Cracking under fretting fatigue: Damage prediction under multiaxial fatigue

2002 ◽  
Vol 37 (6) ◽  
pp. 519-533 ◽  
Author(s):  
M-C Dubourg ◽  
Y Berthier ◽  
L Vincent
Keyword(s):  
Crack Initiation ◽  
Prediction Models ◽  
Crack Nucleation ◽  
Fretting Fatigue ◽  
Multiaxial Fatigue ◽  
Stage I ◽  
Fretting Wear ◽  
Stage Ii ◽  
Contact Conditions ◽  
Damage Prediction

Fretting is one of the plagues of modern industry. It occurs whenever a junction between components is subjected to cyclic sliding, with small relative displacements at the interface of the contacting surfaces. Further cyclic bulk stresses may be superimposed on to one or both components. The investigation of fretting wear and fretting fatigue started in the early 1970s. It is responsible for premature fatigue failures and often limits the life of a component. Crack initiation and growth under fretting contact conditions have been investigated. The fretting map concepts allow the first degradation responses of the material—no degradation, cracking and wear—to be related to a fretting regime with its corresponding local contact conditions during fretting tests. The fretting fatigue prediction models have been developed and compared to experiments conducted either on metallic or photoelastic materials. A special emphasis has been directed towards crack nucleation and early growth during stage I, the stage I-stage II transition and stage II crack growth (crack initiation sites, orientation, growth path, formation of a branch, growth mechanism). The analysis of the different stages that comprise the crack lifetime has been carried out in order to understand the effects of diverse parameters that are thought to influence the fretting damage.

Cracking Induced by Fretting of Aluminium Alloys

1997 ◽  
Vol 119 (1) ◽  
pp. 36-42 ◽  
Author(s):  
Z. R. Zhou ◽  
L. Vincent
Keyword(s):  
Aluminium Alloys ◽  
Small Amplitude ◽  
Crack Nucleation ◽  
Normal Load ◽  
Fatigue Cracking ◽  
Fretting Fatigue ◽  
Fretting Wear ◽  
Partial Slip ◽  
Material Loss ◽  
Main Effects

Fretting-wear and fretting-fatigue loadings can both result in wear (material loss) and in crack nucleation and propagation (fatigue process). This paper deals with cracking induced by small amplitude displacements in the case of aeronautic aluminium alloys. The two sets of fretting maps are introduced: running condition fretting map is composed of partial slip (sticking), mixed fretting and gross sliding regime; material response fretting map is associated with two macro-degradation modes. Crack nucleation and propagation are analysed for every fretting regime. The mixed fretting regime appeared most detrimental with regards to fatigue cracking. Slip amplitude and normal load main effects discussed for fretting wear can be used to justify the fatigue limit decrease often obtained for fretting fatigue experiments.

Crack Initiation Under Low-Cycle Multiaxial Fatigue in Type 316L Stainless Steel

1983 ◽  
Vol 105 (2) ◽  
pp. 138-143 ◽  
Author(s):  
B. Jacquelin ◽  
F. Hourlier ◽  
A. Pineau
Keyword(s):  
Stainless Steel ◽  
Crack Initiation ◽  
Low Cycle Fatigue ◽  
Cyclic Stress ◽  
Fatigue Tests ◽  
Multiaxial Fatigue ◽  
Stage I ◽  
Type B ◽  
Strain Behavior ◽  
Number Of Cycles

Low-cycle fatigue tests corresponding to fatigue life range between 103 and 105 cycles were carried out at room temperature on one heat of 316 L austenitic stainless steel. These tests included: (i) reversed tension-compression, (ii) reversed tension-compression with a superimposed steady torque, (iii) pulsated tension-compression with a stress ratio (Rσ) such that −0.5<Rσ<0, (iv) reversed and pulsated tension-compression with a superimposed steady internal pressure. In tests (ii), the torsional ratcheting effect was measured. SEM observations were used to determine the number of cycles corresponding to Stage I crack initiation and the orientation of Stage I microcracks. It was observed that the in-depth growing Type B shear microcracks were most damaging. A simple criterion is proposed Ni=No(Δγp B)α•(σnB)β where Ni is the number of cycles to crack initiation, Δγp B is the range of plastic shear strain on Type B planes, σnB is the maximum normal stress acting on these planes, No,α and β are parameters adjusted from the Manson-Coffin law and reversed cyclic stress-strain behavior.

scholarly journals Experimental and numerical study on fretting wear and fatigue of full-scale railway axles

