A new model for spall-rolling-element interaction

Evaluation of the spall size of a radially loaded rolling-element bearing is required for the assessment of the bearing damage severity and estimation of its remaining useful life. A new multi-body, nonlinear dynamic model of the interaction between the rolling-element and a spalled outer race is presented. The study focuses on the physics of rolling-element contact in a broader range of spall sizes than has been investigated to date, with intermittent contact between rolling-element and the outer race, which is a relevant defect size for diagnostics and prognosticsquery. The analysis is performed in several time intervals according to periods of rolling-element/race contact and periods when the rolling-element is not connected with the outer race. An explicit expression of the spall size as function of the time-to-impact has been developed by considering radial load, shaft speed, and gravity. The expression of the spall size was used in a sensitivity study of the effect of parameters such as geometry and radial load. The results obtained from the new model are in good agreement with a well-established general bearing model. The acceleration of the outer ring during the rolling-element/spall interaction with intermittent rolling-element race connection is a novel contribution, which allows verification of the model from direct observations using vibration sensors mounted on the structure