M. J.

Hartnett
Supervisor of Analytical Engineering,
The Torrlngton Company,
The Analysis of Contact Stresses
Torrlngton, Conn.
Mem. ASME
in Rolling Element Bearings
A numerical solution is presented which can be used to analyze the complete range of fric-
tionless contact problems found in rolling element bearings. A three dimensional, linear
elastic solution to the problem is developed by combining the Boussinesq force-displace-
ment relationships for a half-space with a modified flexibility method. In this manner a
stable system of linear algebraic equations in terms of the unknown surface pressures is
formed, with no restrictions placed upon either contact symmetry or material connectiv-
ity. Several numerical examples of common but hitherto unsolved contact problems prev-
alent in rolling element bearing applications are also presented.

Introduction using a numerical algorithm aimed at minimizing the potential energy

The design and stress analysis of cylindrical rolling elements has
been one of the more troublesome areas of bearing technology. Indeed,
it has been shown [1] that raceway life is inversely proportional to
stress to the ninth power (or higher). With such a heavily weighted
relationship it is clear that small variations in stress can produce large
changes in bearing life. Once more, it will be shown herein that small
changes in the profile of a rolling element can significantly influence
contact stress. Thus it becomes obvious that one of the most impor-
tant parameters in determining the reliability of a rolling element
bearing is the relationship between roller profile and surface
stress.
H. Hertz [2] was one of the first to successfully analyze elastic body
contact problems. His results, which are limited to the case of con-
tacting ellipsoids, were considered by many to be a major development
in Applied Mechanics. More recently, others [10], [11] have tried to
extend Hertz's work to roller shapes commonly found in antifriction
bearings. This was achieved by dividing the roller into a series of discs,
and then using Hertz's results to predict surface stress. These at-
tempts did provide an approximate means for analyzing the stress
state in rolling element bearings. However, a major deficiency of this
approach was that the three-dimensional elasticity problem was not
solved. Consequently, an accurate appraisal of the surface stress could
not be made.
Within recent years, researchers have attempted to solve contact
problems for a more extensive range of body shapes than the ellipsoids
considered by Hertz. Conry and Seireg [3] solved simple problems
Contributed by the Lubrication Division of THE AMERICAN SOCIETY OP
MECHANICAL ENGINEERS and presented at the ASME-ASLE Joint Lubri-
cation Conference, Minneapolis, Minn., October 24-26,1978. Manuscript re-
ceived by the Lubrication Division April 28,1978, revised manuscript received
June 15,1978. Paper No. 78-Lub-2.
of the contact. Singh and Paul [4], [5] employed the flexibility method
of structural analysis [6] in conjunction with the Boussinesq rela-
tionships for force and displacement on a half-space to derive a set
of equations in terms of surface pressures/Unfortunately, the system
was ill-conditioned with respect to a system of linear algebraic
equations and an exact solution could be found for only a few special
cases. Most recently, Oh and Trachman [7] extended Conry's [3]
method to the contact of cylinders and were able to evaluate surface
stresses for some special cases of symmetry.
In the present work, a numerical technique of solution for three-
dimensional elastic body contact problems is developed. This is
achieved by combining the Boussinesq force-displacement relation-
ships and the flexibility method of structural analysis with a new
procedure which incorporates a local and remote influence concept.
Using this approach, stable systems of linear algebraic equations are
derived in terms of the unknown surface pressures. It should be noted
that although the analysis is limited to linear, isotropic elasticity, no
restrictions are placed upon either symmetry or material connectivity.
Thus the analysis of such problems as misaligned rollers or/and in-
terruptions in the contact area are possible.
Finally, several examples of typical roller-raceway contact situa-
tions, representing heretofore unsolved contact problems, are pre-
sented.
Derivation of the Integral Equation
The contact of two elastic bodies is shown in Fig. 1. Two coordinate
systems (xi, z\) and (x2, 22) are introduced with a common origin at
the first point of contact. If points M and N, which are representative
of any pair of opposing surface points, are brought into contact by a
mutually opposing force system, the rules which relate displacement
and separation there may be written as follows
w\ + Wi + Z\ + 22 = a (inside the region of contact) (1)
w\ +,u>2 + z\ + 22 > a (outside the region of contact) (2)

