Finite element simulation of the influence of fretting wear on fretting crack initiation in press-fitted shaft under rotating bending

• Published in: Wear Vol. 400-401; pp. 177 - 183
• Main Authors: Zhang, Y.B., Lu, L.T., Zou, L., Zeng, D.F., Zhang, J.W.
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 15.04.2018; Elsevier Science Ltd
• Subjects: Bending fatigue; Computer simulation; Crack initiation; Crack propagation; Damage accumulation; Fatigue failure; Finite element; Finite element analysis; Finite element method; Fracture mechanics; Fretting; Fretting fatigue; Fretting wear; Methodology; Predictions; Press-fitted shaft; Rotating shafts; Stress concentration; Studies; Wear; Press-fitted shaft; Fretting wear; Fretting fatigue; Finite element; Crack initiation
• ISSN: 0043-1648; 1873-2577
• DOI: 10.1016/j.wear.2018.01.008

A Finite element based methodology for fretting wear and fretting fatigue prediction in press-fitted shaft is developed. This methodology integrates wear modelling with fretting fatigue analysis to quantitatively predict of the effects of stress redistribution and material removal induced by the fretting wear on fretting crack initiation properties. The fretting wear-induced evolutions of mean normal stress, a mean correction multiaxial damage parameter and accumulated fatigue damage are predicted by this methodology. The results show that the fretting crack initiation at the contact edge is significantly suppressed by the severe fretting wear, since the server stress concentration is relieved and the surface material with high accumulated fatigue damage is grinded off. While, the fretting crack initiation at the inner surface of the contact area is greatly promoted by the slight wear by introducing the large stress concentration near the edge of fretted wear scar. •A Finite element based methodology for fretting wear-fatigue prediction in press-fitted shaft is developed.•The influence of fretting wear on fretting crack initiation in press-fitted shaft has been discussed in detail.•The severe fretting wear significantly suppresses the fretting crack initiation at the contact edge.•The fretting wear greatly promotes the fretting crack initiation at the inner surface of the contact area.