scholarly journals Fretting Fatigue Experiment and Finite Element Analysis for Dovetail Specimen at High Temperature

2021 ◽  
Vol 11 (21) ◽  
pp. 9913
Author(s):  
Zhen Qu ◽  
Kaicheng Liu ◽  
Baizhi Wang ◽  
Zhiying Chen
Keyword(s):  
Finite Element ◽  
Contact Surface ◽  
Elevated Temperatures ◽  
Fatigue Behavior ◽  
Fatigue Cracks ◽  
Fretting Fatigue ◽  
Fretting Wear ◽  
Element Analysis ◽  
Centrifugal Load ◽  
Maximum Contact

The dovetail attachment between the turbine blade and disk for an aero-engine operates under varying centrifugal load and vibration at elevated temperatures. The fretting fatigue is prone to occur at the contact surface of the dovetail attachment. This paper investigated the fretting fatigue behavior of the dovetail specimen at 630 °C through experiment and numerical simulation, in which the blade-like dovetail specimen is nickel-based single crystal superalloy DD10 while two fretting pads in contact with the dovetail specimen simulating the mortise of the disk are made of powder metallurgy FGH99. It is revealed from all the tests that the fracture induced by the fretting wear occurs at the upper edge area of the contact surface. The contact surface near the upper edge is more severely worn; hence, the phenomenon of partition on the worn contact surface can be observed, which is consistent with the fretting fatigue mechanism. Moreover, the calculated area of maximum contact pressure gradient through finite element method is in good agreement with the experimental position of the initial fretting fatigue cracks.

Fatigue Behavior of Ni-Ti Alloy Endodontic Files under Ultrasonic Unconstrained Condition

2009 ◽  
Vol 417-418 ◽  
pp. 77-80
Author(s):  
Hui Min Zhou ◽  
Qing Fen Li ◽  
Yu Feng Zheng ◽  
Li Li
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Fatigue Testing ◽  
Fatigue Behavior ◽  
Fatigue Cracks ◽  
Nickel Titanium ◽  
Experimental Results ◽  
Secondary Phases ◽  
Element Analysis ◽  
Ultrasonic Fatigue

Nickel-titanium alloy are extensively used in engineering and biomedical fields for their excellent properties of shape-memory, super-elasticity and biocompatibility. Their fatigue performance has been attracted increasingly attention, because they are often used under cyclic conditions. In this paper, the ultrasonic fatigue behavior of nickel-titanium endodontic files under unconstrained condition has been studied using the self-designed ultrasonic fatigue testing equipment. The vibration and harmonious response properties of nickel-titanium endodontic files are also analyzed using finite element method. Experimental results show that the average ultrasonic fatigue life of nickel-titanium endodontic files under unconstrained conditions is more than 108. Fracture of the files always occurred at the position about 2 -3 mm near the file tip. Results of finite element analysis show that the maximum stress of the nickel-titanium endodontic files located at the position about 2 -3 mm near the file tip, where is prone to generate fatigue cracks. The results of finite element analysis are consistent with the experimental results. The scanning electronic microscope (SEM) results show that the ultrasonic fatigue cracks always initiated at the surfaces of the files, where the secondary phases or impurities existed and induced fatigue cracks under repeated stress.

Fretting fatigue optimization of piston skirt top surface of marine diesel engine

2018 ◽  
Vol 233 (4) ◽  
pp. 1453-1469 ◽  
Author(s):  
Yi Wang ◽  
Limin Wu ◽  
Shuo Liu ◽  
Mei Li ◽  
Yi Cui
Keyword(s):  
Finite Element ◽  
Diesel Engine ◽  
Contact Surface ◽  
Fretting Fatigue ◽  
Theory Of Elasticity ◽  
Fretting Wear ◽  
Marine Diesel Engine ◽  
Element Mesh ◽  
Piston Skirt ◽  
Marine Diesel

