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Rolling bearings often cause engineering accidents due to early fatigue failure. The study of early fatigue failure mechanism and fatigue life prediction does not consider the integrity of the bearing surface. The purpose of this paper is to find new rolling contact fatigue (RCF) life model of rolling bearing.

An elastic-plastic finite element (FE) fatigue damage accumulation model based on continuous damage mechanics is established. Surface roughness, surface residual stress and surface hardness of bearing rollers are considered. The fatigue damage and cumulative plastic strain during RCF process are obtained. Mechanism of early fatigue failure of the bearing is studied. RCF life of the bearing under different surface roughness, hardness and residual stress is predicted.

To obtain a more accurate calculation result of bearing fatigue life, the bearing surface integrity parameters should be considered and the elastic-plastic FE fatigue damage accumulation model should be used. There exist the optimal surface parameters corresponding to the maximum RCF life.

The elastic-plastic FE fatigue damage accumulation model can be used to obtain the optimized surface integrity parameters in the design stage of bearing and is helpful for promote the development of RCF theory of rolling bearing.

Molecular dynamics is an emerging simulation technique in the field of machining in recent years. Many researchers have tried to simulate different processing methods of various materials with the theory of molecular dynamics (MD), and some preliminary conclusions have been obtained. However, the application of MD simulation is more limited compared with traditional finite element model (FEM) simulation technique due to the complex modeling approach and long computation time. Therefore, more studies on the MD simulations are required to provide a reliable theoretical basis for the nanoscale interpretation of grinding process. This study investigates the crystal structures, dislocations, force, temperature and subsurface damage (SSD) in the grinding of iron-nickel alloy using MD analysis.

In this study the simulation model is established on the basis of the workpiece and single cubic boron nitride (CBN) grit with embedded atom method and Morse potentials describing the forces and energies between different atoms. The effects of grinding parameters on the material microstructure are studied based on the simulation results.

When CBN grit goes through one of the grains, the arrangement of atoms within the grain will be disordered, but other grains will not be easily deformed due to the protection of the grain boundaries. Higher grinding speed and larger cutting depth can cause greater impact of grit on the atoms, and more body-centered cubic (BCC) structures will be destroyed. The dislocations will appear in grain boundaries due to the rearrangement of atoms in grinding. The increase of grinding speed results in the more transformation from BCC to amorphous structures.

This study is aimed to study the grinding of Fe-Ni alloy (maraging steel) with single grit through MD simulation method, and to reveal the microstructure evolution within the affected range of SSD layer in the workpiece. The simulation model of polycrystalline structure of Fe-Ni maraging steel and grinding process of single CBN grit is constructed based on the Voronoi algorithm. The atomic accumulation, transformation of crystal structures, evolution of dislocations as well as the generation of SSD are discussed according to the simulation results.

Bearings in field applications with high dynamic loading, e.g. wind energy plants, suffer from sudden failure initiated by subsurface material transformation, known as white etching cracks in a typical scale of μm, preferably around the maximum Hertzian stress zone. Despite many investigations in this field no precise knowledge about the root cause of those failures is available, due to the fact that failure under real service conditions of wind energy plants differs from what is known from test rig results in terms of contact loading, lubrication or dynamics. The purpose of this paper is to apply Barkhausen noise measurement to a full bearing test ring running under conditions of elastohydrodynamic lubrication (EHL) with high radial preload.

Full bearing tests are carried out by use of DGBB (Deep Grove Ball Bearings) with 6206 specification, material set constant as 100Cr6, martensitic hardening, 10‐12 percent maximum retained austenite and radial preload of 3500 MPa. Speed is set 9000 rpm, temperature is self setting at 80°C by test conditions. For tests, synthetic hydrocarbon base oil (Poly‐α‐Olefine) with a 1 percent amount of molydenum‐dithiophosphate (organic chain given as 2‐ethylhexyl) was used.

Non‐destructive fractal dimension analyses by use of Barkhausen noise measurements is of versatile value in terms of recording bearing manufacturing processes, but can also be part of non‐destructive condition monitoring of bearings in field applications, where predictive reactive maintenance is crucial for availability of the plant.

Barkhausen noise signal recording may also be valuable for case studies related to microstructure changes of steel under operation conditions. Bearings are exposed in plenty of conditions to phenomena such as straying currents, subsequently straying magnetic fields. Hardly anything is known about how microstructure of bearing steel is susceptible to such conditions. This will be part of further studies.

Results given in the paper show that sudden bearing failure, according to formation of subsurface material property changes might be driven by activities of dislocations. Since those activities start with sequences of stress field‐induced formation of domains, later by formation of low‐angle subgrains, and at least phase transformation, recording of the Barkhausen signal would lead to real predictive condition monitoring in applications where a highly dynamic loading of the contact, even with low nominal contact pressure leads to sudden failure induced by white etching.

