Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis

Bahubali Balaso Farande; Soham Suraj Biranje; Suyash Santosh Tupe; Swanand Balkrishna Shinde; Sayali Prakash Kamble; Sujit Mahadev Patil

doi:doi:10.11648/j.ie.20261002.13

Research/Technical Note |

| Peer-Reviewed

Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis

Bahubali Balaso Farande^*

, Soham Suraj Biranje

, Suyash Santosh Tupe

, Swanand Balkrishna Shinde

, Sayali Prakash Kamble

, Sujit Mahadev Patil

Published in Industrial Engineering (Volume 10, Issue 2)

Received: 4 April 2026 Accepted: 25 April 2026 Published: 12 November 2026

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Abstract

Ball bearings are essential in mechanical systems. Fatigue life and stress distribution affect performance and reliability of system. Recently hybrid bearings have attracted attention because they may have advantages over traditional steel bearings, such as reduced friction, better wear resistance, and a longer service life. This study gives a comparative analysis of the analytical and real-life simulation fatigue life of 6206 deep groove ball bearings for conventional (AISI 52100 steel) and hybrid (AISI 52100 races with Si₃N₄ ceramic balls) specification. The main goal of this research is to find the fatigue life and stress behaviour of both types of bearings under similar operating conditions. The study calculates analytical life using the ISO 281 bearing life equation, and the stress distribution in bearing is evaluated using finite element analysis in ANSYS Workbench. The results show that the hybrid bearings have about 30% longer fatigue life compared to conventional steel bearing based on analytical calculations. finite element analysis shows that hybrid bearing experiences a higher von Mises stress due to the ceramic balls but it also shows lower maximum principal stress indicating reduced subsurface stress and improved fatigue resistance. The relation between analytical and ANSYS life estimation shows close agreement, with a life ratio of 1.30 (analytical) and 1.32 (simulation), respectively. In conclusion, hybrid bearing shows higher fatigue life, good stress distribution and suitable for high-load or high-speed applications where longer life and reduced friction is required.

Published in	Industrial Engineering (Volume 10, Issue 2)
DOI	10.11648/j.ie.20261002.13
Page(s)	63-70
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2026. Published by Science Publishing Group

