A Review on Fretting Wear Mechanisms,Models and Numerical Analyses

Fretting wear is a material damage in contact surfaces due to micro relative displacement between them.It causes some general problems in industrial applications,such as loosening of fasteners or sticking in components supposed to move relative to each other.Fretting wear is a complicated problem involving material properties of tribosystem and working conditions of them.Due to these various factors,researchers have studied the process of fretting wear by experiments and numerical modelling methods.This paper reviews recent literature on the numerical modelling method of fretting wear.After a briefly introduction on the mechanism of fretting wear,numerical models,which are critical issues for fretting wear modelling,are reviewed.The paper is concluded by highlighting possible research topics for future work.

Multi-Scale Analysis of Fretting Fatigue in Heterogeneous Materials Using Computational Homogenization

This paper deals with modeling of the phenomenon of fretting fatigue in heterogeneous materials using the multi-scale computational homogenization technique and finite element analysis(FEA).The heterogeneous material for the specimens consists of a single hole model(25% void/cell,16% void/cell and 10% void/cell)and a four-hole model(25%void/cell).Using a representative volume element(RVE),we try to produce the equivalent homogenized properties and work on a homogeneous specimen for the study of fretting fatigue.Next,the fretting fatigue contact problem is performed for 3 new cases of models that consist of a homogeneous and a heterogeneous part(single hole cell)in the contact area.The aim is to analyze the normal and shear stresses of these models and compare them with the results of the corresponding heterogeneous models based on the Direct Numerical Simulation(DNS)method.Finally,by comparing the computational time and%deviations,we draw conclusions about the reliability and effectiveness of the proposed method.

Aspects of Fretting Fatigue Finite Element Modelling

Fretting fatigue is a type of failure that may affect various mechanical components,such as bolted or dovetail joints,press-fitted shafts,couplings,and ropes.Due to its importance,many researchers have carried out experimental tests and analytical and numerical modelling,so that the phenomena that govern the failure process can be understood or appropriately modelled.Consequently,the performance of systems subjected to fretting fatigue can be predicted and improved.This paper discusses different aspects related to the finite element modelling of fretting fatigue.It presents common experimental configurations and the analytical solutions for cylindrical contact.Then,it discusses aspects of fretting fatigue crack initiation,such as crack location,orientation,and length,as well as stress averaging approaches.Then,it deals with the propagation stage;crack face interaction,orientation criteria,and crack growth rate are discussed.Lastly,additional aspects of recent research on fretting fatigue are reviewed:out-of-phase loading,cohesive zone modelling,wear effects,heterogeneity,and crystal orientation.Fretting fatigue is a phenomenon not well understood,and much more research is needed so that its understanding is increased and proper criteria and laws may be available for different cases.

The Effect of Surface Pit Treatment on Fretting Fatigue Crack Initiation

This paper analyses the effect of surface treatment on fretting fatigue specimen by numerical simulations using Finite Element Analysis.The processed specimen refers to artificially adding a cylindrical pit to its contact surface.Then,the contact radius between the pad and the specimen is controlled by adjusting the radius of the pit.The stress distribution and slip amplitude of the contact surface under different contact geometries are compared.The critical plane approach is used to predict the crack initiation life and to evaluate the effect of processed specimen on its fretting fatigue performance.Both crack initiation life and angle can be predicted by the critical plane approach.Ruiz parameter is used to consider the effect of contact slip.It is shown that the crack initial position is dependent on the tensile stress.For same type of model,three kinds of critical plane parameters and Ruiz method provide very similar position of crack initiation.Moreover,the improved sample is much safer than the flat-specimen.

Improvement of Flat Surfaces Quality of Aluminum Alloy 6061-O By A Proposed Trajectory of Ball Burnishing Tool

Burnishing is a profitable process of surface finishing due to its ability to be automated,which makes burnishing method more desirable than other finishing methods.To obtain high surface finish,non-stop operation is required for CNC machine and we can attain that by choosing a suitable trajectory of the finishing tool.In other words,burnishing paths should be multidirectional rather than monotonic,in order to cover uniformly the surface.Indeed,the burnishing force is also a key parameter of the burnishing process because it determines the degree of plastic deformation,and that makes determining the optimum burnishing force an essential step of the burnishing process a success.Therefore,we consider the strategy of ball burnishing path and the burnishing force as variable parameters in this study.In this paper,we propose a new strategy of burnishing tool path with trochoid cycles that achieves a multidirectional burnishing of the surface according to various patterns.Taking into consideration the optimum burnishing force,to improve flat surface finish of AL6061-O samples by reducing the surface roughness parameter(Rz).Experiments carried out on 3-axis milling machine show that the proposed trochoidal path is more effective than the conventional one.

Review on the Prediction of Residual Stress in Welded Steel Components

Residual stress after welding has negative effects on the service life of welded steel components or structures.This work reviews three most commonly used methods for predicting residual stress,namely,empirical,semi-empirical and process simulation methods.Basic principles adopted by these methods are introduced.The features and limitations of each method are discussed as well.The empirical method is the most practical but its accuracy relies heavily on experiments.Mechanical theories are employed in the semi-empirical method,while other aspects,such as temperature variation and phase transformation,are simply ignored.The process simulation method has been widely used due to its capability of handling with large and complex components.To improve its accuracy and efficiency,several improvements need to be done for each simulation aspect of this method.