The objectives of this paper are to assess the sliding wear response of a zinc‐based alloy over a range of sliding speeds and pressures in oil‐lubricated condition with respect to a cast iron, to understand the role of different microconstituents in controlling the observed wear behaviour and to examine various operating material removal mechanisms.

Sliding wear tests have been carried out using a pin‐on‐disc machine in oil‐lubricated condition at different speeds and pressures. The wear response has been explained in terms of specific nature of various microconstituents of the specimen materials and substantiated through the characteristics of wear surfaces, subsurface regions and debris particles.

The wear rate increased with the sliding speed while load produced a mixed influence. Further, the friction coefficient and frictional heating were influenced by the test duration, load and speed in a mixed manner. Moreover, the zinc‐based alloy attained lower wear rate but higher friction coefficient than that of the cast iron while frictional heating followed a mixed trend.

The paper further establishes a zinc‐based alloy as a potential substitute material system to a well‐known cast iron in tribological applications and enables further understanding of the wear mechanisms.

The present paper assesses the sliding wear performance of a lighter zinc‐based alloy as an effective potential substitute material system to cast iron in tribological applications. An attempt has also been made to understand the role played by different microconstituents in controlling the wear behavior and substantiate the wear response through the characteristics of wear surfaces, subsurface regions and debris.

The purpose of this study is to develop a transient wheel–rail rolling contact model to primarily investigate the rail damage under wet condition when the train passes through the welded joints.

The impact force induced by welded joints is obtained through vehicle–track coupling dynamics. The normal and tangential wheel–rail contact pressures were solved by elastohydrodynamic lubrication (EHL) theory and simplified third-body layer theory, respectively. Then, the obtained tangential pressure and normal pressure were applied to the finite element model as moving loads, simulating cyclic loading. Finally, the shakedown map and critical plane method were used to predict rolling contact fatigue (RCF) and the initiation of fatigue cracks.

The results indicate that RCF will occur and fatigue cracks are more prone to appear on the subsurface of the rail, specifically around 2.7 mm below the rail surface in the vicinity of the welded joint and its heat-affected zone.

The cosimulation of numerical model and finite element model was implemented. The influence of surface roughness and fluids was considered. In this model, the normal and tangential wheel–rail contact pressure, the stress and strain and the rail fatigue cracks were obtained under a rail-welded joint excitation.

The purpose of this paper is to study if it is possible applying infrared thermography (both vibro and pulsed) to detect and localise material discontinuities as well as to find the place where the inclusion was introduced.

The experimental investigation is performed on samples manufactured during infusion process. The measurements were performed on three four-layered rectangular composite samples with discontinuities. The discontinuities introduced in the samples were as follow: all three samples between first and second layer counting form the bottom two optical fibres (OFs) were embedded and additionally: sample no. 1 – one of the OF was broken, sample no. 2 – the drop of water was introduced, and sample no. 3 – the little amount of dust was introduced.

For some discontinuities, the vibrothermography is excellent tool (placement of broken OF, drop of water), for same is not sufficient (healthy OFs or dust). For dust, the pulsed thermography seems to be the required tool. Different approaches (vibrothermography and pulsed thermography) for the same sample will confirm that for same defects vibrothermograpy is better and for some pulsed thermography – complex combination of different thermography approaches is needed to have complex response about sample structural condition.

The presented paper is an original research work. There are very limited literature papers applying both vibro and pulsed thermography for one problem. The assessment of different discontinuities (inclusions) and detailed analysis is presented.

This paper aims to reveal the mechanism for improving ductile machinability of 3C-silicon carbide (SiC) and associated cutting mechanism in stress-assisted nanometric cutting.

Molecular dynamics simulation of nano-cutting 3C-SiC is carried out in this paper. The following two scenarios are considered: normal nanometric cutting of 3C-SiC; and stress-assisted nanometric cutting of 3C-SiC for comparison. Chip formation, phase transformation, dislocation activities and shear strain during nanometric cutting are analyzed.

Negative rake angle can produce necessary hydrostatic stress to achieve ductile removal by the extrusion in ductile regime machining. In ductile-brittle transition, deformation mechanism of 3C-SiC is combination of plastic deformation dominated by dislocation activities and localization of shear deformation. When cutting depth is greater than 10 nm, material removal is mainly achieved by shear. Stress-assisted machining can lead to better quality of machined surface. However, there is a threshold for the applied stress to fully gain advantages offered by stress-assisted machining. Stress-assisted machining further enhances plastic deformation ability through the active dislocations’ movements.

This work describes a stress-assisted machining method for improving the surface quality, which could improve 3C-SiC ductile machining ability.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

Considers briefly the history of corrosion in metallic aircraft. Summarizes the different types of corrosion which affect aircraft and the methods for monitoring and measuring this corrosion. Presents an alternative approach called “controlled search peening” where the induced surface compressive stresses stretch and yield the outer material surface and induce visible blistering and flaking at the surface, indicating the existence of exfoliation corrosion.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.