Keywords

Hybrid Bearing, Conventional Bearing, L₁₀Life, ANSYS, Fatigue Life, Stress

References

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[3]	R. S. Khurmi and J. K. Gupta, A Textbook of Machine Design, 15th ed., New Delhi, India: Eurasia Publishing House, 2015.
[4]	SKF Group, Rolling Bearings Catalogue (Publication 10000/EN), Gothenburg, Sweden: SKF, 2020.
[5]	F. Xu et al., “A review of bearing failure Modes, mechanisms and causes,” Oct. 01, 2023, Elsevier Ltd. https://doi.org/10.1016/j.engfailanal.2023.107518
[6]	P. Borghesani, W. A. Smith, R. B. Randall, J. Antoni, M. El Badaoui, and Z. Peng, “Bearing signal models and their effect on bearing diagnostics,” Mech. Syst. Signal Process., vol. 174, Jul. 2022, https://doi.org/10.1016/j.ymssp.2022.109077
[7]	S. M. M. Seyed, X. Jin, and J. Ni, “Physics-based Gaussian process for the health monitoring for a rolling bearing,” Acta Astronaut., vol. 154, pp. 133–139, Jan. 2019, https://doi.org/10.1016/j.actaastro.2018.10.029
[8]	X. Z. Liang and P. E. J. Rivera-Díaz-del-Castillo, “Hydrogen-accelerated white etching area formation in bearings under rolling contact fatigue,” Int. J. Fatigue, vol. 159, Jun. 2022, https://doi.org/10.1016/j.ijfatigue.2022.106753
[9]	I. Durazo-Cardenas et al., “Towards health monitoring of hybrid ceramic bearings in aircraft starter/generators,” in Procedia Manufacturing, Elsevier B. V., 2018, pp. 50–57. https://doi.org/10.1016/j.promfg.2018.01.008
[10]	K. Holmberg, A. Laukkanen, and H. Ronkainen, “Surface Fatigue Mechanisms of Hybrid Ceramic Bearings under Mixed Lubrication,” Tribology International, vol. 119, pp. 507–519, 2018.
[11]	A. Kumar, D. Sharma, and R. Verma, “Influence of Material Properties on Contact Stress of Deep Groove Ball Bearing Using Finite Element Analysis,” International Journal of Mechanical Engineering and Technology (IJMET), vol. 7, no. 3, pp. 150–157, 2016.
[12]	J. Zhang, L. Xu, and Y. Huang, “Comparative Study of Hybrid and All-Steel Bearings under High-Speed Operation,” Wear, vol. 426–427, pp. 1203–1211, 2019.
[13]	P. Ramesh and S. Rajesh, “Correlation of Bearing Fatigue Life with FEA Stress Parameters for Hybrid Materials,” International Journal of Scientific Research and Engineering Trends (IJSRET), vol. 6, no. 4, pp. 112–118, 20.
[14]	B. B. Farande and V. V. Kulkarni “Analysis of stress concentration effect around countersunk hole in composite plate in Composite Plate under transvers loading,” International conference on modern era research in mechanical engineering, 2016. https://ignited.in/index.php/jast/article/view/2230
[15]	B. B. Farande and V. V. Kulkarni “Experimental Investigation of Stress Concentration Factor around Countersunk Hole,” International Journal of Current Engineering and Technology, 2016. https://ignited.in/index.php/jast/article/view/2230/42
[16]	Weiwei Cai, Tancheng Xie, Pengfei Zhao “Residual Life Prediction of Metro Traction Motor Bearing Based on Convolutional Neural Network” HindawiShock and VibrationVolume, 2021. https://doi.org/10.1155/2021/5271785
[17]	Morales-Espejel, G. E., Gabelli, “Application of a Rolling Bearing Life Model with Surface and Subsurface Survival to Hybrid Bearing Cases,” Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 2019, 233(15), 5491–5498. https://doi.org/10.1177/0954406219848470
[18]	Bing Su, Chunhao Lu, Chenghui Li “Current Status of Research on Hybrid Ceramic Ball Bearings,” Machines. 2024, 12(8), 510. https://doi.org/10.3390/machines12080510
[19]	Zha, J., Zhang, H., Lyu, D. “Performance of Water-Lubricated Ceramic Journal Hybrid Bearing. ” Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology. 2022, 236(12), 2328–2339. https://doi.org/10.1177/13506501221090070
[20]	Pushpendra Tiwari, N. V. Saxena. “Finite Element Analysis of Ball Bearing for Different Materials,” International Journal of Trend in Scientific Research and Development (IJTSRD), 2020.

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APA Style

Farande, B. B., Biranje, S. S., Tupe, S. S., Shinde, S. B., Kamble, S. P., et al. (2026). Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis. Industrial Engineering, 10(2), 63-70. https://doi.org/10.11648/j.ie.20261002.13

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ACS Style

Farande, B. B.; Biranje, S. S.; Tupe, S. S.; Shinde, S. B.; Kamble, S. P., et al. Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis. Ind. Eng. 2026, 10(2), 63-70. doi: 10.11648/j.ie.20261002.13

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AMA Style

Farande BB, Biranje SS, Tupe SS, Shinde SB, Kamble SP, et al. Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis. Ind Eng. 2026;10(2):63-70. doi: 10.11648/j.ie.20261002.13

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@article{10.11648/j.ie.20261002.13,
  author = {Bahubali Balaso Farande and Soham Suraj Biranje and Suyash Santosh Tupe and Swanand Balkrishna Shinde and Sayali Prakash Kamble and Sujit Mahadev Patil},
  title = {Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis},
  journal = {Industrial Engineering},
  volume = {10},
  number = {2},
  pages = {63-70},
  doi = {10.11648/j.ie.20261002.13},
  url = {https://doi.org/10.11648/j.ie.20261002.13},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ie.20261002.13},
  abstract = {Ball bearings are essential in mechanical systems. Fatigue life and stress distribution affect performance and reliability of system. Recently hybrid bearings have attracted attention because they may have advantages over traditional steel bearings, such as reduced friction, better wear resistance, and a longer service life. This study gives a comparative analysis of the analytical and real-life simulation fatigue life of 6206 deep groove ball bearings for conventional (AISI 52100 steel) and hybrid (AISI 52100 races with Si3N4 ceramic balls) specification. The main goal of this research is to find the fatigue life and stress behaviour of both types of bearings under similar operating conditions. The study calculates analytical life using the ISO 281 bearing life equation, and the stress distribution in bearing is evaluated using finite element analysis in ANSYS Workbench. The results show that the hybrid bearings have about 30% longer fatigue life compared to conventional steel bearing based on analytical calculations. finite element analysis shows that hybrid bearing experiences a higher von Mises stress due to the ceramic balls but it also shows lower maximum principal stress indicating reduced subsurface stress and improved fatigue resistance. The relation between analytical and ANSYS life estimation shows close agreement, with a life ratio of 1.30 (analytical) and 1.32 (simulation), respectively. In conclusion, hybrid bearing shows higher fatigue life, good stress distribution and suitable for high-load or high-speed applications where longer life and reduced friction is required.},
 year = {2026}
}

