed a good relationship with the experimental findings.