Impact of journal bending on the failure of axle bearings in railroad passenger cars

This research presents a systematic methodology to analyze the failure mechanism of cylindrical roller bearings of railroad passenger cars. Initially, a finite element model is developed to calculate the journal bending and internal contact load distribution, considering multi-interfacial contact parameters. Then, non-Hertzian contact theory is applied to prove the rollers’ abnormal contact behaviors, including load-distribution and displacement. Subsequently, a grease lubrication model is developed to study bearings lubrication under different operating conditions. Additionally, an exact service life model from ISO standards is used to evaluate the effect of journal bending. Finally, a system failure mechanism can be summarized and validated in the experiments, also helpful for axle box system bearings design and assembly.

[1]  Takehiko Kigawa,et al.  Effects of Load Distribution on Life of Radial Roller Bearings , 2012 .

[2]  W. J. Derner,et al.  Determination of Static Load Distributions from Elastic Contacts in Rolling Element Bearings , 1971 .

[3]  Tae-Jo Park,et al.  Elastohydrodynamic lubrication of a finite line contact , 1998 .

[4]  J. Y. Liu,et al.  Analysis of Tapered Roller Bearings Considering High Speed and Combined Loading , 1976 .

[5]  J.L.A. Ferreira,et al.  An investigation of rail bearing reliability under real conditions of use , 2003 .

[6]  Edward L. Wilson,et al.  Numerical methods in finite element analysis , 1976 .

[7]  Erwin V. Zaretsky,et al.  Effect Of Roller Profile On Cylindrical Roller Bearing Life Prediction—Part II Comparison of Roller Profiles , 2000 .

[8]  Daniel Nelias,et al.  Analysis of Double-Row Tapered Roller Bearings, Part I - Model , 2003 .

[9]  J. H. Rumbarger,et al.  The Effect of Misalignment on the Fatigue Life of Cylindrical Roller Bearings Having Crowned Rolling Members , 2015 .

[10]  H. Rahnejat,et al.  Aligned and misaligned contacts of rollers to races in elastohydrodynamic finite line conjunctions , 2002 .

[11]  J. Greenwood,et al.  Elastohydrodynamic Lubrication , 2020 .

[12]  Philippa Cann,et al.  Starved Grease Lubrication of Rolling Contacts , 1999 .

[13]  Patric Waara,et al.  Additive influence on wear and friction performance of environmentally adapted lubricants , 2001 .

[14]  A. Harnoy,et al.  Bearing Design in Machinery: Engineering Tribology and Lubrication , 2002 .

[15]  T. A. Harris,et al.  Essential Concepts of Bearing Technology , 2006 .

[16]  Bogdan Warda,et al.  Effect of ring misalignment on the fatigue life of the radial cylindrical roller bearing , 2016 .

[17]  Luc Houpert.  An engineering approach to non-Hertzian contact elasticity: Part II , 2001 .

[18]  Michael Rygaard Hansen,et al.  A New Quasi-Static Cylindrical Roller Bearing Model to Accurately Consider Non-Hertzian Contact Pressure in Time Domain Simulations , 2012 .

[19]  T. A. Harris,et al.  Life ratings for ball and roller bearings , 2001 .

[20]  H. Rahnejat,et al.  Design of profiled taper roller bearings , 1979 .

[21]  Xi Zhang,et al.  Mechanical analysis of spherical roller bearings due to misalignments between inner and outer rings , 2017 .

[22]  R. Gohar,et al.  Roller bearings under radial and eccentric loads , 1981 .

[23]  Guillermo E. Morales-Espejel,et al.  Film thickness in grease lubricated slow rotating rolling bearings , 2014 .

[24]  Seong-Wook Hong,et al.  Rolling-element bearing modeling: A review , 2016 .

[25]  Erwin V. Zaretsky,et al.  Effect Of Roller Profile On Cylindrical Roller Bearing Life Prediction—Part I: Comparison of Bearing Life Theories , 2001 .

[26]  P. Lugt.  A Review on Grease Lubrication in Rolling Bearings , 2009 .

[27]  Viktor Gerdun,et al.  Failures of bearings and axles in railway freight wagons , 2007 .

[28]  Haoliang Xu,et al.  Mechanical behavior of double-row tapered roller bearing under combined external loads and angular misalignment , 2018, International Journal of Mechanical Sciences.

[29]  Antonius Lubrecht,et al.  An analysis of the mechanisms of grease lubrication in rolling element bearings , 1999 .

[30]  T. A. Harris,et al.  Advanced concepts of bearing technology , 2007 .

[31]  L. Yuwei,et al.  A novel method to model effects of natural defect on roller bearing , 2018, Tribology International.

[32]  A. Cameron,et al.  Elastohydrodynamic Lubrication of a Line Contact , 1974 .

[33]  Ping Huang,et al.  Numerical Calculation of Elastohydrodynamic Lubrication: Methods and Programs , 2015 .

[34]  R. Zhou,et al.  Surface topography and fatigue life of rolling contact bearings , 1993 .

[35]  W. J. Derner,et al.  A Practical Method for Determining Contact Stresses in Elastically Loaded Line Contacts , 1970 .