Rolling Bearing Stress Based LifePart II: Experimental Calibration and Validation

J. Gnagy
The Timken Company, 1835 Dueber Avenue Southwest, P.O. Box 6930, Canton, OH 44706-0930

L. Houpert1
e-mail: luc.houpert@timken.com

F. Chevalier
Timken Europe, B.P. 60089, Colmar, F-68002, France

The stress based life model described in Paper I was calibrated using a large database of experimental results from a global quality audit test program as well as special development tests conducted for this validation effort. All tests used in the calibration of the new model were case carburized or through hardened tapered roller bearings. The initial model comparison to test results showed very good correlation with a median ratio of test life to calculated life very close to one. Higher accuracy of the stress based model compared to the traditional factor based method was also demonstrated by narrower condence bands (less data scatter). Validation testing of case carburized tapered roller bearings as well as through hardened spherical roller bearings was also conducted under expanded test conditions beyond those utilized in the quality audit test program (i.e., high and low load, high and low k, imposed misalignment, and heavy inner ring interference ts). Although the median ratio of relative life for the validation testing showed the stress based method to be conservative and well above one, the stress based method still showed better accuracy than the traditional factor based method as well as narrower condence bands for this additional body of experimental data. The conservative results can be explained by use of high quality steel and manufacturing processes in a prototype facility and not series production equipment as was the case with the quality audit database. [DOI: 10.1115/1.4006136] Keywords: stress based bearing life, experimental validation, condence intervals

Introduction
This paper is a follow up to Ref. [1] in which a new stress based bearing life model has been described. Bearing stresses on the surface and beneath the surface are calculated as accurately as possible and are used in a Dang Van modern multiaxial stress criterion for calculating bearing raceway fatigue life. Many features are included in the model such as raceway proles, asperities, residual stresses, hoop stresses due to t as well as a material endurance limit dened as a function of the hydrostatic pressure. Also used in the model were constant factors and exponents that were dened or calibrated by curve-tting (using a NewtonRaphson optimization process) data from a large body of fatigue life tests. Additional specic life tests were also conducted for validating the model. The objective of this paper is to describe the experimental calibration and validation conducted for comparing calculated and experimental bearing fatigue lives.

Fig. 1 for tapered roller bearings. Similar test schemes were also utilized to evaluate other radial bearing types such as two-row spherical bearings that will be discussed in future sections. Most tapered roller bearings were tested under radial load as shown in Fig. 1. Some small size tapered roller bearings, however, were tested under pure thrust load due to excessive shaft deection caused by radial loading. Pure thrust load testing was accomplished via split shafts as shown in Fig. 2. All testing schemes utilized vibration sensors to detect raceway fatigue spalls of a prespecied size of 0.01 in.2 (6 mm2). A total of 27 different tapered roller bearing series with outer diameter (OD) size ranging from 1.57 in. (39.878 mm) to 9.75 in.

Experimental Calibration
To assure bearings perform to quality standards, bearings are sampled annually out of production and performance tested under specic conditions as part of a global audit testing program. Bearings sampled annually from production undergo performance evaluation including pretest metrology, metallurgical evaluation, and fatigue life testing. In addition to global audit fatigue life test results, data from several special tests conducted under modied audit test conditions for specic development projects were also utilized. Bearings evaluated under audit type conditions were tested using a rst-in-four sudden death testing scheme as shown in
1 Corresponding author. Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received September 12, 2011; nal manuscript received February 3, 2012; published online April 16, 2012. Assoc. Editor: Daniel Ne lias.

Fig. 1 First-in-four tapered roller bearing testing scheme utilized for audit type fatigue life tests under radial load

Journal of Tribology

C 2012 by ASME Copyright V

APRIL 2012, Vol. 134 / 021104-1

Downloaded From: http://tribology.asmedigitalcollection.asme.org/ on 04/28/2013 Terms of Use: http://asme.org/terms

Fig. 2 First-in-four tapered roller bearing testing scheme utilized for audit type fatigue life tests under pure thrust load

