5th International Conference on Power Transmissions BAPT2016

OPTIMAL 2ZB APPROXIMATION OF OPTIMAL PROFILE OF ROLLING

BEARINGS CYLINDRICAL ROLLERS

Lucian Tudose1,2, Constantin Ursache1, Cristina Tudose2, Florina Rusu1

Technical University of Cluj-Napoca, Romania, Faculty of Machine Building

RKB Group, Switzerland

E-mail: [email protected]

Abstract. In this paper a method to find the best approximation of the optimal profile of the rollers of a cylindrical roller
bearing is presented. The purpose is defined as an optimization problem and solved by means of Evolutionary Algorithms.
To validate the optimization, the obtained profile was compared with the optimal one taking into account four significant
criteria. The results were excellent encouraging future research.

Keywords: Cylindrical roller bearings, Roller optimal profile approximation, Evolutionary Algorithms.

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I. INTRODUCTION believe (as many others, see for example [8]) it is

preferable 2ZB profile instead of ZB one.
The fatigue life of the contacting surfaces is The main goal of this paper is to find the best
strongly related to the stress state developed at the approximation OA of the cylindrical roller optimal O
surface as well as within the material of mating parts profile using only 2ZB profile. For this purpose, an
[3], [4]. An analytical relationship between the surface optimization problem was defined and solved by
r a limited means of an own software based on a modified
version of the CMGEA algorithm (Cultural Multi-
shapes of the contact surfaces a lot of efforts were Group Evolutionary Algorithm) [5], [15]. To validate
done in order to achieve an appropriate algorithm to the optimization, the obtained profile was compared
obtain the pressure distribution along the contact area: with the optimal one taking into account the following
to mark somehow the boundaries, over time, of the criteria: basic and modified rating life of the bearing
work done we mention here only [7] recommended according to ISO/TS 16281:2008(E), maximum
also in ISO/TS 16281:2008(E) and [18]. For the contact pressure between the most loaded roller and
same purpose we used the conjugate gradient method the inner ring raceway, and maximum von Mises
(CGM) coupled with discrete convolution fast Fourier stress in the inner ring beneath the contact surface
transform (DC-FFT) [6], [10], [16]. The same between the most loaded roller and the inner ring
combination was used in determining the von Mises raceway (and the depth at this occurs).
stress in the bearing inner ring, beneath the contact
area between roller and raceway [9]. II. OPTIMAL APPROXIMATION OF THE
Regarding the roller bearings, when a roller of CYLINDRICAL ROLLER OPTIMAL PROFILE
finite length contacts a certain ring raceway (wider
than the roller length) the pressure distribution along Shape of the 2ZB profile
the roller is altered, and the end pressure tends to be
higher than that in the center of contact. To counteract In this section we deal with an approximation of the
this condition, cylindrical rollers (or the raceways) optimal profile consisting of a combination of two ZB
y make the stress profiles as presented in Fig. 1. Hereinafter this
distribution more uniform without edge peaks. If the
applied load is increased significantly, edge loading
will occur again.
Unfortunately, a roller profile can be ideally designed
for only one single condition of loading. In the late
s, after many years of investigation, a so-called

substantially optimized stress distribution under most

conditions of loading. This profile can be found also
within the recommendations given by ISO/TS
16281:2008(E) [17]. RKB Group has developed and
uses today more sophisticated logarithmic profiles
optimized for large segments of bearing loads.
Hereinafter the O profile refers as to such optimal
profile.
Many times, for economic reasons, it is desirable to
replace the optimal roller profile by a simpler one,
obtaining in this way: circular single-crowned, circular
double-crowned, partial circular single-crowned (ZB),
or partial circular double-crowned (2ZB). Even
lowering the edge stresses each of these profiles has a
major drawback: unless close attention is paid to

the profiles, stress concentrations can occur here with

important reduction in bearing life.
Under the same light load, a fully crowned roller
does not use the total length of the roller, and for these Fig. 5 Approximate profile (2ZB)
reason, the partially crowned roller experiences less The circle of center O1 and radius R1 intersects the
contact stress. Under the same heavier load for a roller generatrix in S and the circle of center O2 and
crowned profile the contact stress in the center of the radius R2 in T. Further, the circle of center O2 and
contact can greatly exceed that in a partially crowned radius R2 intersects the chamfer profile (not
or even straight profile contact. That is why we represented here) in U. Consequently, the roller profile
is formed by the straight line OS, two circle segments
ST and TU of radius R1 and R2 respectively, and,

