Date of Award

January 2013

Document Type

Thesis

Degree Name

Master of Science (MS)

Department

Mechanical Engineering

First Advisor

Marcellin Zahui

Abstract

Contact fatigue failure has been in research since the early twentieth century. The need for a second generation sliding-rolling contact fatigue tester was proposed by Gregory Dvorak and Dr. Marcellin Zahui. The first generation RCF tester was used for testing super finishing processes for gear surfaces. The second generation RCF tester was funded by the Advanced Engineering Materials lab of University of North Dakota.

Verification of the second generation Rolling Contact Fatigue Tester will be discussed in this thesis including the design details, assembly and testing procedure and to discuss its different parameters. The tester will have the capability of testing hollow specimens using a bobbin eddy current testing probe. This tester will allow a wide range of experiments and is not built for one specific purpose. An eddy current device is used for detecting cracks. The loading force is applied using hydraulic cylinders and a hydraulic power unit. Before testing began, the machine was run for some time at full speed. A lot of minor problems were detected and fixed.

Three specimens of AISI 8620 were tested in this tester. All tests gave results matching with some of the other well-known RCF testers. These tests were performed to evaluate mechanical limits of the tester and to evaluate the software performance of the tester.

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