(247.650 mm) were evaluated. Fatigue life data from a total of 213 tests was utilized in the calibration of the stress based model. Each test generally consisted of 24 bearings. The 213 test groups comprised a total of 5044 bearings evaluated in fatigue life testing. Table 1 lists a summary of the range of test conditions used in the stress based model constant calibration. All bearing tests represented in Table 1 were tapered roller bearings consisting of case carburized rings (cone and cup) and case carburized rollers. Test temperature was measured at the outer ring (cup) OD. Load zone was measured as the arc of roller contact on the cup (stationary member) raceway after life test. Tests conducted under pure thrust load resulted in a 360 load zone. Test misalignment was calculated based on shaft bending due to the applied radial load for all audit radial load tests. Some development tests, however, were conducted with additional imposed misalignment created by off taper outer ring (cup) seats. Misalignment for pure thrust audit tests was assumed to be zero. Audit tests were conducted under load conditions ranging from 1.2 to 1.78 C90 (or Ca90 for pure thrust load tests) with nominal inner ring raceway stresses ranging from 299 to 357 ksi (20622461 MPa) for the maximum loaded rolling element. Development tests were conducted under load conditions ranging from 1.51 to 4.57 C90 with nominal inner ring raceway stresses ranging from 346 to 483 ksi (23863330 MPa) for the maximum loaded rolling element. The data from audit and development tests were divided into two groups: high k and low k operating conditions. The high k groups were used for dening the unknowns Av, cv, and hv while the low k groups were used to dene the surface parameters As and cs. The experimental L10exp life from each bearing series was used for the calibration and later comparison to the calculated stress based model L10calc life. Raw life test data from each rst-in-four test yielded experimental L15.91exp lives. Experimental L15.91exp lives were then converted to experimental L10exp lives using the measured experimental Weibull slope eexp for each group of tests [2,3]. Several bearing series consist of life test data from several production years (214 yr time spans), and results were averaged to reduce the condence intervals on the L10exp used in the calibration and validation calculations. Average measured Ra raceway surface roughness (pretest measurements), outer ring temperature, outer raceway load zone

values, and reference temperature oil viscosities are used as inputs to calculate the stress based and factor based lives. Lambda ratios (range shown in Table 1) based on the central Grubin lm thickness divided by the arithmetic sum of the inner ring raceway (cone) and rolling element Ra surface nishes are used for dening the lubrication factor in the factor based approach [4]. In the stress based approach described in Ref. [1], the k ratio is dened using more recent elasto hydro dynamic (EHD) lm thickness relationships, a thermal reduction factor and the composite root mean square (RMS ) surface roughness Rq. The ratios of experimental L10exp to calculated L10calc were analyzed using Weibull statistics [5] for both the stress based and traditional factor based life prediction methods. All predictive life calculations were performed using the bearing systems analysis (BSA) program SYBER [68]. The factor based method utilized life adjustments for misalignment, load zone, and lubrication. Relative life results (L10exp L10calc) are shown in Fig. 3 for both calculation methods with 90% condence bands [3,9]. This comparison shows that the stress based method yields a more accurate prediction because the median ratio is much closer to 1.0. More importantly, the 90% condence bands are also narrower for the stress based method indicating more accurate life prediction.

Experimental Validation for Through Hardened Bearings

Once the model was calibrated using a large database of case carburized tapered roller bearings, the stress based model was evaluated for through hardened tapered roller bearings. Through hardened tapered roller bearing data were also taken from a quality audit database. A total of 20 bearing series with outer diameter size ranging from 2.0472 to 9.8425 in. (52250 mm) were evaluated. Bearings in this population of data were sampled over a period of time spanning 5 yr and were evaluated in 41 separate test groups generally consisting of 24 bearings each. A total of 944 bearings were life tested in the same rst-in-four testing method used for the case carburized bearings discussed earlier. Through hardened bearing tests were conducted under radial load ranging from 1.29 to 1.66 C90 with nominal inner raceway contact stress for the maximum loaded rolling element ranging from 295 to 386 ksi (20342661 MPa). Table 2 lists a summary of the range of test conditions used to validate the stress based model for through hardened tapered roller bearings. Test temperature was measured at the outer ring (cup) OD. Load zone was measured as the arc of roller contact on the cup (stationary member) raceway after life test. Test misalignment was calculated based on shaft bending due to the applied radial load. All through hardened tapered roller bearing tests represented in Table 2 were conducted under radial load. A similar type of validation analysis using calculated factor and stress based lives and Weibull analysis of resulting relative life ratios (L10exp L10calc) was conducted for the through hardened tapered roller bearing data. The results of this analysis are plotted in Fig. 4 with 90% condence bands.