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finally, by the chamfer profile. The abscissae of the and to associate to every j a corresponding distance dj
f,g
points S, T, and U will be denoted by s, t, and u, between the graphs of the functions f and g. In this
respectively. way an objective function can be easily constructed:
s < t < u < Lw / 2 (where Lw is
the total length of the roller) and R1 > R2 must be
satisfied. Note that if the circle of radius R1 does not
exist, the obtained profile is the old ZB cylindrical The simplest idea (and probably the most used for
roller profile. such approximation) is to consider:
The 2ZB profile is completely and uniquely defined
by four parameters: R1, R2, , and q. Obviously, R1, R2,
are strictly positive and q
that even when the above mentioned constrained are This kind of approach has a flaw for this particular
satisfied there is an infinite number of combinations case in which the function f has a very special shape,
each representing a 2ZB profile. especially in its last part, toward the roller side. In this
A certain 2ZB profile, described by certain four part of the curve the curvature radius decreases rapidly
parameters, R1, R2, , and q, has the following with the increasing of y conferring a special
equation: rounding to the roller. We tried to capture this
aspect by defining a special distance between the two
curves, measured along the normal nj to the graph of
the function f. Obviously at the very last part of the
curves (situation marked with * on Fig. 2) the normal
to the graph of the function f does not intersect the
graph of function g in a point whose abscissa is within
the interval [c, u]. In this case the distance will be
where t, s, u are easily calculated with R1, R2, , and q. measured vertically.
When q = 0 the circle of radius R1 is tangent to the The objective function can be now computed and it
roller generatrix (fully crowned roller). Note that was implemented in a standalone optimization
between these parameters and the parameters needed software based on a modified version of the CMGEA
for the profile machining there are very simple algorithm where a new mechanism for species was
mathematical relationships. introduced and the simulated binary crossover (SBX)
[1] and the simplex crossover (SPX) [14] were added
Optimal approximation of the optimal profile
to the pool of operators. The modified CMGEA
According to the already mentioned approach, the algorithm uses multiple search operators in each
equation of the optimal profile is: generation, an idea similar to MO-GA and SAMO-GA
[2]. The algorithm also employs a teaching-learning
where Kf and a are constants. scheme inspired by TLBO [11] [13] which simulates
two fundamental modes of learning: through a master
and interacting with other peers.
Evaluation of the performances of roller profiles
In order to evaluate the performances of different
roller profiles two possible profiles of a cylindrical
roller were taken into account:
Optimal profile (O) (considered as referential),
Optimal approximation profile (OA).
Also, as evaluation criteria, four important
parameters were taken in consideration for a bearing
equipped with rollers having a certain profile and
loaded with six different levels of the radial load:
Fig. 2 Optimal (f) and 2ZB (g) profiles Basic rating life of the bearing (according to
ISO 16281: 2008),
The goal of the optimization is to find a function g Modified rating life of the bearing (according to
whose graph is as close as possible to the graph of the ISO 16281: 2008),
optimal profile f (Fig. 2). The approximation is Maximum contact pressure between the most
performed along the interval [c, u], where c is the loaded roller and the inner ring raceway,
greatest integer for which the condition f(c m is Maximum von Mises stress in the inner ring
still fulfilled. beneath the contact surface between the most
It is natural to divide the interval [c,u] into several loaded roller and the inner ring raceway and the
subintervals of equal width: depth at this occur.
Case study

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The single-row cylindrical roller bearing NJ 320 II 0.100 0

EMP65SA was selected for the study of the two roller
profiles behavior under different working III 0.100 1.5
circumstances. The basic dynamic radial and basic
radial static load ratings of this cylindrical roller Grease base oil
Speed Lubricant
bearing are Cr = 389 kN and C0r = 439 kN, Working
Kinematic
respectively. The radial internal clearance of the n
temperature
and viscosity
Viscosity
unmounted bearing is in the range RIC index
at 40 C
0.195 mm. The main dimensions of the roller are: [ C]
[rpm] cleanliness
VI
[mm2/s]
Length: Lw = 32 mm
Diameter: Dwe = 32 mm Grease
Chamfer radius: rcfm = 1 mm 1000 90 Normal 150 95
cleanliness

