High-Speed Bearing Reliability: Analysis of Tapered Roller Bearing Performance and Cage Fracture Mechanisms

This investigation examines the fracture mechanisms of 31,311 tapered roller bearing cages using finite element analysis (FEA) and the Gurson–Tvergaard–Needleman (GTN) damage model. Static, dynamic, modal, and harmonic response analyses identify critical stress concentrations at the contact interface between the rolling elements and the outer ring, with maximum deformation occurring in the inner ring. Modal analysis excludes resonance as a potential failure cause. Crack initiation and propagation studies reveal that cracks predominantly form at the pocket bridge corners, propagating circumferentially. The propagation angle increases under circumferential and coupled loading conditions while remaining constant under longitudinal loading. Based on the GTN model, this study is the first to examine the crack propagation and fracture toughness of the cage under various loading conditions. The results indicate that longitudinal loading (Load II) yields the highest fracture toughness, significantly surpassing those under circumferential (Load I) and coupled loading (Load III). Load II exhibits the strongest crack growth resistance, with a peak CTODc of 0.598 mm, attributed to plastic strain accumulation. Fracture toughness decreases with crack depth, as CTODc declines by 66.5%, 20.1%, and 58.4% for Loads I, II, and III, respectively. Crack deflection angles show the greatest variation under Load I (35% increase), while Loads II and III demonstrate minimal sensitivity (<10% change). The optimization of the bearing cage pocket hole fillet radius from 0 mm to 0.75 mm demonstrates a maximum stress concentration reduction of 38.2% across different load conditions. This work introduces a novel methodology for predicting cage fracture behavior and optimizing design, offering valuable insights to enhance the reliability and longevity of systems in high-speed, high-load applications.