Multiscale Analysis of the Effect of Debris on Fretting Wear Process Using a Semi-Concurrent Method

Fretting wear is a phenomenon,in which wear happens between two oscillatory moving contact surfaces in microscale amplitude.In this paper,the effect of debris between pad and specimen is analyzed by using a semi-concurrent multiscale method.Firstly,the macroscale fretting wear model is performed.Secondly,the part with the wear profile is imported from the macroscale model to a microscale model after running in stage.Thirdly,an effective pad’s radius is extracted by analyzing the contact pressure in order to take into account the effect of the debris.Finally,the effective radius is up-scaled from the microscale model to the macroscale model,which is used after running in stage.In this way,the effect of debris is considered by changing the radius of the pad in the macroscale model.Due to the smaller number of elements in the microscale model compared with the macroscale model containing the debris layer,the semi-concurrent method proposed in this paper is more computationally efficient.Moreover,the results of this semi-concurrent method show a better agreement with experimental data,compared to the results of the model ignoring the effect of debris.

Damage detection in steel plates using feed-forward neural network coupled with hybrid particle swarm optimization and gravitational search algorithm

Over recent decades,the artificial neural networks(ANNs)have been applied as an effective approach for detecting damage in construction materials.However,to achieve a superior result of defect identification,they have to overcome some shortcomings,for instance slow convergence or stagnancy in local minima.Therefore,optimization algorithms with a global search ability are used to enhance ANNs,i.e.to increase the rate of convergence and to reach a global minimum.This paper introduces a two-stage approach for failure identification in a steel beam.In the first step,the presence of defects and their positions are identified by modal indices.In the second step,a feedforward neural network,improved by a hybrid particle swarm optimization and gravitational search algorithm,namely FNN-PSOGSA,is used to quantify the severity of damage.Finite element(FE)models of the beam for two damage scenarios are used to certify the accuracy and reliability of the proposed method.For comparison,a traditional ANN is also used to estimate the severity of the damage.The obtained results prove that the proposed approach can be used effectively for damage detection and quantification.

Fatigue crack propagation across grain boundary of Al-Cu-Mg bicrystal based on crystal plasticity XFEM and cohesive zone model

In this paper,a methodology integrating crystal plasticity(CP),the eXtended finite element method(XFEM)and the cohesive zone model(CZM)is developed for an Al-Cu-Mg alloy to predict fatigue crack propagation(FCP)across grain boundary(GB)of Al-Cu-Mg alloy during stageІІ.One GB model is incor-porated into FCP constitutive law to describe grain interaction at GB.A bicrystal containing GB is built up to simulate FCP behavior through L participated GBs.Modelling features including GB characteristic,cumulative plastic strain(CPS)distribution and crystal slipping evidence can be identified.The numer-ical results are compared with published experimental data to check the accuracy of model.This work demonstrates that the combination of CP containing GB constitutive laws,XFEM and CZM is a promising methodology in predicting twist angle-controlled crack deflection through GBs.

Effect of wear debris on fretting fatigue crack initiation

Both wear and fatigue occur in fretting condition,and they interact with one another during the whole process.Fretting fatigue is commonly analysed without considering the effect of wear in partial slip regime,although wear affects the lifetime of crack initiation.This paper investigates,for the first time,the effect of wear debris on fretting fatigue crack initiation.To investigate the effect of debris,first fretting wear characteristics in partial slip regime are analysed for loading conditions.Then,the effect of wear on fretting fatigue crack initiation is investigated using Ruiz parameters and critical plane methods without considering the debris effect.Through the results,we can see that loading conditions affect the wear profiles in different ways.Moreover,wear has a significant effect on the fatigue in partial slip regime without considering debris especially on the crack initiation location.Finally,considering wear debris in the analysis,its effect on critical plane parameters is investigated.It is found that by considering the wear debris effect,the frtting fatigue crack initiation location is shifted towards the trailing edge.The predictions of both crack initiation location and lifetime show a good agreement with the experimental data.

Effect of fatigue load on the bending tribo-corrosion-fatigue behaviors between the main cable wires

The main cable bent around the saddle of the suspension bridge is subjected to the wind,the vehicle,the bridge’s own weight and the corrosive media.The coupling of the three loads and the environments causes the friction,the corrosion,and the fatigue(tribo-corrosion-fatigue)among the wires inside the main cable.In this paper,a wire bending tribo-corrosion-fatigue test rig was designed and developed.The effect of fatigue load on the bending friction behaviors between the cable wires in ultrapure water and 3.5%NaCl solution was explored.The tribological properties and electrochemical corrosion behaviors under different fatigue loading ranges were investigated.The tribo-corrosion-fatigue interaction between the cable wires was quantitatively characterized,and the mechanism of the interaction was analyzed.The results demonstrate that the increasing fatigue load exacerbates the coupling damage of the cable wires attributed to the enhanced interaction.The findings carry theoretical importance when assessing the main cable’s deterioration and the load-bearing safety of a suspension bridge.