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The subsurface initiated contact fatigue failure is one of the dominating mechanisms of failure of moving machine parts involved in cyclic motion. Structural fatigue failure may be of surface or subsurface origin. The analysis of a significant amount of accumulated experimental data obtained from field exploitation and laboratory testing provides undisputable evidence of the most important factors affecting contact fatigue [1]. It is clear that the factors affecting contact fatigue the most are as follows (a) acting cyclic normal stress and frictional stress (detailed lubrication conditions, surface roughness, etc.) which in part are determined by the part geometry, (b) distribution of residual stress versus depth, (c) initial statistical defect/crack distribution versus defect size, and location, (d) material elastic and fatigue parameters as functions of materials hardness, etc., (e) material fracture toughness, (f) material hardness versus depth, (g) machining and finishing operations, (h) abrasive contamination of lubricant and residual surface contamination, (i) non-steady cyclic loading regimes, etc. In case of structural fatigue the list of the most important parameters affecting fatigue performance is similar. None of the existing contact or structural fatigue models developed for prediction of contact fatigue life of bearings and gears as well as other structures takes into account all of the above operational and material conditions. Moreover, at best, most of the existing contact fatiguemodels are only partially based on the fundamental physical and mechanical mechanisms governing the fatigue phenomenon. Most of these models are of empirical nature and are based on assumptions some ofwhich are not supported by experimental data or are controversial as it is in the case of fatigue models for bearings and gears [1]. Some models involve a number of approximations that usually do not reflect the actual processes occurring in material.

Fracture Mechanics Based Models of Structural and Contact Fatigue