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TY  - JOUR
T1  - Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis
AU  - Bahubali Balaso Farande
AU  - Soham Suraj Biranje
AU  - Suyash Santosh Tupe
AU  - Swanand Balkrishna Shinde
AU  - Sayali Prakash Kamble
AU  - Sujit Mahadev Patil
Y1  - 2026/11/12
PY  - 2026
N1  - https://doi.org/10.11648/j.ie.20261002.13
DO  - 10.11648/j.ie.20261002.13
T2  - Industrial Engineering
JF  - Industrial Engineering
JO  - Industrial Engineering
SP  - 63
EP  - 70
PB  - Science Publishing Group
SN  - 2640-1118
UR  - https://doi.org/10.11648/j.ie.20261002.13
AB  - Ball bearings are essential in mechanical systems. Fatigue life and stress distribution affect performance and reliability of system. Recently hybrid bearings have attracted attention because they may have advantages over traditional steel bearings, such as reduced friction, better wear resistance, and a longer service life. This study gives a comparative analysis of the analytical and real-life simulation fatigue life of 6206 deep groove ball bearings for conventional (AISI 52100 steel) and hybrid (AISI 52100 races with Si3N4 ceramic balls) specification. The main goal of this research is to find the fatigue life and stress behaviour of both types of bearings under similar operating conditions. The study calculates analytical life using the ISO 281 bearing life equation, and the stress distribution in bearing is evaluated using finite element analysis in ANSYS Workbench. The results show that the hybrid bearings have about 30% longer fatigue life compared to conventional steel bearing based on analytical calculations. finite element analysis shows that hybrid bearing experiences a higher von Mises stress due to the ceramic balls but it also shows lower maximum principal stress indicating reduced subsurface stress and improved fatigue resistance. The relation between analytical and ANSYS life estimation shows close agreement, with a life ratio of 1.30 (analytical) and 1.32 (simulation), respectively. In conclusion, hybrid bearing shows higher fatigue life, good stress distribution and suitable for high-load or high-speed applications where longer life and reduced friction is required.
VL  - 10
IS  - 2
ER  -

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Author Information

Bahubali Balaso Farande

Department of Mechanical Engineering, Kolhapur Institute of Technology’s College of Engineering (Empowered Autonomous), Kolhapur, India

Contact Email

http://orcid.org/0000-0002-8895-994X
Soham Suraj Biranje

Department of Mechanical Engineering, Kolhapur Institute of Technology’s College of Engineering (Empowered Autonomous), Kolhapur, India

Contact Email

http://orcid.org/0009-0007-6771-9262
Suyash Santosh Tupe

Department of Mechanical Engineering, Kolhapur Institute of Technology’s College of Engineering (Empowered Autonomous), Kolhapur, India

Contact Email

http://orcid.org/0009-0009-9415-955X
Swanand Balkrishna Shinde

Department of Mechanical Engineering, Kolhapur Institute of Technology’s College of Engineering (Empowered Autonomous), Kolhapur, India

Contact Email

http://orcid.org/0009-0008-4842-6269
Sayali Prakash Kamble

Department of Mechanical Engineering, Kolhapur Institute of Technology’s College of Engineering (Empowered Autonomous), Kolhapur, India

Contact Email

http://orcid.org/0009-0005-8300-6946
Sujit Mahadev Patil

Department of Mechanical Engineering, Kolhapur Institute of Technology’s College of Engineering (Empowered Autonomous), Kolhapur, India

Contact Email

http://orcid.org/0009-0009-9540-115X

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Plain Text BibTeX RIS

APA Style

Farande, B. B., Biranje, S. S., Tupe, S. S., Shinde, S. B., Kamble, S. P., et al. (2026). Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis. Industrial Engineering, 10(2), 63-70. https://doi.org/10.11648/j.ie.20261002.13

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ACS Style

Farande, B. B.; Biranje, S. S.; Tupe, S. S.; Shinde, S. B.; Kamble, S. P., et al. Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis. Ind. Eng. 2026, 10(2), 63-70. doi: 10.11648/j.ie.20261002.13

