Abstract
Fretting fatigue experiments and finite element analysis were carried out to investigate the influence of cylindrical-on-flat contact on crack nucleation, crack path and fatigue life of medium-carbon steel. The location of crack nucleation was predicted using the maximum shear stress range criterion and the maximum relative slip amplitude criterion. The prediction using the maximum relative slip amplitude criterion gave the better agreement with the experimental result, and should be used for the prediction of the location of crack nucleation. Crack openings under compressive bulk stresses were found in the fretting fatigues with flat-on-flat contact and cylindrical-on-flat contacts, i.e., fretting-contact-induced crack openings. The crack opening stress of specimen with flat-on-flat contact was lower than those of specimens with cylindrical-on-flat contacts, while that of specimen with 60-mm radius contact pad was lower than that of specimen with 15-mm radius contact pad. The fretting fatigue lives were estimated by integrating the fatigue crack growth curve from an initial propagating crack length to a critical crack length. The predictions of fretting fatigue life with consideration of crack opening were in good agreement with the experimental results.
Highlights
Fretting is a damage process that occurs at the contact between two components under minute relative motion, while fatigue is a progressive damage that occurs when a component is subjected to cyclic loading
It propagates in the direction of maximum tangential stress range
By assuming that Nf is equal to the fretting fatigue crack propagation life, the fretting fatigue life can be predicted using the linear-elastic fracture mechanics (LEFM) approach [4,5,6,7,8,9,10,11,12]
Summary
Fretting is a damage process that occurs at the contact between two components under minute relative motion, while fatigue is a progressive damage that occurs when a component is subjected to cyclic loading. For flat-on-flat contact, a fretting fatigue crack is likely to nucleate at the location of maximum shear stress range. After crack nucleation, it propagates in the direction of maximum tangential stress range. The influence of tangential stress range decreases as the crack propagates away from the contact. Under the combination between contact stress and bulk alternating stress, a fretting fatigue crack nucleates at early stage of fretting fatigue life (Nf ). By assuming that Nf is equal to the fretting fatigue crack propagation life, the fretting fatigue life can be predicted using the linear-elastic fracture mechanics (LEFM) approach [4,5,6,7,8,9,10,11,12]
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