Table 1 Summary of case carburized tapered roller bearing audit and development test conditions used for calibration and validation of the stress based life model Cone bore (in.) (mm) 0.627 15.875177.800 Cone bore (in.) (mm) 1.31257 33.338177.800 Cup OD (in.) (mm) 1.579.75 39.878247.650 Cup OD (in.) (mm) 2.56259.75 65.088247.650 Percent load rating 120178 Percent Load Rating 151457 Speed (rpm) 9002700 Speed (rpm) 182700 Load zone ( ) 127360 Load zone ( ) 115155 Misal. (mrad) 0.01.21 Misal. (mrad) 0.74 Temp ( F) ( C) 106151 4166 Temp ( F) ( C) 145212 63100 Lambda ratio (cone-roller) 0.862.55 Lambda Ratio (cone-roller) 0.062.06 Development tests

Audit tests

021104-2 / Vol. 134, APRIL 2012

Transactions of the ASME

Downloaded From: http://tribology.asmedigitalcollection.asme.org/ on 04/28/2013 Terms of Use: http://asme.org/terms

Fig. 3 Comparison of factor based and stress based methods for audit and development tests using case carburized tapered roller bearings Table 2 model Summary of through hardened tapered roller bearing audit test conditions used for validation of the stress based life Temp ( F) ( C) 107203 4295

Cone bore (in.) (mm) 0.98437.0866 25180

Cup OD (in.) (mm) 2.04729.8425 52250

Percent load rating 129166

Speed (rpm) 9002700

Load zone ( ) 119178

Misal. (mrad) 0.01.0

Lambda ratio (cone-roller) 0.355.90

Audit tests

Fig. 4 Comparison of factor based and stress based methods for audit through hardened tapered roller bearing tests

The results for audit through hardened tapered roller bearings are very similar to those for case carburized audit bearings discussed earlier with a median ratio of experimental life to stress based life very close to 1.0 and slightly narrower condence bands for the stress based calculations. These results show that the stress based model is also valid for through hardened tapered roller bearings as well. Journal of Tribology

Additional Test Campaign and Validation of the Stress Based Life Model for Case Carburized Tapered Roller Bearings
The case carburized tapered roller bearing audit test data used to calibrate the stress based model were conducted under APRIL 2012, Vol. 134 / 021104-3

Downloaded From: http://tribology.asmedigitalcollection.asme.org/ on 04/28/2013 Terms of Use: http://asme.org/terms

somewhat narrow operating conditions. Lambda ratios were generally high (several instances greater than 2.0), and misalignments were mostly low (misalignment resulting from shaft bending only in the life test rig). Furthermore, load levels were generally around 1.5 C90 with exceptions below or above 1.5 C90 due to machine capabilities and/or previous historical data. To validate the stress based fatigue life model for a wider range of conditions, an additional test program was developed and executed. This evaluation spanned a period of 5 yr and consisted of life testing of 456 case carburized tapered roller bearings under various surface and load level conditions. The bearing series selected for this test program was the M802000 series. This series was selected based upon an extensive history of previous testing using this series. The overall bearing envelop dimensions are listed as follows: (a) (b) (c) 1.6250 in. (41.275 mm) bore 3.2500 in. (82.550 mm) cup OD 1.0450 in. (26.543 mm) bearing width

dial M802000 series C90 rating (4950 lb/22,019 N). High k tests were conducted at high speed (5400 rpm), thick oil (ISO VG 068), and low oil temperature. Low k tests were conducted at lower speed (1200 rpm), thin oil (ISO VG 10 PAO), and high oil temperature. A synthetic oil (PAO) was selected for the thin lm tests due to the widespread shift to synthetic base oil types in industrial and automotive applications. The ISO VG 068 oil is mineral base. Most tests consisted of 24 bearings each yielding six rst-infour data points. Weibull analyses of the test data were compared to analytical life predictions using both the stress based and factor based calculations. Analytical life predictions were conducted using the following parameters in the life prediction models: (a) (b) (c) (d) average measured test load zone (measured on cup raceway after test) average measured test temperature (measured on cup OD during test) average measured pre-test raceway surface nishes nominal design prole geometry