For the selected single-row cylindrical roller

Optimal profile (O) (considered as referential), bearing NJ 320 EMP65SA three different working
Optimal approximation profile (OA), obtained scenarios (loading cases) were set (as it is presented in
as it was explained in the previous section. Table II). Whilst speed, working temperature,
lubricant, and lubrication quality were maintained the
same in all three loading cases, in the first case one
TABLE VI supposes that there is neither residual (working) radial
Investigated Roller Profiles internal clearance (RICw) in the bearing, nor
misalignment between the bearing bore and housing
axes of symmetry, in the second case is assumed only
the presence of a certain residual internal radial
clearance, and finally, in the third loading case both
residual radial internal clearance and misalignment
occur. With regard to the radial load level, it has to be
mentioned that in each case the maximum value was
set very close to the value at which the most loaded
roller with optimal profile O loses its performance by

levels of loads were adopted with descending step of

In Fig. 3 the optimal approximation profile OA is 15 kN.
presented together with the optimal profile O. For all loading cases and for all considered loads
the own software for calculating the basic rating life,
modified rating life, contact pressure between all
rollers and inner and outer ring raceways, von Mises
stresses in rings bellow the contact surfaces was ran

results of these simulations are presented in Table III,

Table IV, and Table V, respectively, and in much
more details in the ANNEX. The optimal profile O
demonstrated once again its undisputable quality and
for this reason it was always chosen as referential.
Fig. 3 Optimal (O) and optimal approximation (OA)
profiles 1) Loading case I (RICw = 0, = 0). Results of the
simulations and discussions
TABLE VII In Table III the main results of the simulations in
Bearing Working Conditions this case are given. Taking as referential the basic
rating lives of the bearing with roller with the O
Residual radial Misalign- Bearing profile, the basic rating lives of the bearing with the
internal clearance ment radial load OA profile are given in Fig. 4.
Loading
case RICw Fr

[mm] [min] [kN]

I 0 0

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TABLE VIII
Loading case I (RICw

Fig. 4 Loading case I: Basic rating life, % (relative to

the optimal profile O)

Regarding the maximum contact pressure between

the most loaded roller and the inner ring raceway the
variation of it versus the bearing radial load is
presented in Fig. 5 (in absolute values) and Fig. 6 (in
percent relative to the maximum contact stress in the
case of the bearing with rollers having the optimal O
profile).

The basic rating lives (estimated according to ISO

16281:2008) of the bearing with the OA profile are Fig. 5 Loading case I: Maximum contact pressure
one can
see the difference is low and somehow constant, but The maximum contact pressure in the case of OA
we have to mention here that if the load is increased an in the similar
over 175 kN the difference tends to diminish as the loading condition for the O profile. Once again one
bearing load increases. This is easily explainable since can see that the differences between the maximum
at very high bearing loads the roller profile does not contact pressures in the case of the O and OA profiles
remain more or less constant as bearing load increases.
cancels the beneficial presence of the profile, Note that in absolute terms, if the bearing load does
whatever it may be. On the other hand, as the load not exceed 150 kN Cr) the maximum
decreases, the difference grows towards 2% 4% contact pressure is kept at reasonable values, about
and the advantage of the OA profile, as approximation 2500 MPa in the OA profile case.
of the optimal profile, becomes more evident. The
behavior of the variation of the modified bearing lives
is similar to that of basic rating lives and for this
reason is not presented here in dedicated diagrams.

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Fig. 8 Loading case I: Maximum von Mises stress, %

