Acta Polytechnica https://doi.org/10.14311/AP.2021.61.0163 Acta Polytechnica 61(1):163–173, 2021 © 2021 The Author(s). Licensed under a CC-BY 4.0 licence Published by the Czech Technical University in Prague EFFECTS OF DESIGN PARAMETERS ON STATIC EQUIVALENT STRESS OF RADIAL ROLLING BEARINGS Mehmet Bozca Yildiz Technical University, Mechanical Engineering Faculty, Machine Design Division, 34349 Yildiz, Istanbul, Turkey correspondence: mbozca@yildiz.edu.tr Abstract. The aim of this study is to theoretically investigate the effects of design parameters on the static equivalent stress of radial rolling bearings, such as the point contact case for ball bearings and line contact case for roller bearings. The contact pressure, contact area and von Misses stress of bearings are calculated based on geometrical parameters, material parameters and loading parameters by using the developed MATLAB program. To achieve this aim, both the maximum contact pressure pmax and Von Mises effective stress σV M are simulated with respect to design parameters such as varying ball and roller element diameters and varying ball and roller element elasticity modulus. For the point contact case and line contact case, it was concluded that increasing the diameter of ball and roller elements results in reducing the maximum contact pressure pmax and Von Mises effective stress σV M . Furthermore, increasing the elasticity modulus of the ball and roller elements results in increasing the maximum contact pressure pmax and Von Mises effective stress σV M because of the decrease of contact area A. The determination of the diameter of the ball and roller elements and the selection of material are crucial and play an effective role during the design process. Therefore, bearing designers and manufacturers should make the bearing geometrical dimensions as large as possible and bearing material as elastic as possible. Furthermore, the stress-based static failure theory can also be used instead of the standard static load carrying capacity calculation. Moreover, Von Mises stress theory is also compatible with the finite element method. Keywords: Ball bearing, point contact, roller bearing, line contact, contact pressure, Von Mises stress. 1. Introduction Rolling bearings such as ball and roller bearings are widely used for rotating machines in industry. A sur- face failure can occur during point contact in ball bearing applications. Point contact results in a con- tact pressure and contact stress between two spherical surfaces. Similarly, the surface failure can occur dur- ing line contact in roller bearing applications. Line contact results in a contact pressure and contact stress between two cylindrical surfaces. The purpose of this study is a theoretical investi- gation of the effects of design parameters on static equivalent stress of radial rolling bearings, such as ball bearings and roller bearing. For this purpose, the maximum contact pressure pmax and Von Mises effective stress are calculated with respect to varying design parameters. The following studies focused on load carrying ca- pacity and fatigue life of rolling bearing, based on Hertzian contact stress. Rolling contact fatigue results in metallic particles flaking from the surface of the ball and rolling ele- ments or raceways. Neglecting lubrication effects, the stress in a bearing contact is governed by the Hertzian theory [1]. The calculation of load carrying capacity of stan- dard bearings is widely known and standardized by standard organizations, such as ISO and DIN, and it is based on the Hertzian theory of contact [2]. The life of a rolling bearing has been modelled using basic principles of rolling contact fatigue based on an equivalent stress originating beneath the contacting surface [3]. Developed high-speed angular contact ball bearing products feature improved internal design, including rolling elements of increased diameter. Thus, the load rating has been improved, and the allowable load has been increased [4]. Point contact for ball bearings application was in- vestigated theoretically, and the effects of the ball bearing’s geometry and material on the ball bearing stress were presented. Increasing the ball element’s diameter results in a reduced ball bearing