Author(s)

G. Shi, D. Backman & N. Bellinger

Abstract

This paper presents the results of finite element simulations of contact stresses in fretting fatigue tests. Finite element models were developed using MSC/MARC finite element software. Convergence studies with different mesh configurations were carried out to verify the model by comparing the results with theoretical solutions. To further validate the FE model, simple coupon tests were carried out. Both photoelastic and pressure film measurements were taken during these tests and the experimental test data was compared with the FE results. After the FE model was verified, various simulations were carried out to quantify the effect of varying the applied normal load. The stress distributions including normal, shear tractions and tangential stress were determined and compared with analytical solutions in four different load cases. The obtained FE results showed that the combination of the normal, shear and bulk forces have significant effects on the contact traction and stress distributions. Keywords: fretting contact, finite element simulation, contact tractions and stress, photoelasticity, pressure film, experimental stress analysis. 1 Introduction Fretting can occur between two tight fitting surfaces that are subjected to small amplitude cyclic loads when there is relative motion between the two surfaces. These fretted regions are highly sensitive to fatigue cracking and this kind of damage has been observed between the faying surfaces in riveted lap joints, and is considered a crack nucleation mechanism. Due to the concerns for aircraft safety and integrity, a great deal of research has been carried out to determine the nature of fretting fatigue [1-9].

Keywords

fretting contact, finite element simulation, contact tractions and stress, photoelasticity, pressure film, experimental stress analysis.