Numerical Study of the Effects of Residual Stress on Fretting Fatigue Using XFEM.
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ABSTRACT:
SUBMITTER: Zhang H
PROVIDER: S-EPMC5455364 | biostudies-other | 2015 Oct
REPOSITORIES: biostudies-other
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Project description:Fretting wear is the material damage of two contact surfaces caused by micro relative displacement. Its characteristic is that debris is trapped on the contact surfaces. Depending on the material properties, the shapes of the debris, and the dominant wear mechanisms, debris can play different roles that either protect or harm interfaces. Due to the micro scale of the debris, it is difficult to obtain instantaneous information and investigate debris behavior in experiments. The Finite Element Method (FEM) has been used to model the process of fretting wear and calculate contact variables, such as contact stress and relative slip during the fretting wear process. In this research, a 2D fretting wear model with a debris layer was developed to investigate the influence of debris on fretting wear. Effects of different factors such as thickness of the debris layer, Young's modulus of the debris layer, and the time of importing the layer into the FE model were considered in this study. Based on FE results, here we report that: (a) the effect of Young's modulus of the debris layer on the contact pressure is not significant; (b) the contact pressure between the debris layer and the flat specimen decreases with increasing thickness of the layer and (c) by importing the debris layer in different fretting wear cycles, the debris layer shows different roles in the wear process. At the beginning of the wear cycle, the debris layer protects the contact surfaces of the first bodies (cylindrical pad and flat specimen). However, in the final cycle, the wear volumes of the debris layers exhibit slightly higher damage compared to the model without the debris layer in all considered cases.
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Project description:This article presents an experimental study on the fatigue behaviour of cracks emanating from cold-expanded holes utilizing thermoelastic stress analysis (TSA) and synchrotron X-ray diffraction (SXRD) techniques with the aim of resolving the long-standing ambiguity in the literature regarding potential relaxation, or modification, of beneficial compressive residual stresses as a result of fatigue crack propagation. The crack growth rates are found to be substantially lower as the crack tip moved through the residual stress zone induced by cold expansion. The TSA results demonstrated that the crack tip plastic zones were reduced in size by the presence of the residual compressive stresses induced by cold expansion. The crack tip plastic zones were found to be insignificant in size in comparison to the residual stress zone resulting from cold expansion, which implied that they were unlikely to have had a notable impact on the surrounding residual stresses induced by cold expansion. The residual stress distributions measured along the direction of crack growth, using SXRD, showed no signs of any significant stress relaxation or redistribution, which validates the conclusions drawn from the TSA data. Fractographic analysis qualitatively confirmed the influence on crack initiation of the residual stresses induced by the cold expansion. It was found that the application of single compressive overload caused a relaxation, or reduction in the residual stresses, which has wider implications for improving the fatigue life.
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Project description:A metallurgical zirconium nitride (ZrN) layer was fabricated using glow metallurgy using nitriding with zirconiuming prior treatment of the Ti6Al4V alloy. The microstructure, composition and microhardness of the corresponding layer were studied. The influence of this treatment on fretting wear (FW) and fretting fatigue (FF) behavior of the Ti6Al4V alloy was studied. The composite layer consisted of an 8-μm-thick ZrN compound layer and a 50-μm-thick nitrogen-rich Zr-Ti solid solution layer. The surface microhardness of the composite layer is 1775 HK0.1. A gradient in cross-sectional microhardness distribution exists in the layer. The plasma ZrN metallurgical layer improves the FW resistance of the Ti6Al4V alloy, but reduces the base FF resistance. This occurs because the improvement in surface hardness results in lowering of the toughness and increasing in the notch sensitivity. Compared with shot peening treatment, plasma ZrN metallurgy and shot peening composite treatment improves the FW resistance and enhances the FF resistance of the Ti6Al4V alloy. This is attributed to the introduction of a compressive stress field. The combination of toughness, strength, FW resistance and fatigue resistance enhance the FF resistance for titanium alloy.
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Project description:In the present article, fatigue properties (pure and fretting) of magnesium alloys (AM60) under cyclic bending loading were compared. For this objective, a rotary fatigue testing device was utilized with a fretting module on standard cylindrical samples under bending loads with zero means stress. The fretting fatigue condition decreased fatigue lifetime compared with pure fatigue but in an amazing Epsilon-shaped trend. Comparatively speaking to the state of pure fatigue, the fatigue lifetime of the fretting fatigue condition reduced by 91.0% and 44.8%, respectively, between the lowest level of stress (80 MPa) and the greatest level of stress (120 MPa). To study the fracture behavior and the fractography analysis, field-emission scanning electron microscopy (FESEM) was utilized. In general, since both quasi-cleavage and cleavage were seen; therefore, the fracture behavior for all samples was brittle. In both test conditions (fretting fatigue and pure fatigue), at higher stress levels, the average crack length was higher than at low-stress levels. In addition, the number of cracks (in high- and low-stress levels) was observed to be less in fretting fatigue conditions than in pure fatigue conditions, but the average crack length in fretting fatigue conditions in high-stress levels and low-stress levels was 212.82% and 259.47% higher than the average crack length under the pure fatigue condition, respectively.
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Project description:An investigation was carried out in order to study the fretting fatigue behavior of an AlSi9Cu2Mg aluminum alloy. The fretting fatigue tests of AlSi9Cu2Mg were performed using a specially designed testing machine. The failure mechanism of fretting fatigue was explored by studying the fracture surfaces, fretting scars, fretting debris, and micro-hardness of fretting fatigue specimens using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and micro Vickers hardness test techniques. The experimental results show that the fretting fatigue limit (42 MPa) is significantly reduced to approximately 47% of the plain fatigue limit (89 MPa) under 62.5 MPa contact pressure. Furthermore, the fretting fatigue life decreases with increasing alternating stress and increasing contact pressure. The examination results suggest that the stress concentrates induced by oxidation-assisted wear on the contact interface led to the earlier initiation and propagation of crack under the fretting condition.
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Project description:Fretting is a phenomenon that occurs at the contacts of surfaces that are subjected to oscillatory relative movement of small amplitudes. Depending on service conditions, fretting may significantly reduce the service life of a component due to fretting fatigue. In this regard, the analysis of stresses at contact is of great importance for predicting the lifetime of components. However, due to the complexity of the fretting phenomenon, analytical solutions are available for very selective situations and finite element (FE) analysis has become an attractive tool to evaluate stresses and to study fretting problems. Recent laboratory studies in fretting fatigue suggested the presence of stress singularities in the stick-slip zone. In this paper, we constructed finite element models, with different element sizes, in order to verify the existence of stress singularity under fretting conditions. Based on our results, we did not find any singularity for the considered loading conditions and coefficients of friction. Since no singularity was found, the present paper also provides some comments regarding the convergence rate. Our analyses showed that the convergence rate in stress components depends on coefficient of friction, implying that this rate also depends on the loading condition. It was also observed that errors can be relatively high for cases with a high coefficient of friction, suggesting the importance of mesh refinement in these situations. Although the accuracy of the FE analysis is very important for satisfactory predictions, most of the studies in the literature rarely provide information regarding the level of error in simulations. Thus, some recommendations of mesh sizes for those who wish to perform FE analysis of fretting problems are provided for different levels of accuracy.
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Project description: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.
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