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This paper investigates and describes the fatigue mechanism in bearings for automotive alternators. We have analyzed the peculiar microstructure change found in these bearings. We have also investigated the effects of grease properties, vibration, and elastic deformation of the outer ring. By analyzing the bearings used in actual engine tests and grease tests for fundamental characteristics, we were able to conclude that the fatigue causes were two-fold: load amplification caused by resonance and high bending stresses caused by elastic deformation of the outer ring. As a practical result, we were able to adopt a newly formulated grease which decreased the vibration level and the peak rolling element load. This led to the development of longer life bearings for automotive alternators.

A computer program package named “BRAIN” has been developed to simulate the kinematics and the performance of rolling bearings under various running conditions. The calculation time necessary for running BRAIN software on a PC is very short. Various outputs can be obtained using BRAIN such as running torque, roller skew angle, roller slippage, and PV values. Several experiments have been conducted to confirm the validity of BRAIN. The running torque of a four point contact ball bearing and that of a tapered roller bearing were measured. In addition, the skew of the roller in a needle bearing was measured. These experimental results were compared with the calculation results. The experiments and the calculations showed good agreement.

The conventional rolling bearing life equation (1), which is based on the theory of Lundberg and Palmgren, has a problem in that it does not match the actual bearing life in all operating conditions. For instance, while the actual life of a bearing under clean lubrication is 20 times longer than the calculated life, actual life under contaminated lubrication is as low as one-tenth of the calculated life. To solve this problem, the following life equation (Eq. 1: Advanced Bearing Life Equation) was developed with the aNSK life modification factor: The new aNSK factor is based on data from bearing life aNSK tests involving over 450 roller bearings and over 550 ball bearings under a variety of operating conditions. The new life equation with the aNSK factor showed a satisfactory fit between calculated life and actual life.

Regarding tapered roller bearings used on pinion shafts in differential gearboxes, it has been observed that some cases of bearing failure, like flaking or seizure, occurred much earlier than expected. As to the cause of this kind of failure, it has been clarified that on the shaft system supported by a pair of tapered roller bearings, the actual bearing load, including the preload of the bearings, fluctuates not only under the dynamic state but also under the static state because of the temperature distribution around the bearings. This fluctuation of the actual bearing load and preload greatly affects rolling fatigue life, seizure performance and the stiffness of the shaft support system. This paper discusses optimal design concepts for improving the rolling fatigue life, frictional torque, rigidity and seizure performance of a pair of tapered roller bearings. The design concepts are based on analysis results of the dynamic preload situation under actual operating conditions.