stress. In contrast, the increasing elasticity modulus results in an increased ball bearing stress [6]. Line contact for roller bearings application was in- vestigated theoretically, and the effects of the roller bearing’s geometry and material on the roller bear- ing stress were presented. Increasing the roller el- ement’s diameter results in a reduced ball bearing stress. However, increasing the elasticity modulus of the roller elements results in an increased roller bearing stress [7]. The contact stress in rolling bearings, determined by using analytical and numerical methods, was pre- 163 https://doi.org/10.14311/AP.2021.61.0163 https://creativecommons.org/licenses/by/4.0/ https://www.cvut.cz/en Mehmet Bozca Acta Polytechnica (a) . 3D distribution of surface pressure for point contact [5]. Z X Z Y 2b 2 a F pmax F pmax 2a 2 b (b) . 2D distribution of surface pressure for point contact. Figure 1. sented. The analytical solution is obtained by using Hertizan contact theory. The same problems are also examined by using the finite element method to ex- amine the contact analysis of a rolling bearing. The normal and tangential forces as well as the rolling friction between mated parts are analysed in order to obtain more accurate results. A numerical analysis of contact problems by computer programs gives more accurate results [8]. The effect of the internal radial clearance on the damping characteristics, natural modes of vibration, and fatigue life of rolling element bearings was studied. It was concluded that the experimental results showed that the bearing with the largest radial clearance had the lowest damping ratio, highest natural frequency, and shortest bearing life [9]. The effect of the internal clearance on radially loaded deep groove ball and cylindrical roller bearing load distribution and fatigue life was determined for different clearance groups. The analysis was extended to negative clearance conditions to produce a curve of the life factor versus the internal clearance. It was concluded that rolling-element loads can be optimized and bearing life maximized for a small negative op- erating clearance. The life shortens gradually with a positive clearance and rapidly with an increasing negative clearance [10]. An experimental procedure for predicting the fa- tigue life of each individual rolling element bearing separately using a vibration modal analysis was pre- sented. A statistical analysis was performed to find an empirical model that correlates the dynamic load capacity of rolling bearings to their dynamic char- acteristics such as natural frequencies and damping. A modified formula to the already known Lundberg- Palmgren life formula is proposed for rolling element bearings. Given the modified formula, one can pre- dict the fatigue life of each individual rolling element bearing based on its dynamic characteristics [11]. An optimisation algorithm developed for an optimal axial preload of a rolling bearings system that consists of two angular contact ball bearings or tapered bear- ings to maximize the bearing’s life. The Lundberg and Palmgren model is used to evaluate the rolling bearing’s life. It was concluded that using the Lund- berg and Palmgren model, it is obvious that the axial bearing preload influences the bearing’s fatigue life and the optimal preload value can be determined [12]. 2. Contact pressure and stress 2.1. Ball bearing application For the ball bearing application case, the point contact pressure and Von Mises effective stress are calculated. 2.1.1. Point contact pressure The contact pressure is maximum pmax at the centre and zero at the edge, as shown in Figure 1a and Figure 1b. The total applied load F on the contact patch is equal to the volume of the hemisphere. The total applied load F is written as follows [5, 13–17]: F = 2 3πa 2pmax (1) where a is the half-width (radius) of the contact patch as shown in Figure 1a and Figure 1b. This can be solved for the maximum pressure: pmax = 3 2 F πa2 (2) The average pressure on the contact patch is the ap- plied force divided by its area: pavg = F area = F πa2 (3) Then, the maximum pressure can be re-arranged as follows: pmax = 3 2pavg (4) The material constants m1 and m2 for the two spheres are defined as follows: m1 = 1− ν2 1 E1 (5) and m2 = 1− ν2 2 E2 (6) where ν1, ν2 are the Poisson’s ratios, and E1, E2 are the Young’s moduli for the materials. 