Prediction of the fretting fatigue resistance of various surface-modification layers on 1045 steel: the role of fretting maps

In this work, fretting maps of various surface modifications were established based on the friction logs of fretting experiments. The fretting fatigue resistance of the coatings was analyzed according to the features of the fretting maps of the coatings. The results showed clearly that fretting maps of materials are effective tools to predict the fretting fatigue properties of substrates and surface-modification coatings. It was also demonstrated that the fretting fatigue resistance of a 1045 steel substrate could be improved to different extents through surface modification. The fretting fatigue resistance of solid lubricating coatings was the best and the tendency for initiation and propagation of cracks in the substrate material could also be restrained by depositing hard coatings.     

Some observations on the CLNA model in fretting fatigue

Using the Atzori–Lazzarin criterion, the author has recently proposed a unified model for Fretting Fatigue denominated Crack-Like Notch Analogue—CLNA model, considering only two possible behaviours: either “crack-like” or “large blunt notch”. In a general FF condition, the former condition is treated with a single contact problem corresponding to the MIT Crack Analogue (CA) improved in some details also by the author. The latter, with a simple peak stress condition, i.e. a simple Notch Analogue model, simply stating that below the fatigue limit, infinite life is predicted for any size of contact. In the typical condition of constant normal load and in phase oscillating tangential and bulk loads, both limiting conditions are immediately written, and the CLNA model permits to collapse the effect of the contact loads on a single closed form equation (differently from many other models which do not permit this flexibility). For not too large contact areas (“crack-like” contact) no dependence at all on geometry is predicted, but only on 3 load factors (bulk stress, tangential load and average pressure) and size of the contact. Only in the “large blunt notch” region occurring typically only at very large sizes of contact does size-effect disappear, but the dependence on all other factors including geometry remains. The model compares favourably with some experimental results in the literature. In this paper, some aspects of the CLNA model are further elucidated.     

Finite element analysis of shot-peening effect on fretting fatigue parameters

Shot peening is widely used to improve the fretting fatigue strength of critical surfaces. Fretting fatigue occurs in contacting parts that are subjected to fluctuating loads and sliding movements at the same time. This paper presents a sequential finite element simulation to investigate the shot peening effects on normal stress, shear stress, bulk stress and slip amplitude, which are considered to be the controlling parameters of fretting damage. The results demonstrated that among the modifications related to shot peening, compressive residual stress has a dominant effect on the fretting parameters.     

Effect of contact pressure on fretting fatigue of austenitic stainless steel

The effect of contact pressure on fretting fatigue in solution-treated austenitic stainless steel was studied. With an increase in contact pressure, fretting fatigue life was almost unchanged at low contact pressures, however it decreased drastically at high contact pressures. At low contact pressures, stress concentration due to fretting damage occurred at the middle portion of the fretted area and the main crack responsible for failure was initiated there. At high contact pressures, concavity was formed at the fretted area without accompanying heavy wear. The main crack was initiated at the outer edge corner of the concavity which probably acted as a notch. Plain fatigue prior to the fretting fatigue test increased the fretting fatigue life at high contact pressures since the concavity formation was suppressed by the cyclic strain hardening.     

Effect of contact load on fretting fatigue behaviour of steel wires

Abstract

The tension–tension fretting fatigue tests of steel wires were performed on a self-made fretting fatigue test equipment under contact loads ranging from 40 to 70 N and a strain ratio of 0·8. The results showed that when the contact load increased, the fretting regime of steel wires transformed from gross slip regime to mixed fretting regime. The fretting fatigue life in the mixed fretting regime was significantly lower than that in the gross slip regime. The main fretting wear mechanisms in the gross slip regime, where there were serious fretting damage and a lot of wear debris, were abrasive wear and fatigue wear. Microcracks were observed in the fretting scar of the mixed fretting regime, and the main fretting wear mechanisms were adhesive and fatigue wears. The fretting wear scar was the fatigue source region, and the fatigue fracture surface could be divided into three regions.     