Fig. 6 Loading case I: Maximum contact pressure, %
(relative to the optimal profile)
(relative to the optimal profile O)
The evolution of the maximum von Mises stress in
As the bearing load increases the contact pressures
the bearing rings reflects also all these. Some deep
between the rollers and raceways increase too and,
(about 0.30 mm beneath the contact area) maxima
consequently, the von Mises stresses in the rings and
(called hereinafter lower maxima) are reached and
rollers increase as well.
these correspond to the primary contact pressure peaks
(see for example the first two rows of Table AI from
the ANNEX). Then, as the bearing load increases,
secondary local maxima (called hereinafter upper
maxima) appear corresponding to the secondary
contact pressure peaks (last two rows of Table AI
from the ANNEX). Unfortunately, these upper
maxima are located very close to the contact surface
(about 0.07 mm! highlighted in all tables containing
the results of the simulations) and become very
dangerous because any flaw of the material, inclusion,
nano- or micro-crack, or small indentation (that easily
could reach this level) will highly amplify these
stresses and lead soon to the local breakdown of the
ring (more likely) or roller material. Obviously when
the secondary contact stress peaks become higher the
primary peaks, the values of the upper maximum von
Mises stress exceed the values of the lower maxima
increasing the already mentioned risk of rings/roller
material damage.
The variation of the maximum von Mises stress in
Fig. 7 Loading case I: Maximum von Mises stress the inner ring versus the bearing radial load is
presented in Fig. 7 (in absolute values) and Fig. 8 (in
If a certain profile is used for roller, for lower loads percent relative to the maximum von Mises stress in
it is well known that peaks (more or less sharp) appear the case of the bearing with rollers having the optimal
in the contact pressure distribution along the contact O profile).
surface between the roller and raceway. These peaks The maximum von Mises stress in the case of the
(hereinafter called primary peaks) are not at the edges OA
of the contact area but somehow towards the interior loading condition for the O profile. Following
(see for example the first two rows of Table AI from naturally the behavior of the maximum contact stress
the ANNEX). As the load increases sooner or later variation according to the load values, the differences
another edge peaks (secondary peaks) are developed between the maximum von Mises stresses in the cases
(the third row of Table AI from the ANNEX for the of the O and OA profiles remain constant. Note that in
OA profile and the fifth row for O profile). At a absolute terms, if the bearing load does not exceed
certain normal load on the roller (i.e. a certain bearing 175 kN the maximum von Mises stress is kept bellow
load) these peeks will become higher that the primary 1700 MPa in the O or OA profile cases. It is worth
mentioning here that in the case of 100Cr6 bearing
enforced. As one can see from the mentioned tables steel the yield strength is of 1700 MPa, for martensitic
structure and of 2000 MPa, for bainitic structure.
MPa in the case of the O profile than in the case of the Moreover, only when the bearing load reaches 175 kN
OA profile. But, as one can observe from the last row the maximum von Mises stress is located at 0.07 mm
of Table AI from the ANNEX, the bearing radial load below the contact surface, for both O and OA profiles.
for which the secondary peaks equal the primary ones It worth noting here that for a full-crowned roller this
are the same for both profiles: about 175 MPa (about earlier , fact that diminishes
Cr). considerably the range of loads for which bearings
with fully-crowned rollers can be used.

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2) Loading case II (RICw

Simulation results and discussions
The results of the simulations corresponding to this
loading case are presented in Table IV. Taking as
referential the basic rating lives of the bearing with
roller with the O profile, the basic rating lives of the
bearing with the OA profile are given in Fig. 9.

TABLE IX
Loading case II (RICw
results
Fig. 9 Loading case II: Basic rating life, % (relative to
the optimal profile O)

Fig. 10 Loading case II: Maximum contact pressure

The variation of the maximum contact pressure

between the most loaded roller and the inner ring
raceway as function of the bearing radial load is
presented in Fig. 10 (in absolute values) and Fig. 11
(in percent relative to the maximum contact stress in
the case of the bearing with rollers having the optimal
O profile).

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Fig. 11 Loading case II: Maximum contact pressure, Fig. 13 Loading case II: Maximum von Mises
% (relative to the optimal profile O) stress, % (relative to the optimal profile)

The maximum contact pressure in the case of the

OA an those in the
case of the O profile. If the bearing load does not
exceed 130 kN Cr). the maximum contact
pressure for the O or OA profile cases are kept at
lower values than 2500 MPa.
As one can see from Table AII from the ANNEX
the secondary peaks appear sooner (for a bearing
radial load under 85 kN, lower that in the previous
loading case) in the case of the OA profile, after a
O profile.
The same differences can be observed also for the
moments in which the secondary peaks exceed the
primary peaks.

3) Loading case III (RIC w

In Table V the results of the simulations

corresponding to the third loading case are given.

TABLE X
Loading case III (RICw
results

Fig. 12 Loading case II: Maximum von Mises

stress

The variation of the maximum von Mises stress in

inner ring versus the bearing radial load is presented in
Fig. 12 (in absolute values) and Fig. 13 (in percent
relative to the maximum von Mises stress in the case
of the bearing with rollers having the optimal O
profile).

