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Residual Stress Measurement of Full-Scale Jet-Engine Bearing Elements Using the Contour Method

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Residual Stress, Thermomechanics & Infrared Imaging, Hybrid Techniques and Inverse Problems, Volume 9

Abstract

Compressive residual stresses provide a well-known advantage to the fatigue life of bearing materials under rolling contact fatigue (RCF), but the stresses change under fatigue loading and may later contribute to failures. Previous measurements of the depth-wise distribution of residual stresses in post-fatigue bearings with X-rays involved the time consuming process of etching to determine subsurface stresses and only in limited locations. By contrast, the contour method determines the 2D residual stress map over a full cross section. The method involves the sectioning of the part using Electrical Discharge Machining, measuring the out of plane displacements of the exposed cross section, and using the afforded field as boundary conditions on a finite element model of the component to back calculate the causative residual stress. For this investigation, the residual hoop stresses in the split inner rings of the main shaft bearing assembly of an aircraft jet engine was mapped using the contour method. Prior to measurement, the full-scale bearing made of hardened AISI M50 was subjected to RCF during engine operation. In this talk, the unique challenges of the particular measurements are discussed. The tested bearings showed effectively no residual stresses induced by the RCF, probably because they were conservatively removed from service prior to sufficient cyclic loading. A more highly loaded bearing will be measured in future work.

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Acknowledgements

The authors would like to thank Adrian DeWald and Hill Engineering, LLC for the expert experimental work, both EDM cutting and surface scanning, for the measurements reported in this paper. Gratitude is also expressed to Lewis Rosado, Kevin Thompson, Hitesh Trivedi and their colleagues in the Mechanical Systems Branch of the Air Force Research Laboratory for providing the bearing and their valuable support of the project thus far.

Los Alamos National Laboratory, an affirmative action/equal opportunity employer, is operated by the Los Alamos National Security, LLC for the National Nuclear Security Administration of the U.S. Department of Energy under contract DE-AC52-06NA25396. By approving this article, the publisher recognizes that the U.S. Government retains nonexclusive, royalty-free license to publish or reproduce the published form of this contribution, or to allow others to do so, for U.S. Government purposes. Los Alamos National Laboratory requests that the publisher identify this article as work performed under the auspices of the U.S. Department of Energy. Los Alamos National Laboratory strongly supports academic freedom and a researcher’s right to publish; as an institution, however, the Laboratory does not endorse the viewpoint of a publication or guarantee its technical correctness.

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Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, University of Florida, Gainesville, FL, USA

    Daulton D. Isaac & Nagaraj Arakere

  2. Los Alamos National Laboratory, Los Alamos, NM, USA

    Daulton D. Isaac & Michael B. Prime

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  1. Daulton D. Isaac
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  2. Michael B. Prime
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  3. Nagaraj Arakere
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Correspondence to Michael B. Prime .

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  1. University of Southampton , Southampton, United Kingdom

    Simon Quinn

  2. Clermont AuvergneSigma Clermont, Institut Pascal, Clermont-Ferrand, France

    Xavier Balandraud

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Isaac, D.D., Prime, M.B., Arakere, N. (2017). Residual Stress Measurement of Full-Scale Jet-Engine Bearing Elements Using the Contour Method. In: Quinn, S., Balandraud, X. (eds) Residual Stress, Thermomechanics & Infrared Imaging, Hybrid Techniques and Inverse Problems, Volume 9. Conference Proceedings of the Society for Experimental Mechanics Series. Springer, Cham. https://doi.org/10.1007/978-3-319-42255-8_10

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