Subsurface damage development during fretting fatigue of high strength steel

The results of fretting fatigue experiments performed on two high-strength structural steels, PH 13-8 Mo stainless steel and quenched and tempered 4340 steel, are evaluated. Observations regarding the subsurface deformation and cracking behavior of the steels are compared and contrasted. It was found that the fretting stresses influenced early crack growth to a greater depth in PH 13-8 Mo stainless steel than in 4340 steel. In addition, experiments on PH 13-8 Mo led to the development of a region below the fretting scar that underwent a microstructural transformation, while experiments on 4340 steel did not. Likely reasons for this discrepancy are suggested. Differences in the formation of oxide layers and the occurrence of adhesion between the two materials are also discussed.     

The effect of hydrogen gas environment on fretting fatigue strength of materials used for hydrogen utilization machines

The objective of this study is the characterization of the fretting fatigue strength in a hydrogen gas environment. The test materials were a low alloy steel SCM435H, super alloy A286 and two kinds of austenitic stainless steels, SUS304 and SUS316L. The test was performed in hydrogen gas at 0.12 MPa absolute pressure. The purity of the hydrogen gas was 99.9999%. The fretting fatigue limit was defined by the fretting fatigue strength at 30 million cycles. For all materials, the fretting fatigue strength in the hydrogen gas environment increased in the short-life region. However, the fretting fatigue strength in the hydrogen gas environment decreased in the long-life region when exceeding 10 million cycles except for SCM435H, while there was no reduction in the fretting fatigue strength in air between 10 and 30 million cycles. The reduction rate was 18% for A286, 24% for SUS304 and 7% for SUS316L. The tangential force coefficient in the hydrogen gas environment increased when compared to that in air. It can be estimated that this increase is one of the causes of the reduced fretting fatigue strength found in a hydrogen gas environment. In order to discuss the extension of the fretting fatigue life in hydrogen gas observed at the stress level above the fretting fatigue limit in air, continuous measurement of the fretting fatigue crack propagation was performed in a hydrogen gas environment using the direct current potential drop method. As a result, it was found that the extension of the fretting fatigue life was caused by the delay in the start of the stable crack propagation.     

Microstructure sensitivity of fretting fatigue based on computational crystal plasticity

Three-dimensional finite element simulations are conducted to study the effects of microstructure on the fretting fatigue behavior of duplex Ti-6Al-4V. These fretting simulations involve a rigid cylindrical indenter pressed on the half space of Ti-6Al-4V with different realizations of microstructure. The deformation behaviors of the primary α and α/β lamellar phases at room temperature are described by three-dimensional crystal plasticity constitutive relations. Microstructure attributes considered in this sensitivity study include crystallographic texture, grain size, and grain size distribution. Voronoi tessellation is used to construct the three-dimensional finite element models with various grain size distributions. The plastic strain behaviors and the distribution of the average maximum plastic shear strain among grains are analyzed and contrasted. The relative susceptibility for crack formation, including effects of various microstructure features, is determined using the Fatemi-Socie parameter. The results suggest that both average grain size and especially crystallographic texture have more influence on the plastic deformation and fretting fatigue behavior than grain size distribution for the fretting condition considered.     

On the application of a micromechanical small fatigue crack growth model to predict fretting fatigue life in AA7075-T6 under spherical contact

This work presents a method for assessing the fretting fatigue life by estimating the fatigue crack growth rate from the regime of microcracks to the final failure, which is achieved using a two-threshold small fatigue crack growth model. The propagation thresholds are associated with the interaction of the "monotonic plastic zone" and the "cyclic plastic zone" with the microstructure of the material. The predicted fatigue life and the estimated non-propagating cracks agree very well with the experimental fretting fatigue tests with spherical contact in 7075-T6 aluminium alloy.     