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AMA Style

Farande BB, Biranje SS, Tupe SS, Shinde SB, Kamble SP, et al. Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis. Ind Eng. 2026;10(2):63-70. doi: 10.11648/j.ie.20261002.13

Copy | Download

@article{10.11648/j.ie.20261002.13,
  author = {Bahubali Balaso Farande and Soham Suraj Biranje and Suyash Santosh Tupe and Swanand Balkrishna Shinde and Sayali Prakash Kamble and Sujit Mahadev Patil},
  title = {Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis},
  journal = {Industrial Engineering},
  volume = {10},
  number = {2},
  pages = {63-70},
  doi = {10.11648/j.ie.20261002.13},
  url = {https://doi.org/10.11648/j.ie.20261002.13},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ie.20261002.13},
  abstract = {Ball bearings are essential in mechanical systems. Fatigue life and stress distribution affect performance and reliability of system. Recently hybrid bearings have attracted attention because they may have advantages over traditional steel bearings, such as reduced friction, better wear resistance, and a longer service life. This study gives a comparative analysis of the analytical and real-life simulation fatigue life of 6206 deep groove ball bearings for conventional (AISI 52100 steel) and hybrid (AISI 52100 races with Si3N4 ceramic balls) specification. The main goal of this research is to find the fatigue life and stress behaviour of both types of bearings under similar operating conditions. The study calculates analytical life using the ISO 281 bearing life equation, and the stress distribution in bearing is evaluated using finite element analysis in ANSYS Workbench. The results show that the hybrid bearings have about 30% longer fatigue life compared to conventional steel bearing based on analytical calculations. finite element analysis shows that hybrid bearing experiences a higher von Mises stress due to the ceramic balls but it also shows lower maximum principal stress indicating reduced subsurface stress and improved fatigue resistance. The relation between analytical and ANSYS life estimation shows close agreement, with a life ratio of 1.30 (analytical) and 1.32 (simulation), respectively. In conclusion, hybrid bearing shows higher fatigue life, good stress distribution and suitable for high-load or high-speed applications where longer life and reduced friction is required.},
 year = {2026}
}

Copy | Download

TY  - JOUR
T1  - Assessment of Fatigue Life and Stress in Conventional and Hybrid 6206 Ball Bearings by Theoretical and Finite Element Analysis
AU  - Bahubali Balaso Farande
AU  - Soham Suraj Biranje
AU  - Suyash Santosh Tupe
AU  - Swanand Balkrishna Shinde
AU  - Sayali Prakash Kamble
AU  - Sujit Mahadev Patil
Y1  - 2026/11/12
PY  - 2026
N1  - https://doi.org/10.11648/j.ie.20261002.13
DO  - 10.11648/j.ie.20261002.13
T2  - Industrial Engineering
JF  - Industrial Engineering
JO  - Industrial Engineering
SP  - 63
EP  - 70
PB  - Science Publishing Group
SN  - 2640-1118
UR  - https://doi.org/10.11648/j.ie.20261002.13
AB  - Ball bearings are essential in mechanical systems. Fatigue life and stress distribution affect performance and reliability of system. Recently hybrid bearings have attracted attention because they may have advantages over traditional steel bearings, such as reduced friction, better wear resistance, and a longer service life. This study gives a comparative analysis of the analytical and real-life simulation fatigue life of 6206 deep groove ball bearings for conventional (AISI 52100 steel) and hybrid (AISI 52100 races with Si3N4 ceramic balls) specification. The main goal of this research is to find the fatigue life and stress behaviour of both types of bearings under similar operating conditions. The study calculates analytical life using the ISO 281 bearing life equation, and the stress distribution in bearing is evaluated using finite element analysis in ANSYS Workbench. The results show that the hybrid bearings have about 30% longer fatigue life compared to conventional steel bearing based on analytical calculations. finite element analysis shows that hybrid bearing experiences a higher von Mises stress due to the ceramic balls but it also shows lower maximum principal stress indicating reduced subsurface stress and improved fatigue resistance. The relation between analytical and ANSYS life estimation shows close agreement, with a life ratio of 1.30 (analytical) and 1.32 (simulation), respectively. In conclusion, hybrid bearing shows higher fatigue life, good stress distribution and suitable for high-load or high-speed applications where longer life and reduced friction is required.
VL  - 10
IS  - 2
ER  -

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