2020 ◽  
Vol 28 (4) ◽  
pp. 365-381
Author(s):  
Lang Zou ◽  
Dongfang Zeng ◽  
Yabo Li ◽  
Kai Yang ◽  
Liantao Lu ◽  
...  
Keyword(s):  
Fatigue Crack ◽  
Stress Concentration ◽  
Crack Initiation ◽  
Numerical Study ◽  
Equivalent Stress ◽  
Fatigue Crack Initiation ◽  
Fretting Fatigue ◽  
Full Scale ◽  
Fretting Wear ◽  
Stress Intensity Factor Range

AbstractThis study investigated the fretting wear and fatigue of full-scale railway axles. Fatigue tests were conducted on full-scale railway axles, and the fretting wear and fretting fatigue in the fretted zone of the railway axles were analysed. Three-dimensional finite element models were established based on the experimental results. Then, multi-axial fatigue parameters and a linear elastic fracture mechanics-based approach were used to investigate the fretting fatigue crack initiation and propagation, respectively, in which the role of the fretting wear was taken into account. The experimental and simulated results showed that the fretted zone could be divided into zones I–III according to the surface damage morphologies. Fretting wear alleviated the stress concentration near the wheel seat edge and resulted in a new stress concentration near the worn/unworn boundary in zone II, which greatly promoted the fretting crack initiation at the inner side of the fretted zone. Meanwhile, the stress concentration also increased the equivalent stress intensity factor range ΔKeq below the mating surface, and thus promoted the propagation of fretting fatigue crack. Based on these findings, the effect of the stress redistribution resulting from fretting wear is suggested to be taken into account when evaluating the fretting fatigue in railway axles.

scholarly journals Multiaxial High Cycle Fretting Fatigue

2019 ◽  
Vol 300 ◽  
pp. 02002
Author(s):  
José Alexander Araújo ◽  
Gabriel Magalhães Juvenal Almeida ◽  
Fábio Comes Castro ◽  
Raphael Araújo Cardoso
Keyword(s):  
Fretting Fatigue ◽  
Accurate Estimate ◽  
Multiaxial Fatigue ◽  
Fretting Wear ◽  
Critical Plane ◽  
Life Estimation ◽  
Wide Range ◽  
Tools And Techniques ◽  
Critical Direction ◽  
High Cycle Fretting Fatigue

The aim of this work is to show that multiaxial fatigue can be successfully adpted to model fretting problems. For instance, the paper presents (i) the critical direction method, as an alternative to the critical plane concept, to model the crack initiation path under fretting conditions and (ii) studies on size effects considering the influence of incorporating fretting wear on the life estimation. A wide range of new data generated by a two actuators fretting fatigue rig considering Al 7050-T7451 and of Ti-6Al-4V aeronautical alloys is produced to validate these analyses. It is shown that, the development of appropriate tools and techniques to incorporate the particularities of the fretting phenomenon into the multiaxial fatigue problem allow an accurate estimate of the fretting fatigue resistance/life in the medium high cycle regime. Such tools and techniques can be extended to the design of other mechanical components under similar stress enviroments.

806 Investigation of relationship between fretting wear and fretting fatigue crack initiation

2010 ◽  
Vol 2010.47 (0) ◽  
pp. 279-280
Author(s):  
Yuki KATSUMATA ◽  
Yoshiharu MUTOH ◽  
Yukio MIYASHITA ◽  
Yuichi OTSUKA ◽  
Kosoku NAGATA ◽  
...  
Keyword(s):  
Fatigue Crack ◽  
Crack Initiation ◽  
Fatigue Crack Initiation ◽  
Fretting Fatigue ◽  
Fretting Wear

Fretting Wear and Fretting Fatigue—How Are They Related?

1983 ◽  
Vol 105 (2) ◽  
pp. 230-238 ◽  
Author(s):  
R. C. Bill
Keyword(s):  
Fretting Fatigue ◽  
Surface Treatments ◽  
Fretting Wear ◽  
Experimental Conditions ◽  
Contact Conditions ◽  
Experimental Parameters ◽  
Analogous Manner ◽  
Atmosphere Temperature ◽  
Fatigue Failures

Results from published literature and results obtained by the author are examined in detail to determine how fretting wear and fretting fatigue are related. The effects of various experimental parameters, including slip amplitude, number of fretting cycles, frequency of fretting motion, experimental atmosphere, temperature, and the performance of coatings and surface treatments, are surveyed. All of the results examined indicate that fretting wear and fretting fatigue are influenced in a consistent and analogous manner by controlled variations in experimental conditions. That is, conditions that tend to accelerate fretting wear also accelerate fretting fatigue failures. Correlation of the performance of coatings on material under fretting wear and fretting fatigue conditions is rather tenuous, partly because similar contact conditions for fretting fatigue and fretting wear are not available for very many materials.

