Inner Ring Fracture Characteristics

under Rolling Contact

Kiyoshi Hirakawa, Norifumi Ikeda, Shigeru Okita and Akihiro Kiuchi
Basic Technology Research & Development Center

ABSTRACT
Inner ring fracture sometimes occurs if a rolling bearing is mounted with relatively high hoop stress. NSK has
developed a life test method for inner ring fracture in order to study and develop appropriate materials and effective heat
treatment processes. This method enables accurate simulation of actual inner ring fracture by providing a minute half-
ellipse fatigue crack at a selected origin point on the inner ring raceway.
Using this method, life test results on inner ring fracture caused by hoop stress showed that inner ring fracture life and
hoop stress correlate relatively well. Next, the effect of material and heat treatment on inner ring fracture life was
studied. It was confirmed that compressive residual stress is effective in extending inner ring fracture life. In particular,
it was shown that a fatigue crack in M50NiL at 280 MPa hoop stress propagates negligibly.
Applying results obtained through this test method, NSK developed a special steel and heat treatment (TL
specification) that results in excellent dimensional stability and superior inner ring fracture life and rolling fatigue life,
even under conditions of high temperature and contaminated lubrication.

1. Introduction resistance, it is necessary to have suitable evaluation

The inner ring of a roller bearing mounted with
relatively high hoop stress sometimes fractures in the
axial direction after a certain period of usage. Particularly
in the aerospace industry, demand is high for increased
resistance to inner ring fracture as bearings in todays jet
engines are subjected to ever-higher centrifugal forces.
Fatigue cracking and ultimately in some cases, fracture,
are believed to result from repeated rolling stress being
applied to an inner ring raceway that is under tensile
stress caused by hoop and centrifugal stress. Fatigue
cracking is thought to originate at surface or subsurface
stress concentrations caused by nonmetallic inclusions,
flaking or rust. Fig. 1 shows an example of the inner ring
fracture of a spherical roller bearing with a tapered bore
used in a paper-making machine.
In order to develop effective materials and heat
treatment methods that improve inner ring fracture
technology. Tensile, impact and fracture toughness testing
are not effective for evaluating inner ring fracture
resistance. Concerning this problem, Aberbach and co-
researchers used Compact Tension Specimens to analyze
the influence of residual stress on the rate of crack
propagation, as well as consider compressive residual
stress.1) Clark performed tests under hoop stress after
using electrical discharge machining to introduce semi-
circular defects (0.36 0.71 mm) onto the inner ring
raceway surfaces of cylindrical roller bearings made of
M50 and M50NiL steel.2) Under hoop stress of 30 ~ 38 ksi
(206 ~ 261 MPa), the inner ring of the M50 bearing
fractured as a result of the defect while that of the
M50NiL bearing did not. Additionally, Pearson, based on
both experiments and an analysis of the literature,
discussed the stress limits of crack propagation in
AISI52100 and M50NiL steel under hoop stress in the
range of 170 ~ 400 MPa.3) However, he did not discuss the