Inner rings (cones) and outer rings (cups) for life testing were manufactured from a common high quality steel source. Bearing inner and outer rings were special ordered from production as hardstock (manufactured through green machine and heat treat) and were nished in a prototype environment. Rollers used in test bearing assemblies came from a common nished batch ordered from production. Prototype nishing was utilized to reduce geometry and raceway surface nish variations from test group to test group. All functional raceway contact surfaces (i.e., cone/cup raceways, roller bodies, roller large ends, and cone large rib faces) were honed. High quality steel and prototype manufacture resulted in bearing test lives which in some cases greatly exceeded the predicted stress based lives as explained in the following discussion of the test results. The test program using the M802000 series bearing consisted of 19 life tests. An expert design of experiments (DOE) test matrix was constructed based on the operating conditions desired to be evaluated. These conditions were developed to extend the range of test conditions beyond those encountered in standard audit testing. The following variables were evaluated: (a) (b) (c) (d) (e) high versus low lambda ratio cup edge contact stress versus no cup edge stress (standard prole versus enhanced prole) no imposed misalignment versus imposed misalignment high versus low load standard cone versus heavy cone bore interference t

Table 3 lists a summary of the range of test conditions for the 19 tests conducted using case carburized M802000 series bearings. Lambda ratios shown in Table 3 are calculated in the same manner used in Tables 1 and 2 (central Grubin lm thickness divided by the arithmetic sum of the cone raceway and rolling element Ra surface nishes [4]). All testing was conducted using the rst-in-four sudden death testing method utilizing similar test equipment used for audit testing (see Fig. 1). All tests represented in Table 3 utilized circulating oil, radial loading, and rotating cone with stationary cup. Tests conducted with imposed misalignment were performed using special cup housings with cup seat taper creating 2 mrad misalignment between the cone and cup raceways. Radial load levels were chosen to be 100% (4950 lb/22,019 N), 151% (7480 lb/33,723 N), and 200% (9900 lb/44,037 N) of the ra-

Relative life ratios were calculated for each test condition by dividing the experimental L10exp life by the analytical calculated L10calc life (L10exp L10calc). Weibull analyses of the relative life ratios for both calculation methods are plotted in Fig. 5. Analytical results show a better correlation with test results for the stress based method than that obtained using the factor based method. The stress based method shows narrower condence bands and a median ratio closer to unity but above unity at 2.6. Higher relative life ratios for the M802000 series bearings are attributed to high quality steel and tighter control of manufacturing tolerances for the M802000 series prototype test bearings than for those sampled directly out of production over a span of several years through the audit test programs. In addition to the Weibull analyses of relative life ratios shown in Fig. 5, additional analyses were also performed by considering the trends observed from the M802000 series life test data. Ratios of the median L15.91exp test lives were calculated for corresponding pairs of tests to study the effect of radial load (200% versus 100% C90), misalignment (imposed versus no imposed misalignment), k ratio (low versus high), outer ring (cup) raceway prole (standard versus enhanced), and cone t (heavy versus standard). Corresponding ratios of calculated stress based and factor based L15.91calc predictions were also compared to the corresponding experimental ratios. Ratios for each comparison were averaged and are plotted in Fig. 6. Note that the condence interval of experimental life ratios (Test1 L15.91exp Test2 L15.91exp) is larger than the condence interval of each individual test median L15.91exp (Test1 L15.91exp or Test2 L15.91exp). As shown in Fig. 6, the correlation of analytical to experimental results is better for the stress based method for all comparisons except for k ratio. Correlation is very close for load for both methods. This may be due to a well-established C90 rating for the M802000 series (applies to factor based method only). Better correlation for the stress based model occurs for the contact stress related comparisons of misalignment and prole. The correlation of the stress based model for the cone t comparison is not as good because this comparison consists of only two heavy cone t life test groups. The cone t correlation for the stress based method, however, is still better than the factor based method because the factor based method does not take into account bearing ring ts in its life calculations. The factor based method shows slightly better correlation for k ratio than the stress based method. This is due to a very well-

Table 3 Summary of test conditions for case carburized M802000 series tapered roller bearing stress based model validation test campaign Percent load rating 100200 Speed (rpm) 12005400 Load zone ( ) 114140 Misal. (mrad) 0.342.0 Temp ( F) ( C) 127180 5382 Lambda Ratio (cone-roller) 0.194.80

021104-4 / Vol. 134, APRIL 2012

Transactions of the ASME

Downloaded From: http://tribology.asmedigitalcollection.asme.org/ on 04/28/2013 Terms of Use: http://asme.org/terms

Fig. 5 Comparison of factor based and stress based methods for M802000 series tapered roller bearing test campaign

Fig. 6

M802000 series test campaign trend results

established lubrication adjustment factor used in the factor based method. Historically the majority of the development of bearing life prediction has been focused on the lubrication adjustment factor [2,4].

