Analyses of Contact Pressure and Stress Amplitude Effects on Fretting Fatigue Life

[+] Author and Article Information
K. Iyer

Department of Aeronautical and Astronautics, Air Force Institute of Technology, Wright-Patterson AFB, OH 45433-7817

S. Mall

Materials and Manufacturing Directorate (AFRL/MLLN), Air Force Research Laboratory, Wright-Patterson AFB, OH 45433-7817

J. Eng. Mater. Technol 123(1), 85-93 (Jan 21, 2000) (9 pages) doi:10.1115/1.1288211 History: Received May 25, 1999; Revised January 21, 2000
Copyright © 2001 by ASME
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Schematic of the cylinder-on-flat contact geometry considered for study
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Finite element model of the cylinder-on-flat contact configuration. The supporting mechanism for holding the cylindrical pads in actual fretting fatigue fixtures is also modeled to mimic laboratory test conditions.
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Validity of the finite element model based on a comparison of computed and analytical solutions (Nowell and Hills 8) for the local, sub-surface bulk stress (σxx) distribution generated from the elastic contact of a cylinder with a half-space subjected to a remote bulk stress. “f” is the coefficient of friction, p0 is the peak contact pressure and “a” is the contact semi-width.
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Effect of normal load, P, on fretting fatigue life, Nf for σmax=552 MPa (Iyer and Mall 11). The stress range shown is the nominal (bulk) value applied during the test.
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Computed variations of (a) substrate stress concentration factor (SCF) and SCF’ and (b) stick zone size, with applied stress for an idealized cylinder-on-flat contact
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Distributions of contact pressure, p, slip amplitude and cyclic shear stress at the interface, and local bulk stress adjacent and parallel to the interface for P=3567 N and fatigue loading defined by σmax=552 MPa and R=0.1. The contact pressure and cyclic shear stress have been normalized by their peak values. Region “A” is the stick zone, “B” is the primary slip zone, and “C” is the secondary slip zone.
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Interfacial shear stress, q, under a constant normal load, P, and the maximum and minimum stresses of each load cycle. (a) P=3567 N, (b) P=2230 N, and (c) P=1338 N.
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σ1112 and σ22 (MPa) contours in the substrate under maximum load, σmax=552 MPa, and P=2230 N;T=tensile stress and C=compressive stress, and the arrows point to the peak values. The loading end is to the right.
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σ1112, and σ22 (MPa) contours in the substrate under minimum load, σmin=55.2 MPa, and P=2229 N;T=tensile stress and C=compressive stress, and the arrows point to the peak values. The loading end is to the right. The orientation of the figures is identical to that shown in Fig. 8.
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Computed effects of normal load, P, and stress ratio, R, on the Ruiz-Boddington-Chen parameters for predicting (a) fretting wear (F1) and (b) fretting fatigue life (F2)
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Measured fretting fatigue life, Nf, versus calculated values for maximum local bulk and shear stress ranges, ΔσL,max and ΔτL,max, respectively



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