Origin point

100 m
5 mm
a. Fracture surface b. Magnified area of fractures origin

Fig. 1 Example of inner ring fracture of a spherical roller bearing

15 Motion & Control No. 7 (December 1999)

 Electrode
Notch
a. Schematic of notch produced by electrical discharge machining
Notch
Fatigue crack
c. Notch and fatigue crack from bending fatigue
0.8~1.2mm
3~4mm
e. Shape of pre-crack
Fig. 2 Making a fatigue pre-crack
relationship between inner ring fracture life and hoop stress.
As summarized above, no data was found in the
literature to connect hoop stress or residual stress and
inner ring fracture life. Considering the need for such data
and understanding the necessity of creating a method that
produces inner ring fracture without generating flaking,
NSK developed an inner ring fracture life test that can
reproduce and confirm the morphology of inner ring
fractures that occur during actual applications. Using this
method, we conducted tests to determine the relationship
between hoop stress, residual stress and inner ring
fracture life in roller bearings. In this report, we present
our method for inner ring fracture life testing, discuss test
results on various types of steel (including NSKs own TL-
specification steel), and analyze how hoop stress and
residual stress affect inner ring fracture life.
Motion & Control No. 7 (December 1999)
Bending load
Notch
b. Cracking propagation by bending fatigue
Fatigue crack (Pre-crack)
d. Removal of notch
2. Procedure for Inner Ring Fracture
Life Tests
Inner ring fracture and flaking of rolling bearings
originate from stress concentrations caused by dents, rust,
or nonmetallic inclusions. When the hoop stress of the
inner ring is low and the stress concentration is at the
subsurface site of a nonmetallic inclusion, a fatigue crack
will initiate from the nonmetallic inclusion, propagate
around the bearings circumference almost parallel to the
raceway surface and flaking will occur. If hoop stress is
high, the fatigue crack will propagate perpendicularly to
the raceway surface (i.e., down toward the shaft), expand
axially and eventually lead to inner ring fracture.4)
It is necessary to be able to make artificial crack origin
points of a consistent size and shape in order to evaluate
16
the effectiveness of heat treatments and materials against
inner ring fracture. As defects made just by electric
discharge processing can result in flaking originating from
the defects edge, NSK has developed a method to
introduce fatigue pre-cracks to avoid flaking. Fatigue
pre-cracks are half-ellipse-shaped and positioned
perpendicularly to the raceway surface in the center of the
inner ring raceway of cylindrical roller bearings (NU216).
There are three steps in the process of making a fatigue
pre-crack. First, a half-ellipse shaped notch is made on the
raceway surface by electrical discharge processing (Fig. 2-
a). Then, by applying bending fatigue, cracking propagates
from the notch (Figs. 2-b and c). Finally, the notch is
removed by machining leaving only the fatigue pre-crack
(Figs. 2-d and e). The pre-cracks in these tests had a
length of 3 ~ 4 mm and a depth of 0.8 ~ 1.2 mm. The width
of the pre-cracks was so small that it could only be
detected by magnetic particle detection. Generally
speaking, rolling contact stress causes fatigue cracking to
propagate from the pre-crack. In some cases this
ultimately leads to fracture.
In our inner ring fracture testing, an inner ring with a
fatigue pre-crack is mounted on the tapered shaft of the
test rig (Fig. 3). Both hoop stress and load are applied
Test bearing
Pre-crack
Fig. 3 Cross-section of inner ring fracture test rig
during the rotation test. The tests discussed here were
conducted with bearing loads of 19 600 N (P/C = 0.19) and
29 400 N (P/C = 0.28) at a rotational speed of 1 800 rpm.
Fracture life (N) in these tests is defined as the number of
revolutions until the inner ring is fractured or bearing
vibration becomes excessively high from the propagation of
the pre-crack into a fatigue crack over the width of the
raceway surface. Hoop stress is calculated from the
amount of expansion of the bore of the inner ring that is
mounted on the tapered shaft. Hoop stress is also
measured using a strain gauge. The calculated values
correlate well with measured ones.
3. Results of Inner Ring Fracture
Life Tests
Hoop stress was the primary variable in these tests
because it is the most important factor influencing inner
ring fracture life in most applications. Table 1 shows the
hardness, heat treatment, and material of the inner rings
used in these tests. Fig. 4 presents the results of inner ring
fracture life tests.
3.1 Results of AISI52100 bearing steel inner
ring fracture life tests
Fig. 5-a shows the pre-crack in an inner ring made of
standard 52100 bearing steel before testing. Fig. 5-b shows
the inner ring after fracture and Fig. 5-c shows the
fracture surface. There are three areas labeled in Fig. 5-c:
A is the area of the pre-crack, B is the area that
progressively fractured due to rolling contact fatigue, and
C is where the fracture rapidly progressed.
Because inner ring fracture often occurs in applications
with higher temperatures and hoop stress, high-
temperature-tempered 52100 inner rings and bainite-
treated 52100 inner rings were tested in addition to
standard heat-treated ones. The results are included in
Fig. 4. As shown in the figure, the bainite-treated 52100
inner rings exhibited much longer fracture life than either

Table 1 Materials, heat treatment and hardness

Chemical composition
No. Classification Material Heat treatment Hardness
C Cr Mo V Ni
Bearing steel, standard
1 AISI52100 1.0 1.5 840C, oil quenching, 180C tempering HRC 62.5
heat treatment

High-temperature- 840C, oil quenching,

2 AISI52100 1.0 1.5 HRC 60
tempered bearing steel high-temperature tempering

Bainite-treated
3 AISI52100 1.0 1.5 850C, 240C salt quenching (4 hrs) HRC 59
bearing steel

High-speed steel for high-

4 M50 0.8 4.0 4.2 1.0 1100C, oil quenching, 550C tempering HRC 62
temperature bearings

Carburized high-speed steel Carburizing, 1100C, oil quenching, Raceway surface

5 M50 NiL 0.13 4.1 4.2 1.2 3.4 HRC 62
for high-temperature bearings 550C tempering
Core HRC 38
High-temperature-
6 SAE5120 0.2 1.0 Carburizing, high-temperature tempering HRC 59.5
tempered carburized steel

