A Coupled Crystal Plasticity-Phase-Field Damage Model for Integrated CAD/CAE-Based Fatigue Design of Rolling Bearings

Abstract. This study proposes an integrated multiscale method for rolling contact fatigue (RCF) life prediction of rolling bearings. A dimension-chain mapping drives parametric reconstruction and macroscale contact analysis. The contact parameters are transferred to a grain-scale crystal plasticity-phase-field model as a moving Hertzian load. A three-layer solution framework with a cycle-jump scheme calculates damage evolution. Results show that an elliptical Al2O3 inclusion promotes crack initiation and significantly reduces the predicted life. A larger rolling-element diameter extends the life, while a larger raceway curvature coefficient or positive radial clearance shortens the life.