Effects of process variables on fretting fatigue crack initiation in Ti-6A1-4V

2002 ◽  
Vol 37 (6) ◽  
pp. 535-547 ◽  
Author(s):  
S A Namjoshi ◽  
S Mall ◽  
V K Jain ◽  
O Jin
Keyword(s):  
Fatigue Crack ◽  
Crack Initiation ◽  
Coefficient Of Friction ◽  
Fatigue Crack Initiation ◽  
Orientation Angle ◽  
Fretting Fatigue ◽  
Multiaxial Fatigue ◽  
Process Variables ◽  
Critical Plane ◽  
The Coefficient Of Friction

A fretting fatigue crack initiation mechanism (number of cycles, location and orientation angle) using critical plane based parameters has been addressed by several researchers. There are several process variables that can affect these parameters and thereby the prediction of fretting fatigue crack initiation behaviour. Effects of two such parameters, viz. process volume and the coefficient of friction, were investigated in this work. Fretting fatigue experiments with a titanium alloy were conducted with different contact pad geometries. Finite element analysis (FEA) was used to obtain a stress state in specimens for the experimental conditions used during fretting fatigue tests. Analysis was carried out for two values of the coefficient of friction, thereby providing a framework for calculation of several critical plane based multiaxial fatigue parameters for different process volumes. A program was developed to compute these multiaxial fatigue parameters from the FEA data for different values of process variables. It was observed that parameters for cylindrical pad geometries with no singularity-type behaviour were inversely proportional to the size of process volume and directly proportional to the coefficient of friction. There was no change in the predicted orientation of the primary crack for this geometry, due to variations in these process variables. Parameters for flat-pad geometries with behaviour approaching that of a singularity were also inversely proportional to the size of process volume, but the coefficient of friction had a minimal effect on their values. Predicted orientation of the primary crack for these geometries changed slightly when the process volume increased from that of a grain size of the tested material to a larger size, and then did not change with the increase of process volume size. Overall, the effect of these process variables on the critical plane based parameters was similar in all five contact geometries used in this study, when the scatter in fatigue data is kept in mind. Finally, the modified shear stress range parameter satisfactorily predicted the crack initiation location, orientation angle and number of cycles to fretting fatigue crack initiation independent of the contact geometry for a given process volume size and coefficient of friction.

scholarly journals A crystal plasticity based investigation of fretting fatigue in bioresorbable magnesium elastic stable intramedullary nails (ESINs)

2020 ◽  
Author(s):  
Enda L. Boland ◽  
Parvin Ebrahimi ◽  
Elizabeth A. Gallagher ◽  
Patrick McGarry
Keyword(s):  
Fatigue Life ◽  
Cyclic Loading ◽  
Crack Initiation ◽  
Crystal Plasticity ◽  
Contact Surface ◽  
Pitting Corrosion ◽  
Fretting Fatigue ◽  
Fretting Wear ◽  
Intramedullary Nails ◽  
Plastic Slip

In this paper, the effect of pitting corrosion on fatigue life and fretting fatigue of elastic stable intramedullary nails (ESINs) is investigated. To this end, using a crystal plasticity formulation, the behaviour of magnesium under large deformations is investigated by implementing a user defined material subroutine (UMAT) in the Abaqus/Standard finite element solver. Using data provided by SEM images, the approximate configurations of grains in the polycrystalline material are obtained. Adopting Mg-RE (73-2) as one of candidates for implant applications, the fatigue analysis is performed, and the results are compared to the experimental fatigue data for various strain amplitudes. Furthermore, the effect of pitting corrosion on the fatigue life of the material is investigated. It is shown that the maximum accumulated plastic slip occurs at the tip of a corrosion pit. This suggests a faster crack initiation rate on corroded magnesium specimens compared to non-corroded ones, under cyclic loading. Application of pitting corrosion before cyclic loading, causes a significant reduction in the predicted cycles to crack initiation, compared to the uncorroded case. However, the number of cycles to crack initiation is almost the same irrespective of the amount of mass loss due to corrosion. Next, by modelling the fretting fatigue of ESINs, it is demonstrated that plastic slip accumulates at both the contact surface and deeper into the grain microstructure. However, the maximum values of stress and accumulated plastic slip occur at the contact surface. While the grain geometry and orientation influence the location and magnitude of accumulated plastic slip. By modelling the fretting fatigue of the material with different amounts of corrosion, it is shown that the maximum accumulated plastic slip occurs at the contact surface for the case without corrosion, and also for different percentages of corrosion. Finally, the results of fretting fatigue simulation of ESINs show that corrosion significantly accelerates crack initiation due to fretting wear.

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