三维线接触微动界面疲劳寿命预测及断裂行为研究

doi:10.3901/JME.2024.08.107

摘要/Abstract

摘要： 工程机械中常用的连接结构由两个或多个零件紧密配合而成，在运行过程中接触的零件相互挤压的同时伴随有小幅相对滑动，易发生微动疲劳。微动疲劳主要分为疲劳裂纹萌生、疲劳裂纹扩展和快速断裂三个阶段，连接结构中的零件断裂可引起严重事故。现有的研究主要基于经过简化的二维平面应变模型，为了更清楚地了解微动疲劳的断裂机制，首先建立了微动条件下的三维线接触有限元模型，然后基于临界平面法分析了裂纹萌生寿命、位置和角度，最后基于线弹性断裂力学模拟了三维疲劳裂纹扩展过程。结果表明：在微动载荷的作用下，裂纹以一定倾斜角度在接触区域边缘处萌生，先沿着萌生方向逐渐扩展，当疲劳裂纹扩展至一定深度时，在循环体应力作用下，其方向逐渐变为垂直于接触表面，最终使试件断裂。裂纹萌生阶段的寿命远大于扩展阶段的寿命，占微动疲劳寿命的70%～80%。计算得到的疲劳寿命与文献中微动试验的寿命结果在2倍的分散带内，验证了该方法的有效性。该仿真分析方法可为连接结构的抗微动疲劳设计提供理论基础。

关键词: 微动接触, 部分滑移, 多轴疲劳, 临界平面法, 疲劳断裂

Abstract: The connection structure commonly used in construction machinery is made up of two or more parts that are closely matched. During the operation, the parts in contact with each other are squeezed against each other and accompanied by a small relative sliding, which is prone to fretting fatigue. Fretting fatigue is mainly divided into three stages: fatigue crack initiation, fatigue crack propagation and rapid fracture. The fracture of parts in the connecting structure can cause serious accidents. The existing research is mainly based on the simplified two-dimensional plane strain model. In order to understand the fracture mechanism of fretting fatigue more clearly, a three-dimensional line contact finite element model under fretting conditions is first established. Then, the crack initiation life, location and angle were determined based on the critical plane method. Lastly, the three-dimensional fatigue crack propagation process was simulated according to the linear elastic fracture mechanics. The results show that the crack initiates at the trailing of the contact area at a certain inclination angle and firstly expands along the initiation direction. When the fatigue crack propagates to a certain depth, its growth path gradually becomes perpendicular to the contact surface under the action of the cyclic body stress, eventually breaking the test piece. The life of the crack initiation stage is much longer than that of the propagation stage, accounting for about 70%-80% of the fretting fatigue life. The calculated fatigue life is within a double dispersion band of the life results reported in the literature, which verifies the effectiveness of the method. The developed method can provide a theoretical basis for the anti-fretting fatigue design of the connection structure.

Key words: fretting contact, partial slip, multiaxial fatigue, critical plane method, fatigue fracture

中图分类号:

TH131

董庆兵, 陈壮, 罗振涛, 张杰, 魏静. 三维线接触微动界面疲劳寿命预测及断裂行为研究[J]. 机械工程学报, 2024, 60(8): 107-120.

DONG Qingbing, CHEN Zhuang, LUO Zhentao, ZHANG Jie, WEI Jing. Fatigue Life Prediction and Fracture Behavior Study of Fretting Interface at Three-dimensional Line Contact[J]. Journal of Mechanical Engineering, 2024, 60(8): 107-120.

