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 384 J. S. CLARK J.

Table 1 Tabulation of the failure experience

Bear- Stress
jug Stress Crack Crack intensity
nurn- level depth length factor Type
ber Material (ksi) (in.) (in.) K1 bearing Description Result
1 AISI M50 37 0.11 0.40 19.2 thrust 0. Race 7 cases -slight spalling (4) fracture
-no spalling (3) fracture
2 ATSI M50 30 0. 140 0.33 15.0 thrust 0. Race heavy spalling -outer race
restrained by housing fracture
3 ¯
AISI 52100 26.5 0.174 0.532 16.7 roller I. Race no salling fracture
4 AISI M50 22.5 0.057 0.21 8.4 roller I. Race slight spalling fracture
5 AISI MoO is 0.090 0.320 7.0 thrust 0. Race 2 cases -slight spalling no fracture
6 AISI 52100 26.5 0.14 0.350 13.87 roller I. Race no spalling no fracture
7 AISI M50 27.0 0.110 0.320 13.0 thrust I. Race 3 -in. spall no fracture
8 AISI MoO 27.0 0.120 0.330 13.4 thrust I. Race 2 -in. spall no fracture
9 AISI MOO 24.5 0.170 0.505 14.5 thrust I. Race no spalling no fracture

point is reached where the stress intensity factor is large

enough to produce rapid fracture and is said to reach its
critical value. Figure lb is another schematic represen-
tation showing the effects of hoop stress. The time scale
represents operating time measured from the initiation of
a subsurface defect. At low stress levels, spalls form and if
not detected by the aforementioned methods, the vibra-
tion or impact damage will eventually lead to cage failure.
This is normally the final stage of a bearing failure. At in-
creased stress levels, rapid fracture occurs prior to signifi-
cant spalling and consequently no warning is given. It is
very likely that time to spall is decreased by increasing
the stress level; but for the purpose of this diagram it is
assumed independent of hoop stress.
Fig. 2 Bearing no. 1 outer race cross section and stress dit
Critical tribution. Ball diameter = 1.625 in. Bearing pitch di
ameter 10.827 in.

z Outer Race Stress Levels

Before discussing the aspects of rapid fracture, it woul
be beneficial to understand the stress state of both inne
and outer races. If the outer race is directly mounted
C,
the bearing housing or frame (bolted flange bearing), thi
Threshold race essentially becomes an integral part of the structur
arid, as such, will reflect bending load and stress level
a' similar to those in the structure. Figure 2 shows a sketc]
of the outer race of a bearing bolted directly to th
frame in this manner. This race has been analyzed b
means of a finite -element computer program for loads re
Log Stress Intensity Range ii sulting from the unbalanced rotor thrust load. In thi
a) Crack Growth Rate Versus Stress Intensity Range.
analysis the load was introduced as a linear axisymmetri
load concentrated at the center of the contact zone ant
operating in the direction of the outer race contact angle
Isostress stress lines are shown for the load levels used ii
the rig for the fatigue testing. The stress predicted agree
: with the measured stress within 5% in the circumferentia
(hoop) direction. This is the stress of primary interest. At
additional alternating stress component of ±5% due ti
ball passing loads was measured, which could not be de
Fractsre Mwte of
termined from the computer analysis. The bearing rae
shown in Fig. 3 is from a more conventional bearing, be
it is a lightweight configuration, mounted to a lightweighi
housing. The same computer analysis was conducted or
this race and the results are shown in Fig. 3.

Hoog Stress Level in Races

-

hi Time ot Failure Progression.

Fig. 1 Schematic representation of crack growth rate vs
stress intensity range and representation of time of Fig. 3 Bearing no. 2 outer race cross section and stress dii.
failure propagation. tribution. Ball diameter = 0.875 in.
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386 J. S. CLARK J. AIRCRAFT
APE

1t

se i S
0\
Is

10 resents2caSeSH/ K1 40.0
6 2 K 20.0
KI L 21n 2 (aIQ) 16.0
K1
K1 in ksi 10.0
K1

V ConIete Race Fracture

0 Race Cracks Deveiqied But Has Not Fractured

Cl 1
Fig. 7 Inner race crack of bearing operated at 27,000 psi tan-
aIQ, Inches gential stress giving a K1 -
13.4 ksi (in.)1 2 bearing
Fig. 5 Graphical solution for stress intensity factors. No.8, Table 1.

growth arrested, or was the bearing removed from service the initiation of fatigue fractures. The orthogonal shear
prior to the crack reaching a critical size? To answer this stress which occurs on a plane parallel to the surface, has
question, the exact mode of crack propagation must be an absolute value equal to about 25% of the maximum
understood. The shape and the appearance of the cracks surface compressive stress, and is fully reversed as a roll-
suggest that the rolling element Hertzian stress field when ing element passes. This was the original theory on which
superimposed over the hoop tensile stress provides the bearing life was predicted, and many investigators still
principal crack propagation stress. The surface length of adhere to this premise. The maximum unidirectional
the cracks are usually proportional to the width of the shear stress occurs at a depth slightly greater than the
rolling element contact zone, although some reached criti- orthogonal shear stress and has a value of about 32% of
cal depths before reaching this length. The crack depth, the maximum surface compressive stress. The maximum
however, has not been uniquely related to any characteris- unidirectional shear stress can be expressed as l/2(u5. -

tic of the Hertzian stress field. o). Since the hoop stress is in the same plane as o.,, the
hoop stress increases the value of the shear stress by 1/2
of the applied hoop stress. The Hertzian and shear stress
Crack Initiation analysis follows the development given in Ref. 3. Without
In our early investigations of fractured races, we consid- going into the details, which are given in Ref. 4, the
ered that the cracks initiated from fatigue spalls. How- orthogonal shear stress is not affected by a uniform hoop
ever, later evidence indicated that the cracks were very stress, and thus the unidirectional maximum shear stress
likely the initiation sites for spalling. As can be seen from appears to be the only influence on crack initiation.
Table 1, a significant number of incidents have been ob-
served where cracks were present without spalling evi- Crack Propagation
dence. In all cases where spalling is present, the crack ap-
pears near the leading edge of the spalled area indicating As stated above the Hertzian stress field superimposed
the crack appeared first and initiated the spalling of the over a tensile stress field is assumed to provide the impe-
raceway. tus for crack propagation. First, consider a uniform stress
In the subsurface fatigue spalling mode, two different field with some microscopic flaw below the surface. A roll-
shear stresses have historically been cited as the cause for ing element passing over this flaw introduces a three-dim-
ensional stress array with the three principal stresses in
compression. In bearings of normal geometry, one of the
principal stresses (o-) falls in the plane of the tensile stress
field. Therefore in the zone beneath the contact area, the
stress patterns in the a plane (hoop) will be
o -

o + o when under rolling element load

0 = o, between rolling elements
Since o, will be highly compressive, we have an alter.
nating stress at element passing frequency from very high
compression, to a tensile value equal to the applied hoop
stress. For current engines this frequency will accumulate
between 106 and 10 per hour of operation.
Second, the Hertzian stress pattern decays with depth
into the race. It would be expected that if the crack pro-
pagated out of the Hertzian stress field, the stress intensi-
ty factor would drop below the threshold value and the
crack would "arrest." To this point it has been assumed
Fig. 6 Matching fracture surfaces of the outer race of the No. that the crack does not significantly alter the Hertzian
2 bearing showing initiation from the bottom of a spall stress distribution. While this assumption is not com-
(arrow 1) and propagation by fatigue (arrow 2). pletely true, it will not likely cause a large variation until
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