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Fig. 14 Loading case III: Basic rating life, %

(relative to the optimal profile O)

As previously, taking as referential the basic rating

lives of the bearing with roller with the O profile, the
basic rating lives of the bearing with the OA profile
are given in Fig. 14.
The presence of the bearing residual radial internal
clearance and misalignment between the bearing bore
and housing axes leads to a decreasing of the bearing
lives in all cases and for both profiles by about 35%
relative to the values obtained in the simulations
corresponding to the first loading case, that means Fig. 15 Loading case III: Maximum contact
about 7% decrease due to only the misalignment. The pressure
basic rating lives of the bearings with the OA profile
are about 3% lower than in the case of the O profile.
As in the previous cases, the differences between the
bearing lives for the two considered profiles are
constant.
In Fig. 15 is shown the variation of the maximum
contact pressure (in absolute values) between the most
loaded roller and the inner ring raceway as function of
the bearing radial load, and in Fig. 16 is presented the
variation of the same contact pressure in percent
relative to the maximum contact stress in the case of Fig. 16 Loading case III: Maximum contact
the bearing with rollers having the optimal O profile, pressure, % (relative to the optimal profile O)
versus, again, the bearing radial load.
The maximum contact pressure in the case of the As one can see from Table AIII from the ANNEX,
OA the appearance of the first secondary pressure peaks is,
the case of the O profile. As expected, the differences e case of
between the maximum contact pressures in the case of the O profile than in the case of the OA profile. The
the O and OA profiles remain constant as bearing load same differences can be observed also for the
increases. If the bearing load does not exceed 100 kN moments in which the secondary peaks exceed the
the maximum contact pressure is kept below 2500 primary peaks.
MPa in O and OA profile cases. The variation of the maximum von Mises stress in
inner ring versus the bearing radial load is presented in
Fig. 17 (in absolute values) and Fig. 18 (in percent
relative to the maximum von Mises stress in the case

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of the bearing with rollers having the optimal O the behavior of the optimal profile O (the curves
profile). of any considered parameter for OA and O
;
Even in presence of normally residual radial
internal clearance inside the bearing and
misalignment of the axes of the bearing bore
and housing, in the same loading conditions, the
expected life of a bearing with rollers having
OA profile will be with only 2% ... 4% less than
the expected life of a similar bearing but with
optimally profiled rollers;
In the case of the OA profile, even the above
mentioned clearance and the misalignment are
presented, up to a bearing radial load of about
Cr the maximum von Mises stress in the
ring and roller material does not exceed 1700
MPa, fact that makes the bearing made of steel
with martensitic structure suitable for a large
range of mechanical applications. If the steel
structure is bainitic the load cam increases up to
Cr.
In all above situations the maximum contact
pressure between the most loaded roller and the
inner ring raceway remains at actable values
Fig. 17 Loading case III: Maximum von Mises
bellow 2500 MPa;
stress
In the same conditions a bearing with fully-
crowned rollers reaches only 2/3 from the
The maximum von Mises stress in the case of the performances of a similar bearing having rollers
OA with OA profile.
similar loading condition for the O profile, differences
All these make from the optimal approximation
being more or less constant. If the bearing radial load
OA profile of the ideally profile a very competitive
is lower than 130 kN the maximum von Mises stress is
one at very low manufacturing costs.
kept bellow 1700 MPa in the case of the O and OA
profiles. Moreover, for both O and OA profile, when ACKNOWLEDGMENT
the bearing load reaches about 130 kN the maximum
The authors would like to thank the RKB Group,
von Mises stress is located at 0.07 mm deep below the
the Swiss bearing manufacturer, for the permission to
contact surface, whilst the lower maxima of the
publish these results and the RKB staff for their great
maximum von Mises stress becomes major about 45
interest and support during the development of this
earlier in the fully-crowned roller case.
project.

Fig. 18 Loading case III: Maximum von Mises

stress, % (relative to the optimal profile)

III. CONCLUSIONS
Examining the simulation results in all three
assumed loading cases some important remarks and
conclusions can be drawn:
The optimal profile O is indeed the best from all
points of view assumed in this research;
Whatever is the criterion, the optimal
approximation profile OA follows constantly

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ANNEX
TABLE AI

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TABLE AII

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TABLE AIII

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