Influence of surface-coatings on titanium-alloy resistance to fretting fatigue in cryogenic environment

Fretting damage, also known as small amplitude oscillatory sliding motion, can lead to catastrophic failure in many industrial applications. The understanding of fretting fatigue and its reproduction in laboratory tests have enable us to evaluate the fretting resistance of homogeneous substrate. To reduce the damage caused by fretting fatigue increasing use has been made of coatings or heat treatments which result in non homogeneous solids. From a theoretical point of view, ascertaining the mechanical behaviour of materials so modified is quite complex due to insufficient definition of the contact parameters. This present study seeks to analyse a layered medium undergoing fretting fatigue and the improvement of its fatigue criterion.     

Proposition of a finite element-based approach to compute the size effect in fretting fatigue

The aim of this paper is to propose a finite element (FE)-based methodology capable to predict the pad size effect on specimen life. This phenomenom has been observed in a number of available fretting fatigue tests, which will be considered to validate the analysis. The proposed methodology differs from conventional FE analysis as (i) it provides a direct evaluation of the fatigue strength at nodal points, besides the traditional stress/strain results and (ii) it proposes that, for problems involving the presence of severe stress gradients, as it is the case in many mechanical assemblies subjected to fretting, the size of the FE should be defined so that it characterizes the stress state in a process zone rather in a point. A discussion of how to define a priori the size of such FE is also conducted. Multiaxial stress-based criteria incorporated into the code are considered to carry out the fatigue analysis. The results obtained show that there is not a single range of FE sizes capable to correctly predict the fretting fatigue limit for all tests considered.     

汽车轮胎气压自动调节系统的研究

轮胎气压自动调节、防爆胎、轮胎长寿命、高效节能的汽车车轮，具有高压储气轮辐、自动调压充气阀门、自动卸压排气阀门等部件构成轮胎气压自动调节系统，是汽车车轮设计制造具有实用价值的技术创新。此项发明专利技术基本成熟，其结构简单，经济适用。可以提高汽车的动力性、通过性、制动性、操纵稳定性、燃料经济性、工作可靠性、轮胎耐久性和行驶安全性等。具有标准化、通用化、系列化生产的可行性，具有很高的应用价值和广阔的市场前景。     

An experimental study on bending fretting fatigue characteristics of 316L austenitic stainless steel

Bending fretting fatigue tests of 316L austenitic stainless steel plates against 52100 steel cylinders have been carried out under same normal load and varied bending loads. Tests of plain bending fatigue were carried out as a control group. The S-N curves of the bending fatigue were made. The results indicated that there was an obvious drop of life under the condition of bending fretting fatigue due to higher local contact stress. A dislocation model of micro-crack nucleation mechanism, as a manner of zig-zag mode, was created to explain the nucleation of fretting fatigue cracks.     

Numerical analysis for predicting the rolling contact fatigue crack initiation in a railway wheel steel

This paper concerns the modelling of the rolling contact fatigue of a railway wheel steel, which is simulated with moving Hertzian contact pressure. Parametric studies are carried out with a two-dimensional elastic-plastic finite element model of a part of a wheel containing defects. Several parameters, namely the size and shape of material defects, the load magnitude and the friction coefficient are varied to investigate their effect on the railway wheel fatigue damage. Defects or small friction coefficient are a plausible explanation to the initiation of deep subsurface fatigue cracks.     

The effect of variable amplitude loading on stress distribution within a cylindrical contact subjected to fretting fatigue

A finite element model of a cylindrical Hertzian contact on a test sample subjected to alternating shear loading has been developed. The model has been used to investigate shear stress distributions at the contact during variable amplitude fretting fatigue for a load configuration in which the sample cyclic stress is applied in phase with shear force on the cylindrical contact. It has been found that during constant amplitude cyclic loading, shear stress distributions and positions of the stick-slip boundary at load maxima and minima remain fixed. Application of overloads changes the stress distribution and the position of the stick-slip boundary attained by loading of subsequent cycles. The largest cycle maximum stress determines the position of the stick-slip boundary adopted by subsequent smaller amplitude cycles. In general variable amplitude fretting fatigue the position of the stick-slip boundary will be changing with each load cycle. Hence fatigue initiation processes will occur at locations dispersed over an extended region over the contact. The implications of this behaviour for models for fretting fatigue life calculation are explored.     