Journal of Lubrication Technology JANUARY 1979, VOL 101 / 105

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 CONTACT
Body 1 REGION

Body 1

Body 2

Fig. 1 Contact of elastic bodies

Body 2

Where w\ and w2 are displacements parallel to the z axes, z\ and Z2

Fig. 2 Contact of arbitrarily shaped surfaces
represent the initial separations, and a is the displacement of a point
in body 1 toward a second point in body 2, where both points are
chosen to be distantly removed from the contact region.
Of course the above relationships are typical for any cross section y
along the y i axis, where the direction of the latter is chosen to be or-
thogonal to the Xi - zi system. Hence equation (1) applies at every 2b
point in the contact domain. r ~l
2a 2 3
In addition to the above displacement requirements, we impose two
restrictions on force: 1) The integrated pressure distribution equals
the applied load. 2) Pressure values inside the contact zone must be
I * <> ®
positive. These restrictions may be expressed mathematically as

f P(x', y')dx', dy' = F (3) 1 e u 9

P(x>, y>) 3= 0 (4)

where F is the applied load.

Next, if the assumption is made that the force-displacement re- y
sponse for the bodies is equal to that of a half-space, i.e., 1 ' j» 0

, , l-";2 r P(x',y')dx',dy'
(i = 1,2), (5)
TTE,- JA{(x-x')z+(y-y'Wn 1 i > —X~ e ®

where K; and £,- are Poisson's ratio and the modulus of elasticity for
body i, respectivley, and A is the area over which the distributed 1 • 9 r
pressure acts, then equation (1) can be used to derive the following l_ . J
Fredholm integral equation
Fig. 3 Discretization of the contact region

where
s. P{x',y')dx', dy'
A |(x - * ' ) 2 + (y - y ) 2 ! 1 / 2
+ Z\ + Z2 : (6)

are the distributed pressure function P(x\ y'), the area of contact,
A, and the approach, a. The methods by which these parameters can
k=: •*v •n*
be determined are described below.

Equation (6) is the governing integral equation for three-dimen- The Flexibility Method of Solution
sional elastic body contact problems. The unknowns in this expression The integral equation (6) can be solved for the distributed pressure

^Nomenclature-

u>i = displacement normal to the plane for F = applied load fij - influence Coefficient (see equation
body;', (i = 1,2) k = defined in equation (6) (7))
z; = separation of body i. (i = 1, 2) a' = area of a segment
Ei = modulus of elasticity for body i (i = 1, n = pressure on segment;'
Wip = displacement normal to the plane for Pj
body t, segment p 2) a = approach of body 1 toward body 2
Zip = separation of body i, segment p vi = Poisson's ratio for body i (i = 1, 2) r - total number of segments into which the
P(x', y') = distributed pressure Dj = normal displacement of segment; blanket is divided

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 function P(x', y') by using the following numerical procedure. First, 3000
a plane rectangular region, hereafter referred to as the "blanket" re-
gion, is chosen larger than the expected contact area. This is indicated
2000 ui
by the dashed line shown in Fig. 2. Next, this area is divided into IX
rectangular segments, as shown in Fig. 3, and the pressure over each
segment is assumed to be constant. Subsequently, the integral in (6)
is evaluated over the rectangular region la X 26 shown in Fig. 3. After
performing these operations (6) can be written as a system of linear
algebraic equations in terms of the segment pressures Pj. Thus

E Pjfa • £>; i = 1, 2 , . . . , r (7)

where ^0^

A a - zi,. ~ z2i

Pj is the distributed pressure over segment j , while r is the total

number of segments, /y, the influence coefficient representing the
Fig. 4 Surface pressure distribution—Hertzian contact
deflection of segment i because of a uniform pressure over ;', be-
comes

fij = ny + a) + v (y + ay + (x + oy\
['k\(x n
My - a) + V ( y - a ) 2 + (x+ 6 ) 2 / HERTZ'S RESULTS
, , _ , „ /(x + b) + 2 X PRESENT METHOD
+ (y + a)ln (l(x + b) + V(y + a)2 + (x + b)\
\{x — b) + V(y + a) + (x V
2
/y•y - a) + V(y -a) + (5
+ (x - b) In
My + a) f+ V ( y + o ) 2 + ( j
2
lx-b) b) + V(y-a)
VW^ + (x-b)2
+ (y - a) In nx -
\{x(x +
2
+ b) + V(y - a ) + (x + b)
2
)} —
n
o.
2000-
S
In addition to displacement requirements, two restrictions are
placed on force. These are
1000-
a' Y. Pj = F (equilibrium requirement) (8)