Composite pistons are often used in highly rated marine diesel engines. Fretting usually occurs on the mating surfaces of piston crown and skirt due to alternating loads. A finite element contact model is introduced to calculate the temperature and stress distribution in the composite piston of a marine diesel engine. The Archard model and Smith–Watson–Topper parameter (a prediction parameter of fretting fatigue, also called SWT parameter for short), which is used as fretting wear and fatigue criteria, are calculated according to the stress and strain variation and relative slip on the contact surface. The model has been validated by previous cylindrical–flat contact experiments. The effects of shape of contact face and pretension of bolts on fretting performance have been analyzed. To reduce the possibility of fretting failure of the composite piston, the expression of the generating line of the piston skirt contact surface has been designed by Theory of elasticity. The parameters of the generating line have been optimized with nonlinear sequential quadratic programming and finite element mesh updating method. The optimization results show that the fretting fatigue parameter SWT on the optimized contact surface can be reduced by more than 35.6%, which means the longer fatigue life of the pistons. Some suggestions for designing contact surfaces have also been proposed. In the end, the design was proved by durability tests of the engine.

Finite Element Analysis of Fretting Stresses

1997 ◽  
Vol 119 (4) ◽  
pp. 797-801 ◽  
Author(s):  
P. A. McVeigh ◽  
T. N. Farris
Keyword(s):  
Finite Element ◽  
Tensile Stress ◽  
Element Model ◽  
Fretting Fatigue ◽  
Maximum Tensile Stress ◽  
Multiaxial Fatigue ◽  
Fretting Wear ◽  
Symmetric Distribution ◽  
Element Analysis ◽  
Riveted Joints

Clamped contacts subjected to vibratory loading undergo cyclic relative tangential motion or micro-slip near the edges of contact. This cyclic micro-slip, known as fretting, leads to removal of material through a mechanism known as fretting wear and formation and growth of cracks through a mechanism known as fretting fatigue. In aircraft, fretting fatigue occurs at the rivet/hole interface leading to multisite damage which is a potential failure mechanism for aging aircraft. A finite element model of a current fretting fatigue experiment aimed at characterizing fretting in riveted joints is detailed. A non-symmetric bulk tension is applied to the specimen in addition to the loads transferred from the fretting pad. The model is verified through comparison to the Mindlin solution for a reduced loading configuration, in which the bulk tension is not applied. Results from the model with the bulk tension show that the distribution of micro-slip in the contact is not symmetric and that for some loads reversed micro-slip occurs. Finite element results are given for the effects that four different sets of loading parameters have on the maximum tensile stress induced by fretting at the trailing edge of contact. It can be shown using multiaxial fatigue theory that this stress controls fretting fatigue crack formation. This maximum tensile stress is compared to that of the Mindlin solution for a symmetric distribution of micro-slip. This stress is also compared to that of a variation based on the Mindlin solution for the cases with a non-symmetric distribution of micro-slip. It is concluded that the solution based on the Mindlin variation and the full finite element solution lead to similar predictions of the maximum tensile stress, even when the shear traction solutions differ significantly.

FEA of Fretting Fatigue: A Comparison between ANSYS and ABAQUS

2011 ◽  
Vol 488-489 ◽  
pp. 662-665
Author(s):  
Magd Abdel Wahab ◽  
R. Hojjati Talemi ◽  
Patrick de Baets
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Stress Distribution ◽  
Contact Surface ◽  
Fretting Fatigue ◽  
Element Analysis ◽  
Fatigue Lifetime ◽  
Aluminum Specimen ◽  
Fretting Damage ◽  
Two Bodies

Fretting fatigue occurs when two contact bodies undergo small oscillatory relative motion due to cyclic loading. It leads to fretting damage, which reduces the service life of the bodies in contact. This can be explained by the high stresses generated at the contact surface between the two bodies. Therefore, numerical analysis, such as Finite Element Analysis (FEA), would be useful to understand the fretting fatigue phenomenon and to investigate techniques to reduce its effect on fatigue lifetime of mechanical components. In this paper, FEA of fretting fatigue Aluminum specimen is carried out in order to study the stress distribution and crack initiation location. Two commercial FEA packages, namely ANSYS and ABAQUS are used to analyze the specimen. The stress distribution along the contact surface between the two bodies obtained using both codes is compared and analyzed.

