Multiple frequency ultrasonic detection of subsurface near-race inclusions for improved fatigue life performance

Ping Hu, Joseph A Turner, Constantine Tarawneh, Brent Wilson, Allen J. Fuller

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

1 Citation (Scopus)

Abstract

The importance of steel cleanliness for the performance of tapered roller bearings has been clearly established and has led to on-going improvements in steel production methods. The presence of non-metallic impurities within the steel can result in hard/brittle inclusions that may serve as initiation sites for damage due to sub-surface rolling contact fatigue (RCF) if the inclusions lie within the near-race of the bearing components due to the high mechanical stress present. Current inspection standards define steel cleanliness with respect to bulk inclusion morphology, which limits inspection to a small area that may or may not be representative of the entire steel heat. In this presentation, ultrasonic surface wave methods are described for detecting subsurface inclusions directly on finished bearing inner and outer rings. We expand on our previous work to exploit the different inspection depths that can be achieved with different measurement frequencies. The impact of the different inspection depths is quantified through simulated service life testing with heavy axle loading conditions. For this study, bearing components were first subjected to ultrasonic surface wave testing at three different frequencies to identify near-race inclusions. The simulated service life testing was then used to assess the onset and propagation of RCF failure. RCF spall initiations correlated highly with the positions identified by the ultrasonic inspections suggesting that this approach has a predictive potential. However, additional research is needed to establish the specific criteria needed for such predictions with respect to the inclusion location along the race, the depth from the race surface, the inclusion morphology and the inclusion mechanical properties. This work is anticipated to improve the understanding of RCF damage initiation which will lead a higher level of safety for railroad operations.

Original languageEnglish (US)
Title of host publication2015 Joint Rail Conference, JRC 2015
PublisherAmerican Society of Mechanical Engineers
ISBN (Print)9780791856451
DOIs
StatePublished - 2015
EventASME/ASCE/IEEE 2015 Joint Rail Conference, JRC 2015 - San Jose, United States
Duration: Mar 23 2015Mar 26 2015

Other

OtherASME/ASCE/IEEE 2015 Joint Rail Conference, JRC 2015
CountryUnited States
CitySan Jose
Period3/23/153/26/15

Fingerprint

fatigue
Ultrasonics
inclusion
Fatigue of materials
Bearings (structural)
Inspection
performance
Steel
contact
Ultrasonic waves
Service life
Surface waves
Testing
damages
Tapered roller bearings
production method
Railroads
Axles
Fatigue damage
railroad

ASJC Scopus subject areas

  • Transportation
  • Mechanical Engineering

Cite this

Hu, P., Turner, J. A., Tarawneh, C., Wilson, B., & Fuller, A. J. (2015). Multiple frequency ultrasonic detection of subsurface near-race inclusions for improved fatigue life performance. In 2015 Joint Rail Conference, JRC 2015 American Society of Mechanical Engineers. https://doi.org/10.1115/JRC2015-5785

Multiple frequency ultrasonic detection of subsurface near-race inclusions for improved fatigue life performance. / Hu, Ping; Turner, Joseph A; Tarawneh, Constantine; Wilson, Brent; Fuller, Allen J.

2015 Joint Rail Conference, JRC 2015. American Society of Mechanical Engineers, 2015.

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

Hu, P, Turner, JA, Tarawneh, C, Wilson, B & Fuller, AJ 2015, Multiple frequency ultrasonic detection of subsurface near-race inclusions for improved fatigue life performance. in 2015 Joint Rail Conference, JRC 2015. American Society of Mechanical Engineers, ASME/ASCE/IEEE 2015 Joint Rail Conference, JRC 2015, San Jose, United States, 3/23/15. https://doi.org/10.1115/JRC2015-5785
Hu P, Turner JA, Tarawneh C, Wilson B, Fuller AJ. Multiple frequency ultrasonic detection of subsurface near-race inclusions for improved fatigue life performance. In 2015 Joint Rail Conference, JRC 2015. American Society of Mechanical Engineers. 2015 https://doi.org/10.1115/JRC2015-5785
Hu, Ping ; Turner, Joseph A ; Tarawneh, Constantine ; Wilson, Brent ; Fuller, Allen J. / Multiple frequency ultrasonic detection of subsurface near-race inclusions for improved fatigue life performance. 2015 Joint Rail Conference, JRC 2015. American Society of Mechanical Engineers, 2015.
@inproceedings{19691a8f3364462cb1843a51e6e414c6,
title = "Multiple frequency ultrasonic detection of subsurface near-race inclusions for improved fatigue life performance",
abstract = "The importance of steel cleanliness for the performance of tapered roller bearings has been clearly established and has led to on-going improvements in steel production methods. The presence of non-metallic impurities within the steel can result in hard/brittle inclusions that may serve as initiation sites for damage due to sub-surface rolling contact fatigue (RCF) if the inclusions lie within the near-race of the bearing components due to the high mechanical stress present. Current inspection standards define steel cleanliness with respect to bulk inclusion morphology, which limits inspection to a small area that may or may not be representative of the entire steel heat. In this presentation, ultrasonic surface wave methods are described for detecting subsurface inclusions directly on finished bearing inner and outer rings. We expand on our previous work to exploit the different inspection depths that can be achieved with different measurement frequencies. The impact of the different inspection depths is quantified through simulated service life testing with heavy axle loading conditions. For this study, bearing components were first subjected to ultrasonic surface wave testing at three different frequencies to identify near-race inclusions. The simulated service life testing was then used to assess the onset and propagation of RCF failure. RCF spall initiations correlated highly with the positions identified by the ultrasonic inspections suggesting that this approach has a predictive potential. However, additional research is needed to establish the specific criteria needed for such predictions with respect to the inclusion location along the race, the depth from the race surface, the inclusion morphology and the inclusion mechanical properties. This work is anticipated to improve the understanding of RCF damage initiation which will lead a higher level of safety for railroad operations.",
author = "Ping Hu and Turner, {Joseph A} and Constantine Tarawneh and Brent Wilson and Fuller, {Allen J.}",
year = "2015",
doi = "10.1115/JRC2015-5785",
language = "English (US)",
isbn = "9780791856451",
booktitle = "2015 Joint Rail Conference, JRC 2015",
publisher = "American Society of Mechanical Engineers",