164 vol. 61 no. 1/2021 Effects of design parameters on static equivalent stress. . . (a) . 3D Distribution of surface pressure for line contact [5]. X Y Z Z pmax FF pmax L L 2 b 2b (b) . 2D distribution of surface pressure for line contact. Figure 2. A geometry constant < that depends only on the radii R1 and R2 of the two spheres can be defined as follows: < = 1 2 Å 1 R1 + 1 R2 ã (7) The contact-patch radius a is then found from a = π 4 pmax (m1 +m2 < ) (8) By substituting equation (2) in equation (8), equa- tion (9) is written as follows: a = 3 … 0.375 (m1 +m2 < ) F (9) The pressure distribution within the hemisphere is p = pmax … 1− x2 a2 − y2 a2 (10) 2.1.2. Point contact stress The stresses that are maximal at the surface at which z = 0 are written as follows [5, 13–17]: σz max = −pmax (11) σx max = σy max = − Å1 + 2ν 2 ã pmax (12) τxy = Å1 + 2ν 3 ã pmax (13) 2.1.3. Von Mises effective stress Von Mises effective stress is written according to the applied stresses as follows [5, 13–17]: σV M = 1√ 2 » (σx − σy)2 + (σy − σz)2 + (σz − σx)2 + 6 ( τ2 xy + τ2 yz + τ2 zx ) (14) A stress-based failure criterion for a static loading condition is considered during the design stage as follows: σV M ≤ Sy (15) where Sy is the yield strength of the bearing material. The yield strength point is considered as the failure limit during static loading conditions. 2.2. Roller bearing application For the roller bearing application case, the line contact pressure and Von Mises effective stress are calculated. 2.2.1. Line contact pressure The contact pressure is maximum pmax at the centre and zero at the edges, as shown in Figure 2a and Figure 2b. The applied load F on the contact patch is equal to the volume of the half-prism [5, 13–17]. F = 1 2πaLpmax (16) where F is the total applied load and L is the length of the contact along the cylinder axis as shown in Figure 2a and Figure 2b. This can be solved for the maximum pressure: pmax = 2F πaL (17) The average pressure is the applied force divided by the contact-patch area: pavg = F area = F 2aL (18) The applied force can be written as a function of the average pressure: F = 2aL(pavg) (19) Then, the maximum pressure can be re-arranged as follows: pmax = 4 π pavg ≈ 1.273pavg (20) We now define a cylindrical geometry constant < that depends on the radii R1 and R2 of the two cylinders: < = 1 2 Å 1 R1 + 1 R2 ã (21) The contact-patch half width a is then found from a = … 2 π m1 +m2 < F L (22) where m1 and m2 are material constants defined in the following equations: m1 = 1− ν2 1 E1 (23) 165 Mehmet Bozca Acta Polytechnica and m2 = 1− ν2 2 E2 (24) where ν1, ν2 are the Poisson’s ratios and E1, E2 are the Young’s moduli for the materials. The pressure distribution within the semi-elliptical prism is p = pmax … 1− x2 a2 (25) 2.2.2. Line contact stress The stresses due to the normal loading pmax are writ- ten as follows [5, 13–17]: σxn = −pmax … 1− x2 a2 (26) σzn = −pmax … 1− x2 a2 (27) τxzn = 0 (28) 2.2.3. Von Mises effective stress Von Mises effective stress is written according to the applied stresses as follows [5, 13–17]: σV M = √ σ2 x + σ2 z − σxσz + 3τ2 xz (29) A stress-based failure criterion for static loading condi- tions is considered during the design stage as follows: σV M ≤ Sy (30) where Sy is yield strength of the bearing material. The yield strength point is considered as the failure limit during the static loading condition. 3. Numerical results A radial ball bearing and a radial roller bearing are considered in the numerical examples. The contact pressure, contact area and von Misses stress of bear- ings are calculated based on geometrical parameters, material parameters and loading parameters by using MATLAB program. A flow chart of the calculation algorithm is shown in Figure 3. 