Fatigue Life Prediction and Fracture Behavior Study of Fretting Interface at Three-dimensional Line Contact

doi:10.3901/JME.2024.08.107

Abstract

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

CLC Number:

TH131

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.

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