Empirical Formulas for Plastic Deformation and Yield Criterion of Surface Induction-Hardened Bearings for Wind Turbines

In this study, an elastoplastic finite element (FE) contact model was developed to evaluate the plastic deformation of a surface induction-hardened tapered roller bearing used in wind turbines, incorporating depth-dependent material properties and heat treatment-induced residual stress distribution. The validity of this model was confirmed by comparing the calculated plastic deformation with measured profiles from static compression experiments. The results show that the residual stresses generated by induction hardening have a significant influence on the elastoplastic behavior of bearings. Based on this model, a parametric analysis was performed to investigate the effects of surface hardening depth (SHD), contact pressure, and residual stress on surface plastic deformation. Empirical formulas were developed to predict surface plastic deformation and evaluate material yielding for surface-hardened tapered roller bearings, thereby preventing excessive deformation during service. This allows for the rapid estimation of the maximum plastic deformation for different hardening depths and provides an efficient approach for assessing the yielding risk.