The aim of this study is mainly about preventing crack initiation and propagation in rolling contact under moderate and extreme loading through coating technology using finite element simulation and design of experiment (DOE) optimization techniques. Several applications of rolling contact were conducted and the parameters related to rollers’ materials, coating, temperature, and loads were investigated.

M50 steels (0.8C-4.2Cr-4.3Mo-1V wt.%) and 100CrMnMo8 steel (1.0C-2.0Cr-0.5Mo-1.0Mn-0.5Si wt.%) were analyzed with and without titanium nitride (TiN), zirconium nitride (ZrN) and tungsten carbide (WC) coatings under different temperature and loading conditions. Results showed that cracks propagation were limited to extreme load when using coating technology. A fully three-dimensional finite element model showed the Von Mises stresses and displacement under different temperatures. Findings confirmed that coating will enhance the lifetime of rollers and inhibit cracks and plastic deformation with better contribution from TiN under extreme pressure if compared to WC. DOE optimization of the parameter used in this study correlate closely with previous experiments and provided a solid conclusion of the best combination in rolling contact applications.

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