Analysis of Fretting Fatigue Crack Initiation in A Riveted Two Aluminum Specimen
Analysis of Fretting Fatigue Crack Initiation in A Riveted Two Aluminum Specimen
Analysis of Fretting Fatigue Crack Initiation in A Riveted Two Aluminum Specimen
ABSTRACT
Based on the existing experiment results, the fretting fatigue contact geometry of a riveted two aluminum specimen was
studied using the finite element method. The contact stress fields of the inner and outer contact edges on the two specimens up and down surface under different contact friction coefficient and the fatigue loads were analyzed, the influences of the contact friction coefficient and remote stress on crack initiation were discussed. The results were in well
agreement with the observations of the existing experiments, that is, the crack initiated places of the first aluminum
specimen change from the area of 900 to 450, and the crack initiated places of the second aluminum specimen change
from the area of 900 to 1350 with the increase of the friction coefficient and the remote stress.
Keywords: A Riveted Two Aluminum Specimen; Crack Initiation; Frictional Coefficient; Fatigue Loads
1. Introduction
Fretting fatigue is one of the main reasons for the failure
of structure components, even the causes of many major
accidents in the fields of aviation, transportation and
mechanics etc. The fretting fatigue begins with the wear
and sometimes corrosion damage at the asperities of the
contact surfaces of the riveted components, which will
further induce the initiation and propagation of microcracks. With the appearance of the micro-cracks, the fatigue strength of the riveted components will significantly reduce, leading to the decrease of the components
service life [1]. Actually, the fretting fatigue is a damage
process which is induced by the cyclic stress that works
on the asperities of the materials near-surface and causes
the locally permanent structure deformations on the surface [2]. Under the action of the cyclic stress, the components immediately enter into a fatigue development
process. The results of the damage accumulation during
this process are the initiation and propagation of the
cracks, following with the final fracture to end the
process. The researches of fretting fatigue are very significant to ease fretting damage industry today. Due to
the complicate deformation process and the difficulties
on current experimental measurements, the researches of
*
Project supported by the National Natural Science Foundation of China (Grant No. 11072092 and 11262007).
#
Corresponding author.
Open Access
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ff f 2 P0 (1 e S K )
=
Aluminum plate II
(1)
3. Modeling
3.1. Computational Model
The 3D finite element model of the rived aluminum specimen and its meshing result are showed in Figure 1. In
order to reduce the computational cost, only half of the
FEM model is constructed according to the symmetries
of the specimen. The model is composed of 8 parts, including two aluminum plates, one screw bolt, one protective sleeve, two screw caps and two gaskets. In order to
further reduce the model size and computational cost, the
reducing of the meshing numbers and contact areas is
are often adopted in the FEM simulation. Thus, we treat
the screw bolt, the protective sleeve, the screw caps and
the gaskets as an integrated section to neglect the contacts between those parts. Three contacts regions are investigated in the simulations as shown in Figure 2: The
first region is the contact area between the upper protective sleeves lower surface and the aluminum plate Is
upper surface; the second region is the contact area between the two aluminum plates; the third region is the
area between the lower protective sleeves upper surface
and the aluminum plate IIs lower surface. Among these
three regions, the stress distributions of upper and lower
surfaces of the two aluminum plates are emphatically
analyzed to evaluate the specimens fatigue life. The
eight-node hexahedral solid elements are employed in the
Open Access
Aluminum plate I
ET AL.
Aluminum plate I
parts
material
C45 steels
(elastoplasticity)
Youngs modulus E
210 GPa
210 GPa
70 GPa
Poissons ratio
0.3
0.3
0.3
Fatigue load
(a)
Aluminum plate II
Contact area
Fatigue load
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50
x
(b)
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ET AL.