Validation of the Stress Based Life Model for Through Hardened Spherical Roller Bearings
All of the life test correlations and validations discussed so far have focused on tapered roller bearings. Although the stress based life model was originally developed to be used primarily for tapered roller bearing applications operating under line contact, its use has expanded to other types of bearings such as spherical and cylindrical roller bearings. To validate the stress based model for bearings under truncated-point contact, an additional test campaign was Journal of Tribology

conducted using spherical roller bearings. This test campaign is similar in concept to the M802000 series tapered roller bearing program, but consists of fewer test groups. It should be noted that consideration was also given to conduct validation testing using cylindrical roller bearings. The decision, however, was made to pursue spherical roller bearing validation testing rather than cylindrical roller bearing validation because the contact pattern of cylindrical roller bearings is very similar to that of tapered roller bearings because both operate under line contact. The spherical roller bearing series selected for this test program was the 22212 series. This series was selected based upon its common use in medium industrial applications. It consists of through hardened rings and rolling elements. The overall bearing envelop dimensions are listed as follows: APRIL 2012, Vol. 134 / 021104-5

Downloaded From: http://tribology.asmedigitalcollection.asme.org/ on 04/28/2013 Terms of Use: http://asme.org/terms

Table 4 summary of test conditions for through hardened 22212 series spherical roller bearing stress based model validation test campaign Percent load rating 100200 Speed (rpm) 12005400 Load zone ( ) 127141 Temp ( F) ( C) 158193 7089 Lambda ratio (cone-roller) 0.100.81

(a) (b) (c)

2.3622 in. (60 mm) bore 4.3307 in. (110 mm) OD 1.1024 in. (28 mm) bearing width

Spherical roller bearing components were special ordered from production, and minor nishing processes were performed on the functional raceway surfaces in a prototype environment. All bearing components came from the same special order batch from production. The test program using the 22212 bearing series consisted of seven life test groups. An expert design of experiments (DOE) test matrix was also constructed based on the operating conditions desired to be evaluated. These conditions were developed to extend the range of test conditions beyond those encountered in standard audit testing. The following variables were evaluated: (a) (b) (c) moderate versus low lambda ratio high versus low load raceway surface nish typeground, honed, tumbled

Table 4 lists the range of test conditions for the through hardened 22212 spherical test campaign. Three radial load levels were selected: 9022 lb/40,132 N (100% C(2)90), 13,533 lb/60,198 N (150% C(2)90), and 18,044 lb/80,264 N (200% C(2)90). The median load level of 13,533 lb/60,198 N (150% C(2)90) was selected for evaluation of the variation of different surface nish processes ground, honed, and tumbled. Low k conditions (k < 1.0) were selected for the surface processing evaluation to capture the differences in asperity contact without separation of the rolling element and raceway surfaces by a full lubricant lm condition (k > 1.0). All spherical roller bearing tests were conducted using the rstin-four sudden death testing method utilizing similar test equipment used for audit testing. Figure 7 shows the rst-in-four life test rig used for spherical roller bearing fatigue life testing. All tests utilized circulating oil, radial loading, and rotating inner ring with stationary outer ring. Moderate k tests utilized higher rotational speed and thick oil (ISO VG 068). Low k tests utilized lower speed and thin oil (ISO VG 10 PAO). A synthetic oil (PAO) was selected for the low k tests due to the widespread shift to synthetic base oil types in industrial and automotive applications. The ISO VG 068 oil is mineral base. Most tests consisted of 24 bearings each yielding 6 rst-in-four data points. A total of 156 spherical roller bearings were tested for this special test program. To consider a larger population of data, the 22212 series special test campaign was augmented by spherical roller bearing audit testing. Eleven spherical roller bearing audit tests were considered. Each test consisted of sample sizes ranging from 8 to 28 bearings. Audit spherical roller bearing data consisted of four different series with outer ring diameter ranging from 4.3307 to 14.1732 in. (110360 mm) sampled from production over a period
Table 5

