Simplified 3D Finite Element Simulations of Manufacturing Process-Induced Distortions in Large Bearing Rings

This article describes a simplified 3D thermo-mechanical coupled finite element modeling approach developed to simulate geometric distortions in large bearing rings induced by manufacturing processes such as machining and heat treatment. Excessive distortions in the product may require increased stock conditions and extra machining steps and time, and therefore increase the material and manufacturing costs. The present modeling approach is focused on studying the geometric distortions induced by macro-scale residual stresses. To prevent the machining and material characteristics in the localized cut area from becoming dominating factors that make modeling challengingly complex and the simulation extremely expensive, simplifications and assumptions in the models are made. This simulation has been applied to several large bearing rings in production, and the distortion patterns correlate well with the actual products. The simulation results are also used to support decision-making in the selection of the various manufacturing processes.