Newly developed, Carbo-nitriding,

7 TL specification steel Patent pending HRC 61
case-hardened steel high-temperature tempering

17 Motion & Control No. 7 (December 1999)

 500
Standard heat-treated bearing steel with pre-crack ( R = 0 ~ 20 MPa)
Standard heat-treated bearing steel without pre-crack
High-temperature-tempered bearing steel with pre-crack
450 Bainite-treated bearing steel with pre-crack ( R = -120 MPa)
Bainite-treated bearing steel without pre-crack
M50 with pre-crack ( R = -20 ~ -50 MPa)
400 M50NiL with pre-crack ( R = -250 MPa)
TL specification with pre-crack ( R = -250 MPa)
TL specification without pre-crack
Carburized steel with pre-crack ( R = -200 MPa)
350
Fitting stress t , MPa

Marks with an arrow pointing to the right indicate that

no fatigue cracking was observed.

300

250

200

150
P/C = 0.28

100

105 106 107 108 109

Fracture life N, rev.

Fig. 4 Results of inner ring fracture test (P/C = 0.19)

1 mm
5 mm
a. Pre-crack (magnetic particle detection image)
b. Inner ring after fracture

B A

C 5 mm

c. Fracture surface (A-Pre-crack, B-Fatigue cracking, C-Section of rapid fracture)

Fig. 5 Pre-crack and inner ring fracture of 52100 inner ring (Standard heat treatment, Hoop stress t = 210 MPa, N = 6 106 rev.)

Motion & Control No. 7 (December 1999) 18

the standard heat-treated or high-temperature-tempered
inner rings. This result is attributed to the higher
compressive stress in the surface of the bainite-treated
inner rings. Overall, the test results indicate a good
correlation between hoop stress (t) and inner ring
fracture life (N) and show that inner ring fracture life
decreases with increasing bearing load.
3.2 Results of M50 inner ring fracture life tests
M50 is a bearing steel for high-temperature
applications. It is used for bearings, such as those in gas
turbines and jet engines, that exceed operating
temperatures of 200C.
Testing of M50 inner ring fracture life was conducted on
two bearings at two levels of hoop stress: 200 MPa and 270
MPa. In both bearings, fatigue cracks propagated almost
over the entire raceway width and vibration increased
after about N = 3 106 revolutions. As testing continued,
the inner ring under hoop stress of 270 MPa fractured at
N = 1.5 107 revolutions while that under hoop stress of
200 MPa managed N = 2.2 107 revolutions without
fracturing before the test was discontinued due to
excessive vibration. As Fig. 4 shows, the inner ring
fracture life of M50 is almost equivalent to 52100.
However, comparing Figs. 5-b and 6-b, the condition of the
fatigue cracking on the raceway surface of the M50 inner
ring is different from that of the 52100 inner ring. The
fatigue crack of the 52100 inner ring propagated in an
almost straight line in the axial direction and then the
1 mm
a. Pre-crack (magnetic particle detection image)
B A
C 5 mm
c. Raceway cross-section (A-Pre-crack, B-Fatigue cracking, C-Section fractured on purpose to facilitate observation)
Fig. 6 Pre-crack and fatigue crack propagation from pre-crack (M50, Hoop stress t = 200 MPa, N = 2.2 107 rev.)
19 Motion & Control No. 7 (December 1999)
inner ring fractured (Fig. 5-b), whereas the fatigue crack of
the M50 inner ring stopped at the raceway width and then
propagated like flaking (Fig. 6-b).
The circumferential sections of the 52100 and M50 inner
rings in Figs. 7-a and b show how the fatigue cracks
developed. The fatigue crack of the 52100 inner ring is
almost straight while that of the M50 inner ring branches
out in different directions. The nature of the M50 fatigue
crack is believed to be due to M50s high tempering
temperature.
3.3 Results of M50NiL inner ring fracture
life tests
M50NiL is case-hardened M50 steel that was developed
for the high rotating speeds of jet engine bearings.
Because M50NiL has lower carbon content and contains
Ni, its core has greater toughness and its case higher
compressive residual stress than M50.
M50NiL exhibited longer inner ring fracture life than
both 52100 and M50. Virtually no fatigue cracking was
observed after N = 1.7 108 rotations under hoop stress of
280 MPa. When the hoop stress was raised to 390 MPa
and after N = 5 107 rotations, a fatigue crack propagated
from the pre-crack across the raceway width but the inner
ring did not fracture (Fig. 8). Similar to the fatigue crack
in the M50 inner ring, the fatigue crack in the M50NiL
ring branches out in different directions (Fig. 7-c).
It is believed that the higher compressive residual stress
(-250 ~ -300 MPa) of M50NiL is primarily responsible for
Raceway width
5 mm
b. Fatigue crack propagation from pre-crack
 Fatigue
progression
area

Area
rapidly
fractured
1 mm 1 mm

a. 52100 (Standard heat treatment, t = 210 MPa, a. Pre-crack (magnetic particle detection image)
N = 6 106 rev.)