参考文献

[1] ANDRESEN H，HILLS D A. A review of partial slip solutions for contacts represented by half-planes including bulk tension and moments[J]. Tribology International，2020，143：106050.
[2] JEUNG H-K，KWON J-D，LEE C Y. Crack initiation and propagation under fretting fatigue of inconel 600 alloy[J]. Journal of Mechanical Science and Technology，2015，29(12)：5241-5244.
[3] ARNAUD P，FOUVRY S. Modeling the fretting fatigue endurance from partial to gross slip：The effect of debris layer[J]. Tribology International，2020，143：106069.
[4] MADGE J J，LEEN S B，MCCOLL I R，et al. Contact-evolution based prediction of fretting fatigue life：Effect of slip amplitude[J]. Wear，2007，262(9)：1159-1170.
[5] CARDOSO R A，DOCA T，NÉRON D，et al. Wear numerical assessment for partial slip fretting fatigue conditions[J]. Tribology International，2019，136：508-523.
[6] BERTHEL B，MOUSTAFA A R，CHARKALUK E，et al. Crack nucleation threshold under fretting loading by a thermal method[J]. Tribology International，2014，76：35-44.
[7] HILLS D A，ANDRESEN H N. Mechanics of fretting and fretting fatigue[M]. Berlin：Springer，2021.
[8] LIU J，ZHANG Z，LI B，et al. Multiaxial fatigue life prediction of GH4169 alloy based on the critical plane method[J]. Metals，2019，9(2)：255.
[9] PEREIRA K，BHATTI N，ABDEL WAHAB M. Prediction of fretting fatigue crack initiation location and direction using cohesive zone model[J]. Tribology International，2018，127：245-254.
[10] CARPINTERI A，KUREK M，ŁAGODA T，et al. Estimation of fatigue life under multiaxial loading by varying the critical plane orientation[J]. International Journal of Fatigue，2017，100：512-520.
[11] BHATTI N A，ABDEL WAHAB M. Fretting fatigue crack nucleation：A review[J]. Tribology International，2018，121：121-138.
[12] SMITH K N，TOPPER T，WATSON P. A stress–strain function for the fatigue of metals[J]. J. Materials，1970，5：767-778.
[13] SOCIE D F，MORROW J. Review of contemporary approaches to fatigue damage analysis [M]//BURKE J J，WEISS V. Risk and failure analysis for improved performance and reliability. Boston：Springer，1980：141-194.
[14] BROWN M W，MILLER K J. Initiation and growth of cracks in biaxial fatigue[J]. Fatigue & Fracture of Engineering Materials & Structures，1979，1：231-246.
[15] RANGEL D，ERENA D，VÁZQUEZ J，et al. Prediction of initiation and total life in fretting fatigue considering kinked cracks[J]. Theoretical and Applied Fracture Mechanics，2022，119：103345.
[16] SOCIE D. Multiaxial fatigue damage models[J]. Journal of Engineering Materials and Technology，1987，109(4)：293-298.
[17] LYKINS C D，MALL S，JAIN V. An evaluation of parameters for predicting fretting fatigue crack initiation[J]. International Journal of Fatigue，2000，22(8)：703-716.
[18] LYKINS C D，MALL S，JAIN V K. Combined experimental-numerical investigation of fretting fatigue crack initiation[J]. International Journal of Fatigue，2001，23(8)：703-711.
[19] RUTHERFORD B A，CISKO A R，ALLISON P G，et al. Effect of tensile mean strain on fatigue behavior of Al-Li alloy 2099[J]. Journal of Materials Engineering and Performance，2020，29(8)：4928-4933.
[20] NESLÁDEK M，PACETTI L，PAPUGA J. Validation of fatigue criteria under fretting fatigue conditions[J]. International Journal of Fatigue，2022，161：106895.
[21] LI J，ZHANG Z，SUN Q，et al. A new multiaxial fatigue damage model for various metallic materials under the combination of tension and torsion loadings[J]. International Journal of Fatigue，2009，31：776-781.
[22] LI X，ZUO Z，QIN W. A fretting related damage parameter for fretting fatigue life prediction[J]. International Journal of Fatigue，2015，73：110-118.