3.1. Example of ball bearing application In the numerical example for a ball bearing shown in Figure 4, the maximum contact pressure and Von Mises stress are simulated by varying the radius and elasticity modulus of the ball element. The results of the simulation for a varying radius of the ball element are reported in Table 1. Increasing the radius of the ball element R1 results in an increased contact area A, as shown in Figure 5. Increasing the radius of the ball element results in a reduced maximum contact pressure pmax, as shown in Figure 6. Increasing the radius of the ball element results in a reduced Von Mises stress σV M , as shown in Figure 7. Calculate Input R, L, E, F Contact pressure pmax Contact area A von Misses stress σvM YES NO Design is significant If σvM ≥ Sy r Figure 3. Flow chart of the von Mises stress calcula- tion of a roller bearing. The simulation results for a varying elasticity mod- ulus of the ball element are presented in Table 2. Increasing the elasticity modulus of the ball element results in a decreased contact area A, as shown in Figure 8. Increasing the elasticity modulus of the ball element results in an increased maximum contact pressure pmax, as shown in Figure 9. Increasing the elasticity modulus of the ball element results in an increased Von Mises stress σV M , as shown in Figure 10. 3.1.1. Example of a standard ball bearing A numerical example of a standard ball bearing is performed for the 6014 ball bearing, as shown in Figure 11. Basic dimensions of the 6014 ball bearing are presented in Table 3. The maximum contact pressure pmax and Von Misses stress σV M of 6014 ball bearings are calcu- lated. The obtained results are presented in Table 4. It is shown that increasing the radius of the ball ele- ment results in a reduced the Von Mises stress σV M , since the standard ball bearing ball radius is larger than the simulation values of the ball radius. 3.2. Example of roller bearing application In the numerical example for a roller bearing shown in Figure 12, the average contact pressure, maximum contact pressure and Von Mises stress are simulated 166 vol. 61 no. 1/2021 Effects of design parameters on static equivalent stress. . . B dD d 1 = 2 R 2 D 2 R1 Figure 4. Ball bearing. R1 R2 < a A pmax σV M [mm] [mm] [mm−1] [mm] [mm2] [MPa] [MPa] 3.00 40 0.1792 0.4512 0.6396 11727 3940 3.50 40 0.1554 0.4732 0.7033 10663 3583 4.00 40 0.1375 0.4928 0.7630 9829 3302 4.50 40 0.1236 0.5106 0.8191 9156 3076 5.00 40 0.1125 0.5296 0.8722 8598 2889 5.50 40 0.1034 0.5419 0.9226 8129 2731 6.00 40 0.0958 0.5558 0.9706 7727 2596 Table 1. Contact pressure and Von Mises stress results for a varying radius of the ball element. Figure 5. Relation between the contact area and the radios of the ball element. Figure 6. Relation between the maximum contact pressure and the radius of the ball element. 167 Mehmet Bozca Acta Polytechnica Figure 7. Relation between Von Mises stress and the radius of the ball element. E1 E2 < a A pmax σV M [MPa] [MPa] [mm−1] [mm] [mm2] [MPa] [MPa] 180000 210000 0.1125 0.5412 0.9200 8152 2739 190000 210000 0.1125 0.5360 0.9025 8309 2792 200000 210000 0.1125 0.5313 0.8867 8458 2842 210000 210000 0.1125 0.5269 0.8722 8598 2889 220000 210000 0.1125 0.5229 0.8589 8731 2933 230000 210000 0.1125 0.5192 0.8467 8857 2976 240000 210000 0.1125 0.5157 0.8355 8977 3016 Table 2. Contact pressure and Von Mises stress for a varying elasticity modulus of the ball element. Figure 8. Relation between the contact area and elasticity modulus. Figure 9. Relation between the maximum contact pressure and elasticity modulus. d D B d1 D2 [mm] [mm] [mm] [mm] [mm] 70 110 20 82.85 99.9 Table 3. Basic dimensions of standard 6014 ball bearing. 168 vol. 61 no. 1/2021 Effects of design parameters on static equivalent stress. . . Figure 10. Von Mises stress and elasticity modulus relation. B dD d 1 = 2 R 2 D 2 R1 Figure 11. Basic Dimensions of 6014 ball bearing. by varying the radius and elasticity modulus of the roller element. The simulation results for a varying radius of the roller element are reported in Table 5. Increasing the radius of the roller element results in an increased contact area A, as shown in Figure 13. Increasing the radius of the roller element results in a decreased maximum contact pressure pmax, as shown in Figure 14. Increasing the radius of the roller element results in a decreased Von Mises stress σV M , as shown in Figure 15. The simulation results for a varying elasticity mod- ulus of the roller element are reported in Table 6. Increasing the elasticity modulus of the roller ele- ment results in a decreased contact area A, as shown in Figure 16. Increasing the elasticity modulus of the roller ele- ment results in an increased maximum contact pres- sure pmax, as shown in Figure 17. Increasing the elasticity modulus of the roller el- ement results in an increased Von Mises stress, as shown in Figure 18. 