Fig. 7 First-in-four testing scheme used for spherical roller bearing test campaign and audit tests

of 9 yr. Audit spherical roller bearing tests consisted of load levels ranging from 0.99 to 1.51 C(2)90 resulting in nominal inner raceway center stresses ranging from 338 to 381 ksi (23302627 MPa) for the maximum loaded rolling element. Table 5 list a summary of the range of test conditions for the audit spherical roller bearing test data utilized. All spherical roller bearing tests (including the 22212 special test campaign mentioned earlier) were conducted using the rstin-four sudden death testing method as shown in Fig. 7. A total of 220 bearings were evaluated for the audit tests represented in Table 5. Combining these tests results with the 156 22212 series spherical roller bearings from the special test campaign discussed earlier, gives a total 376 bearings evaluated via 18 separate rstin-four life tests. To compare the accuracy of the stress based model to that of the factor based method, a similar analysis was conducted for spherical roller bearings. Relative life ratios for the 18 spherical roller bearing tests were analyzed using Weibull statistics and are plotted in Fig. 8 for both stress based and factor based methods. The results shown in Fig. 8 indicate that the stress based method of life prediction is more accurate than the factor based method with a median life ratio closer to unity. Condence bands for both factor based and stress based comparisons are somewhat wide. Wide condence bands are due to a very diverse spherical roller bearing sample consisting of both production and prototype nishing as well as a very broad range of bore sizes.

Summary of test conditions for audit spherical roller bearing tests considered in the validation of the stress based model Outer ring OD (in.) (mm) 4.330714.1732 110360 Percent load rating 99151 Speed (rpm) 5002700 Load zone ( ) 90149 Temp ( F) ( C) 122219 50104 Lambda (inner ring/roller) 0.261.61

Inner ring bore (in.) (mm) 2.36229.4488 60240

021104-6 / Vol. 134, APRIL 2012

Transactions of the ASME

Downloaded From: http://tribology.asmedigitalcollection.asme.org/ on 04/28/2013 Terms of Use: http://asme.org/terms

Fig. 8 Comparison of factor based and stress based methods for 22212 validation and audit spherical roller bearing tests

Fig. 9 Comparison of factor based and stress based methods for all bearing tests

Combining Tapered Roller Bearing and Spherical Roller Bearing Data

Combining all the audit and special test campaign data for both tapered and spherical roller bearings discussed so far results in a total of 291 separate tests evaluating a total of 6820 bearings. Figure 9 shows the comparison for combining the relative life ratios for all these tests into one composite Weibull analysis. This nal comparison shows more accurate results with narrower 90% condence limits and a median relative life ratio closer to 1.0 for the stress based life prediction method.

Conclusions
The stress based life model has been calibrated using fatigue life test data from 5044 case carburized audit and development Journal of Tribology

test tapered roller bearings tested via 213 separate life tests. Data used for the calibration spanned a time period of 14 yr. Correlation with this data is very good with a median relative life ratio of 1.0 and narrow 90% condence bands of 0.8 and 1.25 using the stress based model. Factor based median ratio is 1.4 with 90% condence bands of 1.1 and 1.8. The stress based model has been validated for through hardened tapered roller bearings by comparing calculated results to life test results from 41 tests consisting of 944 audit tapered roller bearings sampled over a period of 5 yr. Similar results were obtained with stress based median relative life ratio of 1.1 with 90% condence bands of 0.81 and 1.4. Factor based calculations resulted in a median relative life ratio of 1.4 with 90% condence limits of 1.1 and 1.75. Nominal audit test conditions of 150% C90 load and high k were expanded to include low k, bearing misalignment, 100% and APRIL 2012, Vol. 134 / 021104-7

Downloaded From: http://tribology.asmedigitalcollection.asme.org/ on 04/28/2013 Terms of Use: http://asme.org/terms