Pj > 0 ;' = 1, 2,. . . , r (9)

where a' is the area of a single segment.
-1-
Equations (7), (8), (9) are now solved simultaneously for the contact .2 -r
.4 .6
area, approach, and surface stress. A stable method for their solution
Fig. 5 Comparison of transverse pressures
incorporating a local and remote influence concept is described fully
in reference [8].

Numerical Results
The technique of solution developed earlier can be applied to a wide 3000
range of frictionless contact problems. To demonstrate its application,
a number of studies of common but hitherto unsolved problems Z000 in
typically found in roller bearings are presented below. In all of the
following examples, a cylindrical roller is loaded by a 20,000 N force
onto a shaft. Both bodies are steel, the roller is 10 mm in diameter and
36 mm in length, and the shaft is 50 mm in diameter. The purpose of
these studies is to show the influence of roller profile and misalign-
ment on contact stress. (The term misalignment as it is used herein
refers to the angular displacement of the axis of the roller with respect
to the axis of the shaft in the plane defined by the applied load vector
and the shaft axis.)
First, consider the case of Hertzian contact where the roller is fully
crowned with a crown radius of 7500 mm. The resulting contact stress
distribution is shown in Fig. 4. In that illustration, stress intensity at
any point is represented as the height of the surface above the plane, <&-*
while the contact area is the light region under the dome. A compar-
ison of stresses at the center of contact, and transverse to the roller Fig. 6 Surface pressure distribution—fully crowned roller (.002 mm/mm
axis, with those of Hertz is shown in Fig. 5. Good agreement is seen misalignment)
to exist between the two methods.
Fig. 6 shows the stresses that result when this same fully crowned
roller is misaligned to .002 mm/mm (radians). From this illustration truncation point. However, the current numerical approach averages
it is seen that the contact area ends abruptly (is truncated) and the the pressure over a rectangular segment, hence singularities in the
stress increases at one end of the roller. Because the analysis is limited surface stress can only be represented in an approximate manner. In
to linear elasticity theory, yielding of the material is precluded and this case this representation is a sharp increase in stress at the roller's
therefore a singularity in the stress field would be expected at the edge.

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 10mm

Fig. 7 Surface pressure distribution—right circular cylinder (zero mis-

alianmentl
alignment)

Fig. 10 Typical roller profile design

Fig. 8 Surface pressure distribution—right circular cylinder (.001 mm/mm

misalignment)

., 3000
Fig. 11 Surface pressure distribution—partially crowned roller (zero mis-
alignment)

Fig. 9 Surface pressure distribution—right circular cylinder (.002 mm/mm <p.

misalignment) "^

Figs. 7, 8, and 9 show the stresses t h a t occur when a right circular

cylinder is misaligned to 0 mm/mm (radians), .001 mm/mm (radians),
<&->
and .002 mm/mm (radians), respectively. It is of interest to note, for
the case of zero misalignment, the predicted region of contact has an
Fig. 12 Surface pressure distribution—partially crowned roller (.001 mm/mm
hourglass shape, which is in agreement with the experimental work misalignment)

