Enhancement of roller bearing fatigue life by innovative production processes

Purpose: The efficient and economical use of natural resources is a big issue. Machine elements with a rolling contact are highly relevant because of their wide application in technical systems and a large production quantity. Innovative hard machining can reduce the friction and increase the fatigue strength of rolling element bearings. The purpose of this study is to focus on the surface properties of such parts. Design/methodology/approach: A new model to predict bearing fatigue life is presented which takes compressive residual stresses in the bearing subsurface area into consideration. The investigated bearings were machined by the processes of hard turning, hard turning with subsequent deep rolling and a combination of hard turning and deep rolling (turn-rolling) in one process step. Changes in the residual stress state during bearing fatigue tests were investigated and the influence of residual stresses on the bearings fatigue life was researched. Findings: Both combinations including the deep rolling process decrease the surface roughness and induce compressive residual stresses. As a result, the L₁₀ fatigue life of roller bearings was increased by the factor of 2.5. Owing to the developed models, this effect can be considered within the design process. Originality/value: In the context of the research program “Resource efficient Machine Elements (SPP1551),” machining processes of bearings were investigated regarding the bearing fatigue life. By inducing beneficial residual stresses on the bearings’ subsurface area, the fatigue life could be increased. Thus higher resource efficiency was achieved. To increase the productivity, a combination of hard turning and deep rolling was evaluated.