200% C90 load through a M802000 series case carburized tapered roller bearing test program. This test program consisted of 19 separate test groups for a total of 456 bearings evaluated. Relative life ratios of test life to calculated stress based life resulted in a median of 2.6 and 90% condent limits of 1.9 and 3.5. The stress based life results show higher accuracy when compared to the factor based median relative life of 4.2 with 90% condence limits of 3.0 to 5.6. High relative life ratios greater than unity for this test campaign are attributed to high steel quality and tight control of manufacturing tolerances of the M802000 series bearings evaluated. Life test data for spherical roller bearing designs was also evaluated through a special test campaign of seven test groups for a total of 156 22212 series bearings. This test program expanded audit conditions in a similar fashion utilized for the M802000 series tapered roller bearing program. Relative life ratios from the special seven test 22212 series bearing program were combined with 11 audit spherical roller bearing tests (376 total spherical roller bearings tested) to illustrate greater accuracy of the stress based model compared to the factor based model for spherical roller bearings. The median relative life ratio was 2.2 with 90% condence limits of 0.98 to 4.3 using the stress base life prediction method. Corresponding factor based predictions resulted in a median of 3.2 and 90% condence limits of 2.0 and 4.75. Combining all the audit and special test campaign data for both tapered and spherical roller bearings (291 separate tests evaluating a total of 6820 bearings) results in a median relative life ratio of 1.4 with 90% condence limits of 1.2 and 1.7 for the stress based calculation method. This composite analysis for the factor based model results in a median of 2.0 with 90% condence limits of 1.7 and 2.3. As shown by all these comparisons, the stress based model is validated as a reliable prediction of bearing fatigue life for both line contact and truncated point contact rolling element bearings. Calculated results from the stress based model are more accurate with median relative life ratios closer to unity, and, for most cases, narrower condence bands. The stress based calculation method described in Ref. [1] and validated in this paper represents the next generation of bearing fatigue life calculation by considering the total stress and surface interaction in the bearing raceway contacts in one comprehensive calculation and thus eliminating compounding error from independently calculated life adjustment factors.

h Exponent used in the stresslife criterion C90 single row bearing rating corresponding to 90 106 revolutions (lb or N) C (2) 90 two-row bearing rating corresponding to 90 106 revolutions (lb or N) L10 bearing life corresponding to 10% failure probability (revolutions) L15.91 bearing life corresponding to 15.91% failure probability (revolutions) e experimental Weibull slope Ra average surface roughness (lin. or lm) Rq RMS surface roughness (lin. or lm) k; lambda ratio (Grubin central lm thickness sum inner ring and rolling element raceway Ra nishes)

Subscripts
v s exp calc a volume surface experimental calculated analytical axial load direction

References
[1] Houpert, L., and Chevalier, F., 2011, Rolling Bearing Stress Based Life. Part I: Calculation model, presented at the ASME/STLE International Joint Tribology Conference (IJTC), October 2326, 2011, Los Angeles, California; submitted to ASME Journal of Tribology, Draft paper TRIB-11-1171. [2] Harris, T., Kotzalas, A., and Michael, N., 2007, Roller Bearing Analysis: Advanced Concepts of Bearing Technology, 5th ed., CRC Press, Taylor and Francis Group, Boca Raton, FL. [3] Houpert, L., 2003, An Engineering Approach to Condence Intervals and Endurance Test Strategies, STLE Tribol. Trans., 46(2), pp. 248259. [4] Moyer, C. A., 1990, Applying the Modied Lambda Ratio to Bearings and Gears, SAE Technical Paper Series No. 900910. [5] Johnson, L. G., 1964, The Statistical Treatment of Fatigue Experiments, Elsevier Publishing Company, New York. [6] Houpert, L., 1995, Prediction of Bearing, Gear and Housing Performances, Proceedings of the Institute of Mechanical Engineer Seminar, Rolling Bearing Practice Today, London, 29 p. [7] Houpert, L., and Merckling, J., 1998, A Successful Transition from Physically Measured to Numerically Simulated Bearings, Shafts, Gears, and Housing Deections in a Transmission, Proceedings of the GPC98 Global PowerTrain Congress (New Powertrain Materials and Processes), Vol. 4, pp. 131137. [8] Martens, M., and Pickford, N. 2009, Successful Bearing Design Through Proper Bearing System Analysis, Proceedings of the Institution of Mechanical Engineer Conference, Performance-Enhancing Technologies for Transmissions, Yeovil, 14 p. [9] Zantopulos, H., 1986, Extension of 65% and 90% Upper and Lower Weibull Condence Limits, Project Number 85899, Internal Report, The Timken Company.

Nomenclature
A constant used in life model c exponent used in the stresslife criterion

021104-8 / Vol. 134, APRIL 2012

Transactions of the ASME

Downloaded From: http://tribology.asmedigitalcollection.asme.org/ on 04/28/2013 Terms of Use: http://asme.org/terms