2- Hertzian contact stress

2 Hertzian contact stress1

Nomenclature
diameter of the larger
D l contact length, mm
cylinder in contact, mm
diameter of the smaller
d N Number of cycle
cylinder in contact, mm
F applied force, N σ Hertzian stress, MPa

2.1 Introduction

When two elements with curved surfaces make contact with each other and
are pressed together, contact stresses (also called Hertzian contact stresses)
are developed within the contact areas. Practical examples include the
contact between wheels and rails, valve cams and tappets, mating gears and
rolling bearings. Theoretically, the contact is either a point (when at least
one of the elements is a sphere) or a line (when at least one of the elements
is a cylinder).
Figure 2-1 shows different types of such contacts in which the Hertzian
contact stresses can occur. High contact stresses may lead to failures such as
cracks, pits and flaking in the surface material.

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This work is subject to copyright. Design of Machine Elements by Graphical Methods for
Engineers and Machine Builders. Majid Yaghoubi
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2- Hertzian contact stress

2.2 Design method

2.2.1 Line contact

In cylindrical or line contacts the contact between parts is as a line. To

calculate the stress, the Hertz formula can be used. However, for two
elements which are made of steel, Equation 2-1 (see section 2.3) can be
simply used for calculating the stress.
1
In case that one of the elements is flat, D = ∞ and therefore, = 0. “+” is
n

applied when the outer curved surface of the larger cylinder is in contact and
“−” is used when the inner curved surface of the larger cylinder is in contact
(Figure 2-1).
Instead of Equation 2-1, the graphs of Figure 2-2 may be used. The
following example shows the use of the graphs.

Cylinder on cylinder Cylinder on flat plate Cylinder in inner cylinder

Figure 2-1: different types of line contacts

Example 2-1: consider a crane that moves on a rail via rollers. Assume that
on one of the rollers, a force of 2400 kg (≈ 24000 N) is applied (Figure 2-3).
The rollers and the rail are made of ck45 steel with a hardness of 45 HRC.
Check if the roller and rail can tolerate the load or not? The diameter and
width of the roller are 50 and 60 mm, respectively and the width of the rail
is 50 mm.

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2- Hertzian contact stress

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Figure 2-2: graphs for estimating Hertzian stress of line contact

Solution:

To solve this problem we follow the steps below:

1. In the second quadrant (the upper left corner) of Figure 2-2 we find
the force, 2400 kg (or 24000 N). We go up from that point to cross
the curve related to the roller with diameter of 50 mm.

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2- Hertzian contact stress

2. Then we go right to cross the curve pertaining to width of 50 mm

(we select the minimum width of the contacting elements).

Figure 2-3: schematic of contact between a roller of a crane and a rail for
Example 2-1
1. Then we go down to reach the curve of cylinder on a flat surface (or

rail) ( ). From that point, we go left to cross the vertical axis

and find the stress (Hertzian stress) of the roller or rail that is 850
MPa.
2. In the fourth quadrant (the lower right corner) of Figure 2-2, we find
45 HRC on the horizontal axis, and go up to cross the curve (For
safety, we choose the lower limit of the graph). Then we go left to
reach the vertical axis. The maximum allowable stress for the roller
and rail is 1050 MPa.
We can also use the AGMA curves to find the maximum allowable contact
stress.

Conclusion: as the estimated Hertzian stress (850 MPa) is lower than the
maximum allowable stress for the elements (1050 𝑀𝑃𝑎 > 850 𝑀𝑃𝑎), the

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2- Hertzian contact stress

can tolerate the load.

However, to ensure a safe design, we apply a safety factor of 1.5. Therefore,
the minimum values for the diameter of the roller or width of the rail should
be:
𝑑 = 1.5 × 50 = 75 𝑚𝑚
Or
𝑙 = 1.5 × 50 = 75 𝑚𝑚
The number of cycles to failure at maximum allowable stress in Figure
2-2 is 180 × 106 for H ≤ 350 HB and 3000 × 106 for H ≥ 350 HB. For
instance, in Example 2-1, after 3000 × 106 cycles the roller starts to fail.

2.2.2 Point contact

In point or spherical contacts the contact between parts is as a point (Figure

2-4). To calculate the stress, the Hertz formula can be used. However, for
two elements which are made of steel, Equation 2-12-2 (see section 2.3) can
be simply used for calculating the stress.

Figure 2-4: Spherical contacts

Instead of Equation 2-12-2, the graphs of Figure 2-6 may be used. The
following example shows the use of the graphs.