3.2.1. Example of a standard roller bearing A numerical example of a standard roller bearing is performed for NU 1014 roller bearing, as shown in Figure 19. Basic dimensions of NU 1014 roller bearing are presented in Table 7. The maximum contact pressure pmax and von Misses stress σV M of NU 1014 roller bearings are calculated. The obtained results are presented in Ta- ble 8. It is shown that increasing the radius of the roller element results in a reduced the Von Mises stress σV M since the standard radius of a roller bearing is larger than the simulation values of the roller radius. 4. Discussion Increasing the radius of the ball element R1 from 3 [mm] to 6 [mm] results in an increased contact area A from 0.6396 [mm2] to 0.9706 [mm2] while reduc- ing the geometry constant from 0.1792 [mm−1] to 0.0958 [mm−1]. In contrast, increasing the radius of the ball element R1 results in an increased contact- patch radius a from 0.4512 [mm] to 0.5558 [mm], as reported Table 1. Increasing the elasticity modulus of the ball element E1 from 180000 [N/mm2] to 240000 [N/mm2] results in a decreased contact area A from 0.9200 [mm2] to 0.8355 [mm2] while keeping the geometry constant as constant. In contrast, increasing the elasticity modulus of the ball E1 results in a decreased contact- patch radius a from 0.5412 [mm] to 0.5157 [mm], as reported in Table 2. Increasing the radius of the roller element R1 from 3 [mm] to 6 [mm] results in an increased contact area A from 2.4975 [mm2] to 3.4149 [mm2] while decreas- ing the geometry constant from 0.1792 [mm−1] to 0.0958 [mm−1]. In contrast, increasing the radius of the roller element R1 results in an increased contact- 169 Mehmet Bozca Acta Polytechnica R1 R2 < a A pmax σV M [mm] [mm] [mm−1] [mm] [mm2] [MPa] [MPa] 8.00 40 0.0750 0.6032 1.1429 6562 2204 Table 4. Contact pressure and Von Mises stress results for standard 6014 ball bearing. d B D F R 1 D 1 = 2 R 2 Figure 12. Roller bearing. R1 R2 < a A pmax σV M [mm] [mm] [mm−1] [mm] [mm2] [MPa] [MPa] 3.00 40 0.1792 0.1249 2.4975 2549 4211 3.50 40 0.1554 0.1341 2.6820 2373 3921 4.00 40 0.1375 0.1425 2.8509 2233 3689 4.50 40 0.1236 0.1503 3.0068 2117 3498 5.00 40 0.1125 0.1576 3.1518 2019 3337 5.50 40 0.1034 0.1644 3.2874 1936 3199 6.00 40 0.0958 0.1707 3.4149 1864 3080 Table 5. Contact pressure and Von Mises stress results for a varying radius of the roller element. Figure 13. Relation between the contact area and the radius of the roller element. Figure 14. Relation between the maximum contact pressure and the radius of the roller element. 170 vol. 61 no. 1/2021 Effects of design parameters on static equivalent stress. . . Figure 15. Relation between Von Mises stress and the radius of the roller element. E1 E2 < a A pmax σV M [MPa] [MPa] [mm−1] [mm] [mm2] [MPa] [MPa] 180000 210000 0.1125 0.1640 3.2805 1940 3206 190000 210000 0.1125 0.1617 3.2337 1968 3252 200000 210000 0.1125 0.1595 3.1909 1995 3296 210000 210000 0.1125 0.1576 3.1518 2019 3337 220000 210000 0.1125 0.1558 3.1158 2043 3376 230000 210000 0.1125 0.1541 3.0825 2065 3412 240000 210000 0.1125 0.1526 3.0517 2086 3446 Table 6. Contact pressure and Von Mises stress for a varying elasticity modulus of the roller element. Figure 16. Relation between the contact area and elasticity modulus. Figure 17. Relation between the maximum contact pressure and elasticity modulus. d D B D1 F [mm] [mm] [mm] [mm] [mm] 70 110 20 95.7 90 Table 7. Basic dimensions of standard NU 1014 roller bearing. 171 Mehmet Bozca Acta Polytechnica Figure 18. Relation between Von Mises Stress and elasticity modulus. R1 R2 < a A pmax σV M [mm] [mm] [mm−1] [mm] [mm2] [MPa] [MPa] 8.00 40 0.7050 0.1930 3.8601 1649 2725 Table 8. Contact pressure and Von Mises stress results for standard NU 1014 roller bearings. d B D F R 1 D 1 = 2 R 2 Figure 19. Basic Dimensions of NU 1014 roller bear- ing. patch radius a from 0.1249 [mm] to 0.1707 [mm], as reported in Table 5. Increasing the elasticity modulus of the roller ele- ment E1 from 180000 [N/mm2] to 240000 [N/mm2] re- sults in a decreased contact area A from 3.2805 [mm2] to 3.0825 [mm2] while keeping the geometry constant as constant. In contrast, increasing the elasticity modulus of the roller element E1 results in a re- duced contact-patch radius a from 0.1640 [mm] to 0.1526 [mm], as reported in Table 6. 