Fatigue
progression
area

Area fractured
on purpose to
facilitate
1 mm observation 5 mm
b. Fatigue crack propagation from pre-crack
b. M50 (t = 200 MPa, N = 2.2 107 rev.)

A B
Fatigue
progression
area

Area fractured
on purpose to
facilitate C 5 mm
1 mm observation
c. Raceway cross-section (A-Pre-crack, B-Fatigue cracking,
c. M50NiL (t = 390 MPa, N = 5 107 rev.)
C-Section fractured on purpose to facilitate observation)

Fig. 7 Fatigue crack propagation Fig. 8 Pre-crack and fatigue crack propagation from pre-crack
(Circumferential sections of inner rings) (M50NiL, Hoop stress t = 390 MPa, N = 5 107 rev.)

its long inner ring fracture life.
3.4 Inner ring fracture life and rolling contact
fatigue life of TL bearings
NSKs new TL bearings are made of special case-
hardened steel and undergo carbo-nitriding. (TL stands for
Tough and Long-life.) Their compressive residual stress is
equivalent to conventional carburized steel bearings and
they have higher raceway hardness than high-
temperature-tempered 52100 bearings or conventional
carburized steel bearings. As shown in Fig. 4, the inner
ring fracture life of TL bearings is on the same level as
M50NiL and carburized steel.
In rolling contact fatigue (flaking) life tests, TL bearings
showed exceptionally long life under conditions of
contaminated lubrication at high temperatures due to the
high hardness of their raceways (see the Weibull plotting
of test results in Fig. 9).
3.5 Results of inner ring fracture life tests
without pre-cracks
We have already discussed the influence of heat
treatment, material, and hoop stress on the fracture life of
inner rings with pre-cracks. Next, considering inner ring
fracture in actual applications, we review tests done on
inner rings without pre-cracks and present analyses of the

Motion & Control No. 7 (December 1999) 20

 99.9
99
95
90
Accumulated failure probability, %
50
10
5
1
1 5
Fig. 9 Rolling contact fatigue test under high temperature and contaminated oil
origin points of fractures and the effect of hoop stress on
fracture life. Tests were conducted on standard heat-
treated 52100, bainite-treated 52100 and TL bearings. The
test results are shown in Fig. 4.
The standard heat-treated 52100 inner ring fractured at
N = 1.2 108 revolutions under hoop stress of 280 MPa.
The fracture surface is shown in Fig. 10-a. The origin point
of the fracture can be seen near the raceway surface. Fig.
10-b is a magnified image of the fracture origin point. Fig.
10-c is a further magnification of the origin point showing
a nonmetallic inclusion site. Located about 40 m below
the raceway surface, the concave section can be seen
running almost parallel to the raceway surface. The
elements Mn, Ca, and S were detected in this concave area
by EDS analysis (Fig. 10-d). It was concluded that the
inner ring fracture occurred due to the presence of CaS
inclusions. Also, an Al2O3 and CaS inclusion site was
determined to be the fracture origin point in a test under
hoop stress of 230 MPa, and a CaS inclusion was the
fracture origin point in a test under hoop stress of 400
MPa. As for the bainite-treated 52100 inner rings,
fractures occurred at Al2O3 and CaS inclusions under hoop
stress ranging from 380 to 410 MPa. In contrast, TL steel
inner rings did not fracture under hoop stress as high as
420 MPa. Fractures did finally occur at Al2O3 inclusion
sites under hoop stress ranging from 470 to 490 MPa. To
summarize, inner ring fracture occurred at Al2O3 and CaS
inclusion sites in tests without pre-cracks.
21 Motion & Control No. 7 (December 1999)
High-temperature-tempered
bearing steel
Bainite-treated bearing steel
TL-specification steel
High-temperature-tempered
carburized steel
Thrust bearing life test
P max: 4 900 MPa
Test temperature: 130C
10 50 100 500 1 000
( 105 )
+
Stress cycles
4. Residual Stress and Fracture Life of
Inner Rings
Fig. 11 shows measurement results on residual stress
(R). Residual stress measurements were made on
untested inner rings that received the same heat
treatments as the tested inner rings.
Fig. 11 shows that the residual stress at the surface of
the inner rings ranges from -300 to -500 MPa. This level of
stress is attributed to the grinding process. The residual
stress approximately 0.5 mm below the surface of both
standard heat-treated and high-temperature-tempered
52100 inner rings is approximately 0 ~ +20 MPa. At the
same approximate depth, the residual stress values for the
other inner rings in the tests are as follows: bainite-
treated 52100, approximately -120 MPa; TL specification,
approximately -240 MPa; and M50NiL, approximately
-280 MPa.
Comparing the inner ring fracture life test results in
Fig. 4 to the residual stress values in Fig. 11, inner ring
fracture life becomes longer as compressive residual stress
increases. In the tests, the standard heat-treated 52100
inner ring fractured at about N = 1 107 revolutions under
hoop stress of 400 MPa and at about N = 3 108
revolutions under hoop stress of 240 MPa. A bainite-
treated 52100 inner ring fractured under hoop stress of
380 MPa at about N = 7 107 revolutions. In contrast,
another bainite-treated 52100 inner ring under hoop
stress of 350 MPa and the TL specification inner ring
 A