150
51
500
120
(=0.35)
(=0.5)
(=0.7)
90
(=0.35)
(=0.5)
(=0.7)
400
300
60
20
40
60
80
100
-30
120
140
160
180
200
angle degree
MPa
-60
-90
200
100
0
0
20
MPa
stress amplitudes
stress amplitudes
30
40
60
-120
-150
80
100
120
140
160
180
200
angle degree
-100
-200
(a)
(b)
120
(f=0.35)
(f=0.5)
(f=0.7)
60
400
20
40
60
80
-30
-60
-90
100
120
140
160
180
200
angle degree
stress amplitudes
MPa
stress amplitudes
30
(=0.35)
(=0.5)
(=0.7)
300
200
100
0
0
-100
-120
-150
20
MPa
90
40
60
80
100
120
140
160
180
200
angle degree
-200
(c)
(d)
Figure 4. The distributions of stress amplitude in the inner and outer circle contact edges of the aluminum plates under different friction coefficient conditions. (a) The outer circle contact edges of the aluminum plate Is upper surface; (b) The inner
circle contact edges of the aluminum plate Is upper surface; (c) The outer circle contact edges of the aluminum plate IIs
lower surface; (d) The inner circle contact edges of the aluminum plate IIs lower surface.
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52
50
ET AL.
00
(f=0.35)
(f=0.5)
(f=0.7)
20
90
(f=0.35)
(f=0.5)
(f=0.7)
00
00
60
00
30
00
0
20
40
60
80
60
90
100
120
140
160
180
200
angle degree
00
0
0
20
00
20
00
50
00
MPa
MPa
30
40
60
80
20
120
140
(b)
180
200
(f 0.35)
(f=0.5)
(f=0.7)
00
00
90
160
angle degree
(a)
(
)
(f=0.5)
(f=0.7)
50
100
00
60
00
30
00
0
20
60
90
40
60
80
100
120
140
160
180
200
angle degree
00
0
0
00
20
00
50
00
20
MPa
MPa
30
40
60
(c)
80
100
120
140
160
180
200
angle degree
(d)
Figure 5. The distributions of stress amplitude in the inner and outer circle contact edges of the aluminum plates under different fatigue stress conditions; (a) The outer circle contact edges of the aluminum plate Is upper surface; (b) The inner circle contact edges of the aluminum plate Is upper surface; (c) The outer circle contact edges of the aluminum plate IIs upper
surface; (d) The inner circle contact edges of the aluminum plate IIs upper surface.
5. Discussions
The fretting fatigue contact geometry of a riveted two
aluminum specimen was studied. The distributions of
normal stress amplitude and shear stress amplitude in the
inner and outer circle contact edges of the aluminum
plates under different friction coefficient and fatigue load
conditions are elastically analyzed using the finite element method and the following conclusions are obtained.
1) In the light of traditional fatigue damage without
fretting damage, the main factor influencing fatigue is
hoop normal stress amplitude max, the dangerous point
of traditional crack initiation is just the place where hoop
normal stress amplitude max reached the maximum.
2) The aluminum plate Is fatigue crack initiation angle shifts from 900 to 450 with the increasing of friction
coefficient and fatigue load, the aluminum plate IIs fatigue crack initiation angle shifts from 900 to 1350 with
the increasing of friction coefficient and fatigue load.
The increasing of friction coefficient and fatigue load, on
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H. LI
the one hand, would weaken the role of traditional fatigue damage on the aluminum plates and delay the corresponding crack initiation at the 90 region near the hole;
and on the other hand, would strengthen the role of fretting fatigue damage and lead to the transition of the crack
initiation positions from 90 point at the inner edge to 45
point at the outer edge for plate I and from 90 point at
the inner edge to 135 point at the outer edge for plate II.
3) Either traditional fatigue or fretting fatigue has been
accelerated with the increasing of fatigue loads, the increasing of fatigue stress would increase the tends to shift
the initiation position far away from its original 90 region at the inner contact edge and shift the crack initiation positions toward the region whose angle is less than
45 or larger than 135 at the outer contact edge.
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ET AL.
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Model Development and Validation, Composite Structure, Vol. 71, 2005, pp. 140-158.
http://dx.doi.org/10.1016/j.compstruct.2004.09.024
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