MACHINE DESIGN - An Integrated Approach, 4th Ed.

7-20-1
PROBLEM 7-20
Statement: Determine the size of the contact patch and the maximum contact stresses for a 20-mm-dia steel
ball rolled against a 40-mm-dia steel cylinder, 25-mm long with 10 kN force.
Given: Ball radii R1 10.00 mm The parts are steel. Therefore:
R'1 10.00 mm E 206.8 GPa 0.28
Cylinder radii R2 20.00 mm (radial)
R'2 mm (axial)
Radial load F 10 kN (normal to contact plane)
Angle between planes of R1 and R2 0 deg

Assumptions: The relative motion is rolling with < 1% sliding.

Solution: See Mathcad file P0720.
1. Find the material constants from equation 7.9b.
2
1 6 1
Material constants m1 m1 4.456 10
E MPa
m2 m1
2. Two geometry constants are needed from equations 7.19a.

Geometry 1 1 1 1 1 1
constants A A 0.1250 mm
2 R1 R'1 R2 R'2
1
2
2 2
1 1 1 1 1 1
B B 0.0250 mm
2 R1 R'1 R2 R'2
1 1 1 1
2 cos( 2 )
R1 R'1 R2 R'2

B 180
Angle acos 78.46
A

Factors from 0.86215

equations 7.19e ka 50.192 ka 1.167

2
kb 0.0045333 0.043581 0.0017292
5 3 7 4
3.7374 10 3.7418 10
9 5
1.4207 10
kb 0.875
3. Determine the contact patch dimensions using the material and geometry constants in equations 7.19d.
1
Major axis 3
3 m1 m2
half-width a ka F a 0.947 mm
4 A

1
Minor axis 3
3 m1 m2
half-width b kb F b 0.710 mm
4 A

© 2011 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be
 MACHINE DESIGN - An Integrated Approach, 4th Ed. 7-20-2

2
Contact area A ab A 2.11354 mm
4. The average and maximum contact pressure can now be found from equations 7.18b and c.
F
Average pressure p avg p avg 4731 MPa
A
3
Maximum pressure p max p avg p max 7097 MPa
2
5. The maximum normal stresses in the center of the contact patch at the surface are then found using equations
7.21a.
b
In-plane x 2 (1 2 ) p max x 5312 MPa
a b

a
y 2 (1 2 ) p max y 5759 MPa
a b

Axial z p max z 7097 MPa

These stresses are principal:

1 x 2 y 3 z

The maximum shear stress associated with them at the surface is

1 3
13 13 892 MPa
2

6. The maximum shear stress under the surface on the z-axis is approximately
Max shear stress 13max 0.34 p max 13max 2413 MPa

7. All of the stresses found so far exist on the centerline of the patch. At the edge of the patch, at the surface,
there will also be a shear stress. Two constants are found from equation 7.21b for this calculation.
b
k3 k3 0.75
a

1 2 2
k4 a b k4 0.662
a

8. These constants are used in equations 7.21c and d to find the shear stresses on the surface at the ends of the
major and minor axes.

k3 1
Major axis xy (1 2 ) atanh k4 1 p max xy 1084 MPa
2 k4
k4

k3 k3 k4
Minor axis xy (1 2 ) 1 atan p max xy 966 MPa
2 k4 k3
k4

© 2011 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This publication is protected by Copyright and written permission should be