Thermal Modeling of a Railroad Tapered-Roller Bearing Using Finite Element Analysis

2012 ◽  
Vol 4 (3) ◽  
Author(s):  
Constantine M. Tarawneh ◽  
Arturo A. Fuentes ◽  
Javier A. Kypuros ◽  
Lariza A. Navarro ◽  
Andrei G. Vaipan ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Surface Temperature ◽  
Elevated Temperatures ◽  
Roller Bearing ◽  
Fe Model ◽  
Element Analysis ◽  
Tapered Roller Bearing ◽  
Outer Race ◽  
Railroad Industry

In the railroad industry, distressed bearings in service are primarily identified using wayside hot-box detectors (HBDs). Current technology has expanded the role of these detectors to monitor bearings that appear to “warm trend” relative to the average temperatures of the remainder of bearings on the train. Several bearings set-out for trending and classified as nonverified, meaning no discernible damage, revealed that a common feature was discoloration of rollers within a cone (inner race) assembly. Subsequent laboratory experiments were performed to determine a minimum temperature and environment necessary to reproduce these discolorations and concluded that the discoloration is most likely due to roller temperatures greater than 232 °C (450 °F) for periods of at least 4 h. The latter finding sparked several discussions and speculations in the railroad industry as to whether it is possible to have rollers reaching such elevated temperatures without heating the bearing cup (outer race) to a temperature significant enough to trigger the HBDs. With this motivation, and based on previous experimental and analytical work, a thermal finite element analysis (FEA) of a railroad bearing pressed onto an axle was conducted using ALGOR 20.3™. The finite element (FE) model was used to simulate different heating scenarios with the purpose of obtaining the temperatures of internal components of the bearing assembly, as well as the heat generation rates and the bearing cup surface temperature. The results showed that, even though some rollers can reach unsafe operating temperatures, the bearing cup surface temperature does not exhibit levels that would trigger HBD alarms.

Finite Element Study of the Effect of Load Sequence on the Fretting Wear

2020 ◽  
Author(s):  
Pankaj Dhaka ◽  
Raghu V. Prakash
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Fretting Wear ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Low Load ◽  
Dimensional Finite Element ◽  
Wear Modelling ◽  
Load Sequence ◽  
Contact Parameters

Abstract Understanding the effect of load sequence is important in the context of a blade-disc dovetail joint in an aero-engine and many other such applications where, the mating surfaces undergo fretting wear under variable slip amplitude loading conditions. In the present work, a two-dimensional finite element analysis is carried out for a cylinder-on-plate configuration. The cylinder is modeled as deformable whereas the plate is modelled as rigid. An incremental wear modelling algorithm is used to model the wear of cylindrical pad while the plate is assumed as un-worn. This simulates a practical scenario where, generally one of the mating surfaces is sufficiently hardened or an interfacial harder/sacrificial element is inserted to restrict the wear to only one of the surfaces. A Fortran-based ABAQUS® subroutine UMESHMOTION is used to simulate the wear profile for the cylinder. A constant extrapolation technique is used to simulate 18000 cycles of fretting. The finite element analysis results are validated with the analytical solutions and literature data. The fretting wear modelling is carried out for two different slip amplitudes viz., 25 μm and 150 μm, to simulate the low and high slip amplitude loading respectively. Two blocks of alternate low and high slip amplitudes are applied to understand the influence of load sequence. Important contact parameters viz., contact pressure, contact stresses and contact slip are extracted. A comparison is made between the low-high and high-low load sequence based on the contact tractions and worn out profiles.

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