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 Fig. 13 Surface pressure distribution—partially crowned roller (.002 mm/mm
misalignment)
of others [9], Also, the maximum stress level at the roller's center is
in agreement with Hertz's prediction for line contact.
The rollers used in most cylindrical bearings are designed in such
a manner that the diameter at the ends is smaller than that at the
center. The purpose for this modification is to eliminate the problem
of edge stresses mentioned above. A typical means of specifying such
a design is shown in Fig. 10. Figs. 11,12, and 13 depict the stresses that
result when the roller detailed in Fig. 10 is used. A comparison of the
three cases of misalignment demonstrates the influence of this pa-
rameter on contact stress—and ultimately fatigue life.
As a bearing operates over a period of time the components collect
imperfections such as fatigue pits, dents, scratches, etc., which appear
as discontinuities in the surfaces. It is of interest to know how these
macroscopic surface irregularities affect the stress field. Fig. 14 shows
the influence that a 1 mm wide discontinuity will have on stress; the
roller profile is again a right circular cylinder. Obviously, surface
imperfections of this kind can elevate the stresses considerably and
consequently have a disastrous affect on fatigue life.
The solution for multiply connected surfaces discussed above is a
good example of the versatility of the mathematical technique de-
scribed earlier. Indeed, although several singularities in the surface
stress field were identified, and the surface defect was positioned in
an area which eliminated contact symmetry, no difficulties were en-
countered in the solution.
After reviewing the results described above it becomes apparent
that small changes in roller profile can produce large differences in
contact stress. Indeed, by comparing the results from the fully
crowned roller shown in Fig. 4, to those from the partial crown design
in Fig. 11, it is seen that a considerable reduction in stress magnitude
can be realized from small changes in roller shape. It is now possible
to extend the work presented herein to the design of roller shapes
which minimize contact stress.
Closure
Solutions of a broad range of hitherto unsolved, three dimensional,
frictionless contact problems in both simply and multiply connected
regions have been obtained using the methods discussed herein. These
methods, which were specifically constructed to avoid both the
problems of numerical instability and the restriction of contact
symmetry found in the work of others, offer for the first time a means
Journal of Lubrication Technology
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Fig. 14 Surface pressure distribution—multiply connected surface
of analyzing the realistic contact problems found in rolling element
bearings.
Several studies made to access the influence of roller shape and
misalignment on stress show that very substantial changes in the
contact stress field can result from small variations of these param-
eters. Finally, a comparison of the stresses resulting from Hertzian
contact with the predictions of Hertz indicates good agreement be-
tween the two methods of solution exists.
Acknowledgment
The author would like to thank Mr. E. Tharp for his assistance in
the preparation of the computer program and the figures. The author
would also like to thank The Torrington Company for permission to
publish this paper.
References
1 Lundberg, G., and Palmgren, A., "Dynamic Capacity of Rolling Bear-
ings," Acta Polytechnica Mechanical Engineering Series, Vol. 1, No. 3, Royal
Swedish Academy of Engineering Sciences, Stockholm, Sweden, 1947.
2 Hertz, H., Miscellaneous Papers—On the Contact of Elastic Solids,
translation by Jones, D. E., Macmillan and Co., Ltd., London, 1896.
3 Conry, T. F., and Seireg, A., "A Mathematical Programming Method
for Design of Elastic Bodies in Contact," ASME Journal of Applied Mechanics,
June 1971.
4 Singh, K. P., and Paul, B., "Numerical Solution of Non-Hertzian Elastic
Contact Problems," ASME Journal of Applied Mechanics, Vol. 41, No. 2, June
1974.
5 Singh, K. P. and Paul, B., "A Method for Solving Ill-Posed Integral
Equations of the First Kind," Computer Methods in Applied Mechanics and
Engineering, Vol. 2,1973.
6 Little, R. W., Elasticity, Prentice-Hall Inc., Englewood Cliffs, N. J.,
1973.
7 Oh, K. P.; and Trachman, E. G., "A Numerical Procedure for Designing
Profiled Rolling Elements," ASME JOURNAL OP LUBRICATION TECHNOLOGY,
Vol. 98, Oct. 1976.
8 Hartnett, M. J., "A General Numerical Solution for Elastic Body Contact
Problems," to be published.
9 Goodelle, R. A., Dener, W. J., and Root, L. E., "A Practical Method for
Determining Contact Stresses in Elastically Loaded Line Contacts," ASLE
Transactions, Vol. 13,1970, pp. 269-277.
10 Harris, T. A., "The Effect of Misalignment on the Fatigue Life of Cy-
lindrical Roller Bearings Having Crowned Rolling Members," ASME JOURNAL
OF LUBRICATION TECHNOLOGY, Vol. 91, No. Apr. 1969, pp. 294-300.
11 Liu, J. Y., "The Effect of Misalignment on the Life of High Speed Cy-
lindrical Roller Bearings," ASME JOURNAL OP LUBRICATION TECHNOLOGY,
Vol. 93, No. 1, Jan. 1971, pp. 60-68.
JANUARY 1979, VOL 101 / 109