Discrete Element Method Simulation of Silicon Nitride Ceramic Bearings with Prefabricated Crack Defects

Silicon nitride (Si3N4) ceramic bearings inevitably contain crack-like defects, yet their compressive capacity degradation and crack-driven failure mechanisms remain unclear. This study proposes a discrete element method (DEM) numerical framework within PFC2D to simulate a bearing containing a single prefabricated crack. First, a bearing DEM model was established and calibrated to reproduce the compressive mechanical response. Then, particle deletion introduced controllable central cracks in the ball and raceway with prescribed inclination angles. Finally, displacement-controlled compression-splitting simulations, serving as a surrogate for a quasi-static overload scenario relevant to quality screening, tracked crack initiation, propagation, and failure modes; under a fixed raceway-crack inclination, crack length was varied to quantify size effects. Results show that a single crack markedly reduces compressive strength. Failure progresses through elastic deformation, crack propagation, and final fracture, with cracks initiating at stress concentrators near crack tips. Crack inclination significantly regulates capacity: raceway cracks are most detrimental near 45°, while ball cracks exhibit an overall decrease in initiation and peak stresses with increasing inclination (with local non-monotonicity). Crack length has a stronger weakening effect than inclination, with accelerated capacity loss beyond 0.3 mm and a pronounced drop in initiation stress beyond 0.6 mm. The framework enables controllable defect parametrization and micro-scale failure interpretation for defect sensitivity assessment under compressive overload. Thus, this study focuses on simulating monotonic fracture events to elucidate fundamental defect–property relationships, which provides a foundation distinct from the prediction of rolling contact fatigue life under cyclic service conditions.