}

TY - GEN

T1 - Multiple frequency ultrasonic detection of subsurface near-race inclusions for improved fatigue life performance

AU - Hu, Ping

AU - Turner, Joseph A

AU - Tarawneh, Constantine

AU - Wilson, Brent

AU - Fuller, Allen J.

PY - 2015

Y1 - 2015

N2 - The importance of steel cleanliness for the performance of tapered roller bearings has been clearly established and has led to on-going improvements in steel production methods. The presence of non-metallic impurities within the steel can result in hard/brittle inclusions that may serve as initiation sites for damage due to sub-surface rolling contact fatigue (RCF) if the inclusions lie within the near-race of the bearing components due to the high mechanical stress present. Current inspection standards define steel cleanliness with respect to bulk inclusion morphology, which limits inspection to a small area that may or may not be representative of the entire steel heat. In this presentation, ultrasonic surface wave methods are described for detecting subsurface inclusions directly on finished bearing inner and outer rings. We expand on our previous work to exploit the different inspection depths that can be achieved with different measurement frequencies. The impact of the different inspection depths is quantified through simulated service life testing with heavy axle loading conditions. For this study, bearing components were first subjected to ultrasonic surface wave testing at three different frequencies to identify near-race inclusions. The simulated service life testing was then used to assess the onset and propagation of RCF failure. RCF spall initiations correlated highly with the positions identified by the ultrasonic inspections suggesting that this approach has a predictive potential. However, additional research is needed to establish the specific criteria needed for such predictions with respect to the inclusion location along the race, the depth from the race surface, the inclusion morphology and the inclusion mechanical properties. This work is anticipated to improve the understanding of RCF damage initiation which will lead a higher level of safety for railroad operations.

AB - The importance of steel cleanliness for the performance of tapered roller bearings has been clearly established and has led to on-going improvements in steel production methods. The presence of non-metallic impurities within the steel can result in hard/brittle inclusions that may serve as initiation sites for damage due to sub-surface rolling contact fatigue (RCF) if the inclusions lie within the near-race of the bearing components due to the high mechanical stress present. Current inspection standards define steel cleanliness with respect to bulk inclusion morphology, which limits inspection to a small area that may or may not be representative of the entire steel heat. In this presentation, ultrasonic surface wave methods are described for detecting subsurface inclusions directly on finished bearing inner and outer rings. We expand on our previous work to exploit the different inspection depths that can be achieved with different measurement frequencies. The impact of the different inspection depths is quantified through simulated service life testing with heavy axle loading conditions. For this study, bearing components were first subjected to ultrasonic surface wave testing at three different frequencies to identify near-race inclusions. The simulated service life testing was then used to assess the onset and propagation of RCF failure. RCF spall initiations correlated highly with the positions identified by the ultrasonic inspections suggesting that this approach has a predictive potential. However, additional research is needed to establish the specific criteria needed for such predictions with respect to the inclusion location along the race, the depth from the race surface, the inclusion morphology and the inclusion mechanical properties. This work is anticipated to improve the understanding of RCF damage initiation which will lead a higher level of safety for railroad operations.

UR - http://www.scopus.com/inward/record.url?scp=84936816886&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=84936816886&partnerID=8YFLogxK

U2 - 10.1115/JRC2015-5785

DO - 10.1115/JRC2015-5785

M3 - Conference contribution

SN - 9780791856451

BT - 2015 Joint Rail Conference, JRC 2015

PB - American Society of Mechanical Engineers

ER -