Introduction

Rolling element bearings are critical components in rotating machinery, providing smooth motion transmission while supporting high loads with minimal friction. The performance and reliability of these bearings depend largely on the stress distribution at the contact interfaces between rolling elements (rollers) and raceways (cones and cups). Uneven contact stresses can lead to premature wear, surface fatigue, and failure, reducing the bearing’s service life.
Finite Element Analysis (FEA) offers a powerful approach to study these stresses in detail, enabling engineers to optimize roller geometry for better load distribution. In particular, roller profile design—whether straight or crowned—has a significant influence on the contact pressure distribution. While straight rollers provide maximum contact area under ideal conditions, they are more sensitive to misalignment. Crowned rollers, on the other hand, reduce edge stresses and enhance performance under misalignment, but may slightly reduce the total contact area.

Objective

The objective of this study is to determine and compare the contact pressure distribution between the roller and the cone in a tapered roller bearing subjected to radial displacement using FEA in ANSYS for two roller profile cases:

1. Straight roller profile

2. Crowned roller profile

The aim is to evaluate the effect of roller geometry on stress distribution, identify the profile that provides more uniform load sharing and reduced peak stresses, and recommend the most effective design for improved bearing performance and durability.