Experimental investigation on the effect of tangential force on wear and rolling contact fatigue behaviors of wheel material

The study aims to explore the effect of tangential force on wear and rolling contact fatigue (RCF) behaviors of wheel material using a JD-1 wheel/rail simulation facility. The normal, tangential and lateral forces between the wheel/rail rollers are controlled, and the magnetic power brake was used to generate the tangential forces (16–330 N). The results indicate that the surface hardness and wear loss of wheel rollers increase with the tangential force increasing. The surface cracks mouths are perpendicular to the resultant directions of the frictional forces. There are visible secondary cracks and multilayer cracks and the interlayer material of multilayer cracks are easy to break. The compositions of wear debris consist of Fe₂O₃, Fe₃O₄ and iron.     

Torsional fretting fatigue strength of a shrink-fitted shaft with a grooved hub

Fretting causes considerable reduction in the fatigue strength of a shrink-fit assembly and failures through fretting are as numerous as failures from normal fatigue. The purpose of this investigation was to determine the effect of contact pressure and slip amplitude on the fatigue limit, and a favourable value for overhang of hub and fillet radius with constant diameter ratio, at which fretting failure can be avoided and the maximum normal fatigue strength will be obtained. The torsional fatigue strength of shrink-fitted shaft couplings was estimated by tests performed by varying the overhang of the hub, the fillet radius of the shaft and the contact pressure of the shrink-fitted assembly. Press-fitting of the hub overhanging the shoulder was used to increase the contact pressure. The tests were performed using a grooved hub. These experiments showed that fretting was reduced with an increase in contact pressure, because the slip amplitude decreased. The shaft was fractured just inside the end of the fit by fretting fatigue with low contact pressure, but if the contact pressure was very high, the shaft fractured at the fillet by normal fatigue. The fretting fatigue limit at a constant diameter ratio increases with an increase in the fillet radius, and reaches its maximum value at a certain radius using the grooved hub.     

材料特性对车轮疲劳强度的影响

研究材料非线性本构、非金属夹杂物、低温冲击功和断裂韧性对高速动车组车轮疲劳强度的影响。考虑弹塑性接触带钢轨车轮有限元分析模型,研究不同轮径下车轮轮辋应力分布规律。研究影响车轮疲劳强度的材料主要性能指标,研究夹杂物尺寸和许用应力、裂纹扩展门槛值的关系。研究断裂韧性和踏面剥离的关系、低温冲击功和车轮瞬间脆性破坏的关系。分析不同轮径和车轮疲劳强度的关系。     

Modelling and evaluation of the fretting fatigue cracking risk in smooth spherical contacts

A numerical model for the calculation of fretting fatigue crack initiation is presented and compared with experiments. The model is focused on smooth sphere-on-plane contact in partial and gross slip conditions. It is based on Hamilton’s explicit stress equations and the multi-axial Dang Van and Findley fatigue criteria enhanced with a statistical size factor concept. Promising correlation was found between the model and the experimental results with quenched and tempered steel 34CrNiMo6. The model assumptions, limitations and general application are also discussed.     

Fretting fatigue strength estimation considering the fretting wear process

In fretting fatigue process the wear of contact surfaces near contact edges occur in accordance with the reciprocal micro-slippages on these contact surfaces. These fretting wear change the contact pressure near the contact edges. To estimate the fretting fatigue strength and life it is indispensable to analyze the accurate contact pressure distributions near the contact edges in each fretting fatigue process.So, in this paper we present the estimation methods of fretting wear process and fretting fatigue life using this wear process. Firstly the fretting-wear process was estimated using contact pressure and relative slippage as follows:

W=K×P×S,