5. Conclusion The purpose of this study is a theoretical investiga- tion of the effects of design parameters on the static equivalent stress of radial rolling bearings, such as ball bearings and roller bearings. For the point contact case of ball bearings and for the line contact case of roller bearings, the maximum contact pressure pmax for varying design parameters is calculated. The contact stress is calculated according to the Von Mises effective stress hypothesis. The following results are obtained for the point contact case of a ball bearing application and for the line contact case of a roller bearing application: (1.) Increasing the radius of the ball and roller ele- ments R1 results in a decreased geometry constant <. In contrast, increasing the radius of the ball and roller elements R1 results in an increased contact area A, due to the increased contact-patch radius a. (2.) Increasing the radius of the ball and roller ele- ments results in a decreased maximum contact pmax and Von Mises effective stress σV M . (3.) Increasing the elasticity modulus of the ball and roller elements E1 results in a constant geometry constant <. In contrast, increasing the elasticity modulus of the ball and roller elements E1 results in a decreased contact area A, due to the decreased contact-patch radius a. (4.) Increasing the elasticity modulus of the ball and roller elements results in an increased maximum contact pressure pmax and Von Mises effective stress σV M , because of the decreased contact area. The determination of the diameters and the selec- tion of material of the ball and roller elements are crucial and play an effective role during the design process. Therefore, bearing designers and manufactur- ers should make the bearing geometrical dimensions as large as possible and the bearing material as elastic as possible. Furthermore, the stress-based static fail- ure theory can also be used instead of the standard static load carrying capacity calculation. Moreover, von Mises stress theory is also compatible with the finite element method. 172 vol. 61 no. 1/2021 Effects of design parameters on static equivalent stress. . . The bearing static and dynamic load carrying ca- pacity and bearing service life will be investigated by the author in a future study. References [1] F. Sadeghi, B. Jalalahmadi, T. S. Slack, et al. A review of rolling contact fatigue. Journal of tribology 131(4):041403, 2009. doi:10.1115/1.3209132. [2] R. Potočnik, P. Göncz, J. Flašker, S. Glodež. Fatigue life of double row slewing ball bearing with irregular geometry. Procedia engineering 2(1):1877 – 1886, 2010. doi:10.1016/j.proeng.2010.03.202. [3] G. E. Morales-Espejel, A. Gabelli, A. J. C. de Vries. A model for rolling bearing life with surface and subsurface survival tribological effects. Tribology Transactions 58(5):894 – 906, 2015. doi:10.1080/10402004.2015.1025932. [4] F. Kosugi. High-speed angular contact ball bearings new 9 series for machine tool. 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Springer International Publishing, Ludwigsburg, Germany, 2016. 173 http://dx.doi.org/10.1115/1.3209132 http://dx.doi.org/10.1016/j.proeng.2010.03.202 http://dx.doi.org/10.1080/10402004.2015.1025932 http://dx.doi.org/10.1007/s12206-019-0406-y http://dx.doi.org/10.1080/10402004.2011.639050 http://dx.doi.org/10.1007/s12206-017-1210-1 http://dx.doi.org/10.1088/1757-899X/393/1/012055 Acta Polytechnica 61(1):163–173, 2021 1 Introduction 2 Contact pressure and stress 2.1 Ball bearing application 2.1.1 Point contact pressure 2.1.2 Point contact stress 2.1.3 Von Mises effective stress 2.2 Roller bearing application 2.2.1 Line contact pressure 2.2.2 Line contact stress 2.2.3 Von Mises effective stress 3 Numerical results 3.1 Example of ball bearing application 3.1.1 Example of a standard ball bearing 3.2 Example of roller bearing application 3.2.1 Example of a standard roller bearing 4 Discussion 5 Conclusion References