Residual stress engineering for highly loaded rolling-sliding contacts: Finding the sweet spot for maximum durability by hard turning and deep rolling

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dc.article.number119027
dc.catalogadoraba
dc.contributor.authorDechant, Simon
dc.contributor.authorNordmeyer, Henke
dc.contributor.authorPape, Florian
dc.contributor.authorBreidenstein, Bernd
dc.contributor.authorPoll, Gerhard
dc.contributor.authorMarian, Max
dc.date.accessioned2025-08-29T15:48:00Z
dc.date.available2025-08-29T15:48:00Z
dc.date.issued2025
dc.description.abstractThe durability of highly loaded rolling-sliding contacts, such as those in rolling bearings, is critically determined by subsurface microstructure and residual stresses engineered during manufacturing. This study systematically investigates the interplay between thermal and mechanical process parameters during deep rolling, using bearing inner rings as a representative example, to identify optimal conditions for maximizing fatigue life. By isolating the effects of process temperature (20–400 °C) and deep rolling pressure (200–400 bar), we demonstrate that moderate mechanical loading at room temperature can more than double bearing life through beneficial compressive residual stresses, while excessive pressure or thermal input above 200 °C sharply reduces durability. Notably, we reveal a previously unrecognized mechanism of hidden thermal degradation that limits lifetime, even when conventional hardness or microstructural metrics remain unchanged. These results define a process window for residual stress engineering in bearing steels and provide generic guidelines for hybrid manufacturing of rolling-sliding components subjected to severe tribological loading. The findings advance fundamental understanding of process-induced fatigue mechanisms and offer a framework for the rational design of subsurface-optimized, durable, and sustainable machine elements.
dc.description.funderThe German Research Foundation (DFG)/ “Functionalized subsurface for load-oriented fatigue behavior of hardened components”; Folio: BR 2967/28–1, PO-675/22–1 and PA-3279/8–1
dc.format.extent20 páginas
dc.fuente.origenORCID
dc.identifier.doi10.1016/j.jmatprotec.2025.119027
dc.identifier.eissn1873-4774
dc.identifier.issn0924-0136
dc.identifier.scopusid105013569037
dc.identifier.urihttps://doi.org/10.1016/j.jmatprotec.2025.119027
dc.identifier.urihttps://repositorio.uc.cl/handle/11534/105375
dc.information.autorucEscuela de Ingeniería; Marian, Max; 0000-0003-2045-6649; 1247429
dc.issue.numero13
dc.language.isoen
dc.nota.accesocontenido completo
dc.revistaJournal of Materials Processing Technology
dc.rightsacceso abierto
dc.rights.licenseAttribution 4.0 International
dc.rights.urihttps://creativecommons.org/licenses/by/4.0/
dc.subjectHard turning
dc.subjectDeep rolling
dc.subjectSubsurface
dc.subjectMachine elements
dc.subjectRolling contact fatigue
dc.subjectFatigue life
dc.subject.ddc620
dc.subject.deweyIngenieríaes_ES
dc.titleResidual stress engineering for highly loaded rolling-sliding contacts: Finding the sweet spot for maximum durability by hard turning and deep rolling
dc.typeartículo
sipa.codpersvinculados1247429
sipa.indexSCOPUS
sipa.trazabilidadORCID;2025-08-22
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