B 0.5 mm
100 m
a. Fracture surface (A-Origin point of fracture,
b. Magnified image of fracture origin point
B-Fatigue cracking)

10 m

c. Nonmetallic inclusion site at crack origin d. EDS analysis of chemical composition of nonmetallic
inclusions at crack origin

Fig. 10 Example of inner ring fracture test result without pre-crack (fatigue crack propagated from nonmetallic inclusions)
(52100, Hoop stress t = 280 MPa, N = 1.3 108 rev.)

under hoop stress of 430 MPa did not fracture even after N cracks, the importance of compressive residual stress is
= 3 108 revolutions. clear. There is a distinct tendency for inner rings with
From the results on inner ring fracture without pre- higher compressive residual stress to have longer fracture
life when fractures originated from nonmetallic inclusions.
We believe the correlation is strong enough to support the
+100 conclusion that higher compressive residual stress
prolongs inner ring fracture life.

0
Residual stress R, MPa

5. Conclusion
-100

(1) Inner ring fracture life correlates well with

-200
compressive residual stress. Compressive residual
stress is effective in extending inner ring fracture life.
-300 In particular, it was shown that a fatigue crack
Bearing steel (Standard heat treatment)
Bearing steel (Bainite-treated) propagates negligibly in an M50NiL inner ring with a
-400 M50 pre-crack under 280 MPa hoop stress. The residual
M50NiL
TL specification stress of M50NiL is approximately -280 MPa.
-500
0 0.5 1.0 1.5 2.0 2.5 (2) In the tests on inner rings without pre-cracks (results
Depth below surface, mm in Fig. 4), the standard heat-treated 52100 inner ring
Fig. 11 Results of residual stress measurements (residual stress approximately 0 ~ +20 MPa) fractured

Motion & Control No. 7 (December 1999) 22

 under hoop stress of 400 MPa after about N = 1 107 Kiyoshi Hirakawa
revolutions, and the bainite-treated 52100 inner ring
(residual stress approximately -120 MPa) fractured
under approximately the same hoop stress after at
about N = 7 107 revolutions. In contrast, the TL inner
ring (residual stress approximately -240 MPa) did not
fracture under hoop stress of 430 MPa after about N =
3 108 revolutions.

(3) The origin points of the inner ring fractures in the tests Norifumi Ikeda
without pre-cracks were nonmetallic inclusions such as
Al2O3 and CaS.

(4) TL-specification bearings with higher raceway surface

hardness showed longer rolling contact fatigue life
under high temperature and contaminated oil.

References: Shigeru Okita

1) B. L. Aberbach, et al, Fatigue Crack Propagation in
Carburized High Alloy Bearing Steels, Metal. Trans., A 16A
(1985) 1253-1265.
2) J. C. Clark, Fracture Tough Bearing for High Stress
Applications, AIAA-85-1138 AIAA/SAE/ASME/ASEE 21st
Joint Propulsion Conference July 8 -10 (1985).
3) P. K. Pearson, Fracture and Fatigue of High Hardness
Bearing Steels under Low Tensile Stresses, SAE Technical
Paper 901628, International Off-Highway and Exposition,
Akihiro Kiuchi
Milwaukee, September 10-13 (1990).
4) T. Czyzwski, Influence of a Tension Stress Field Introduced in
the Elastohydrodynamic Contact Zone on Rolling Contact
Fatigue, Wear, 34 (1975) 201-214.

23 Motion & Control No. 7 (December 1999)