[23] NAMJOSHI S，MALL S，JAIN V，et al. Fretting fatigue crack initiation mechanism in Ti-6Al-4V[J]. Fatigue & Fracture of Engineering Materials & Structures，2002，25：955-964.
[24] 王肇喜，白金，王海东，等. 临界平面多轴疲劳寿命估算模型的验证与评估[J]. 失效分析与预防，2020，15(6)：343-348. WANG Zhaoxi，BAI Jin，WANG Haidong，et al. Verification and evaluation of critical plane-based multiaxial fatigue life prediction models[J]. Failure Analysis and Prevention，2020，15(6)：343-348.
[25] 陈壮. 球-滚道接触运动对滚道疲劳寿命的影响研究[D]. 昆明：昆明理工大学，2020. CHEN Zhuang. Study on the effect of ball-raceway contact movement on raceway fatigue life[D]. Kunming：Kunming University of Science and Technology，2020.
[26] KONG Y，BENNETT C J，HYDE C J. A review of non-destructive testing techniques for the in-situ investigation of fretting fatigue cracks[J]. Materials & Design，2020，196：109093.
[27] HOJJATI-TALEMI R，ABDEL WAHAB M，DE PAUW J，et al. Prediction of fretting fatigue crack initiation and propagation lifetime for cylindrical contact configuration[J]. Tribology International，2014，76：73-91.
[28] DENG Q，YIN X，WANG D，et al. Numerical analysis of crack propagation in fretting fatigue specimen repaired by stop hole method[J]. International Journal of Fatigue，2022，156：106640.
[29] MINDLIN R D. Compliance of elastic bodies in contact[J]. Journal of Applied Mechanics，2021，16(3)：259-268.
[30] NOWELL D，HILLS D A. Crack initiation criteria in fretting fatigue[J]. Wear，1990，136(2)：329-343.
[31] TAGHIZADEH H，CHAKHERLOU T N，AGHDAM A B. Prediction of fatigue life in cold expanded Al-alloy 2024-T3 plates used in double shear lap joints[J]. Journal of Mechanical Science and Technology，2013，27(5)：1415-1425.
[32] SUM W S，WILLIAMS E J，LEEN S B. Finite element，critical-plane，fatigue life prediction of simple and complex contact configurations[J]. International Journal of Fatigue，2005，27(4)：403-416.
[33] LEMAITRE J，CHABOCHE J-L. Mechanics of solid materials[M]. Cambridge：Cambridge University Press，1990.
[34] 张远彬. 铁路轮轴过盈配合部位微动疲劳裂纹萌生的仿真研究[D]. 成都：西南交通大学，2018. ZHANG Yuanbin. Finite element simulation of fretting fatigue crack initation in press-fitted part of railway wheel-axle[D]. Chengdu：Southwest Jiaotong University，2018.
[35] 董国疆，张猛，魏留伟，等. 底盘构件多轴随机载荷下高周疲劳准则研究[J]. 中国机械工程，2021，32(19)：2294-2304. DONG Guojiang，ZHANG Meng，WEI Liuwei，et al. Study on high cycle fatigue criteria under multi-axial random loads of chassis parts[J]. China Mechanical Engineering，2021，32(19)：2294-2304.
[36] MADGE J J，LEEN S B，SHIPWAY P H. The critical role of fretting wear in the analysis of fretting fatigue[J]. Wear，2007，263(1)：542-551.
[37] ERDOGAN F，SIH G C. On the crack extension in plates under plane loading and transverse shear[J]. Journal of Basic Engineering，1963，85(4)：519-525.
[38] LIN Xinhao，XU Yazhou. An equivalent damage model to fretting fatigue initiation life considering wear[J]. International Journal of Fatigue，2022，163：107048.
[39] GINER E，SUKUMAR N，DENIA F D，et al. Extended finite element method for fretting fatigue crack propagation[J]. International Journal of Solids and Structures，2008，45(22)：5675-5687.
[40] Fracture Analysis Consultants，Inc. Franc3D user’s guide[M]. Version 8.1. Ithaca：Fracture Analysis Consultants，Inc.，2022.
[41] 杨新华，陈传尧. 疲劳与断裂[M]. 2版. 武汉：华中科技大学出版社，2008. YANG Xinhua，CHEN Chuanyao. Fatigue and fracture [M]. 2nd ed. Wuhan：Huazhong University of science & Technology Press，2008.
[42] WANG C，PEREIRA K，WANG D，et al. Fretting fatigue crack propagation under out-of-phase loading conditions using extended maximum tangential stress criterion[J]. Tribology International，2023，187：108738.
[43] PINTO A L，ARAÚJO J A，TALEMI R. Effects of fretting wear process on fatigue crack propagation and life assessment[J]. Tribology International，2021，156：106787.