Project Scope:

  • EDC was engaged to investigate the effect that the following parameters have on fretting and spalling, leading to premature failures of ore car axle shafts:
    • bearing press fit load.
    • end cap bolt torque.
    • interference tolerances.
  • This project included a combination of the following advanced measurement and simulation techniques:
    • Strain gauging.
    • Non-linear Finite Element Analysis (FEA).


  • Develop testing regime useful for advanced simulation correlation.
  • Develop representative non-linear contacts and load cases required to diagnose the issue utilising advanced simulation (FEA).


  • Good correlation was reached between test measurements and FEA.
  • Able to determine possible contributing factors that led to premature failure of bearings in service.