Method and system for predicting surface contact fatigue life

A computer system for predicting surface contact fatigue life of a power transmission bearing or gear, the system comprising:

• a memory to store material parameters related to a power transmission bearing or gear;
• and
• a processor including computer-executable instructions to:
• generate a finite element model based on the material parameters related to a power transmission bearing or gear, wherein the finite element model describes a grain structure of the power transmission bearing or gear;
• generate loading parameters, wherein the loading parameters characterize a surface roughness of the power transmission bearing or gear;
• simulate a loading event onto the finite element model, wherein the loading event represents one loading cycle of the power transmission bearing or gear and is divided into discrete time steps, and using the finite element model, a defined load is simulated to travel a distance over the power transmission bearing or gear in each time step, wherein the defined load is simulated to exert different amounts of pressure across the power transmission bearing or gear in each time step due to asperity contact;
• generate a surface pressure time history for a loading event on the finite element model, wherein the surface pressure time history is based on one or more loading parameters;
• determine, based on the surface pressure time history for a loading event, a finite element solution that describes stress in the grain structure;
• calculate damage in the finite element solution using a damage model, the damage model utilizing the stress in the grain structure;
• and
• determine whether the damage exceeds a damage threshold;
• wherein if the damage threshold is exceeded, the processor outputs a number of load events preceding the damage threshold.