Acoustic emission monitoring for rolling contact fatigue damage of machined components by hard turning vs. grinding

A. W. Warren, Y. B. Guo

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

The fundamental knowledge of fatigue damage mechanism is necessary for understanding manufacturing process effects. However, the artificial defects on the test samples in traditional fatigue tests will change the surface integrity and therefore may not reflect the nature of fatigue damage. This paper studies the fatigue damage resulting from real-life rolling contact tests and finite element analysis of AISI 52100 steel and identifies the possible mechanisms for fatigue failure in the presence of process induced surface integrity. Rolling contact fatigue damage was real-time monitored using an acoustic emission (AE) sensor. Surface and subsurface fatigue damage of the samples was then characterized using optical and scanning electron microscopy (SEM) and surface profiling. The results suggest that shear stress induced Mode II crack is the dominant fatigue mechanism. Two types of subsurface cracks were observed: main cracks that propagate parallel to the surface due to subsurface shear stress induced fracture/debonding of inclusions or second phase particles. Shear stress induced surface cracks propagate at shallow angles (∼35°) from the surface. Branching cracks eventually form and connect the main crack to surface, The formation of main cracks and surface cracks may be parallel processes, and spalling occurs as a combined effect of the main, surface, and branching cracks. The relationship between AE signals and fatigue damage was been established.

Original languageEnglish (US)
Title of host publicationProceedings of the ASME International Mechanical Engineering Congress and Exposition, IMECE 2007
Pages727-736
Number of pages10
DOIs
StatePublished - May 30 2008
Externally publishedYes
EventASME International Mechanical Engineering Congress and Exposition, IMECE 2007 - Seattle, WA, United States
Duration: Nov 11 2007Nov 15 2007

Publication series

NameASME International Mechanical Engineering Congress and Exposition, Proceedings
Volume10 PART A

Other

OtherASME International Mechanical Engineering Congress and Exposition, IMECE 2007
CountryUnited States
CitySeattle, WA
Period11/11/0711/15/07

All Science Journal Classification (ASJC) codes

  • Engineering(all)
  • Mechanical Engineering

Keywords

  • Fatigue damage
  • Machining
  • Monitoring
  • Rolling contact fatigue
  • Surface integrity

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  • Cite this

    Warren, A. W., & Guo, Y. B. (2008). Acoustic emission monitoring for rolling contact fatigue damage of machined components by hard turning vs. grinding. In Proceedings of the ASME International Mechanical Engineering Congress and Exposition, IMECE 2007 (pp. 727-736). (ASME International Mechanical Engineering Congress and Exposition, Proceedings; Vol. 10 PART A). https://doi.org/10.1115/IMECE2007-43846