Hierarchical microstructure based crystal plasticity-continuum damage mechanics approach: Model development and validation of rolling contact fatigue behavior

A microstructure-based integrated crystal plasticity (CP) and continuum damage mechanics (CDM) model is proposed for simulating rolling contact fatigue (RCF). The damage process through the formation of the dark etching region (DER) under RCF is implemented, i.e., a DER-CPCDM approach. A hierarchical microstructure of lath martensite is virtually generated by the Voronoi tessellation technique and the theoretical Kurdjumov-Sachs orientation relationship between the prior austenite grains and substructures of lath martensite. Moreover, the micro-plasticity calculated from the polycrystal finite element is coupled with dislocation-assisted carbon migration theory, which enables accurate predictions of the deformation inhomogeneity and the DER/damage distribution at the subsurface. The RCF lifespan of AISI 52100 bearing steel can be predicted within reasonable accuracy, in terms of Weibull probability analysis, when the jump-in-cycles approach is implemented in the DER-CPCDM model. The predicted representative lifespan of the Weibull plot is within an error of 13% when compared with reported experimental data. Process factors, including contact pressure, rotational speed, temperature, carbon concentration, and grain size, are analyzed in a numerical sensitivity study, which can be utilized for potential optimization of the RCF process for improving the performance of materials and parts.