• Journal of the Korean Society of Industry Convergence
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• v.20 no.2
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• pp.195-204
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• 2017

Predicting the failure life of automated manufacturing systems can reduce overall downtime, maintenance costs, and total plant operation costs. Therefore, there is a growing interest in fatigue failure mechanisms as the safety or service life assessment of manufacturing systems becomes an important issue. In particular, fretting fatigue is caused by repeated tangential stresses that are generated by friction during small amplitude oscillatory movements or sliding between two surfaces pressed together in intimate contact. Previous studies in fretting fatigue have observed size effects related to contact width such that a critical contact width exists where there is drastic change in the fretting fatigue life. However, most of them are the two-dimensional finite element analyses based on the plane strain assumption. The purpose of this study is to investigate the contact size effects on the three-dimensional finite element model of a finite width of a flat specimen and a cylindrical pad exposed to fretting fatigue. The contact size effects were analyzed by means of the stress and strain averages at the element integration points of three-dimensional finite element model. This study shows that the fretting fatigue life of manufacturing systems can be predicted by three-dimensional finite element analysis based on SWT critical plane model.

• Journal of the Korea Institute of Military Science and Technology
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• v.14 no.1
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• pp.92-99
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• 2011

In this study, new multi-axial, critical plane based, fretting fatigue crack initiation parameter is developed by the addition of a new term into the Modified Shear Stress Range(MSSR) parameter. The newly developed parameter (MSSR') is then used to evaluate fretting fatigue life of titanium alloy, Ti-6A1-4V with various contact conditions. Finite element analysis is also used in order to obtain stress distribution on the contact surface during fretting fatigue test, which is then used for the calculation of fretting fatigue parameter. The MSSR' parameter shows better performance in predicting fretting fatigue lives from the conventional fatigue data, and less scattering within fretting fatigue data with different contact geometries.

• Proceedings of the KSR Conference
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• 2004.06a
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• pp.632-637
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• 2004

In the shrink or press fitted shaft such as railway axle, fretting can occur by cyclic stress and micro-slippage due to local movement between the shaft and the hub. When the fretting occurs in the press fitted shaft, the fatigue strength remarkably decreases compared with that of without fretting. In this paper, the analysis of contact stresses in a press fitted shaft in contact with a hub was conducted by finite element method and the micro-slip according to the bending load was analyzed. It is found that the largest stress concentration and maximum slip amplitude of shrink fitted shaft are found at the edge of the interface and the distribution of contact stresses at the contact edge has largely influenced and coefficient of friction.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.11 s.176
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• pp.125-134
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• 2005

Recently, there have been reported on the results that the material life is reduced by fretting conditions and the initial crack made by low stress under fretting. The purpose of this paper is to show that the results of finite element analysis for the fretting contact problems of a flat rounded punch are nearly consistent with the theoretical solutions and to research that the results about effects of the contact zone according to geometries and mechanical properties of pad.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.5
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• pp.139-145
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• 2007

Fretting is a kind of surface damage mechanism observed in mechanically jointed components and structures. The initial crack under fretting damage occurs at lower stress amplitude and lower cycles of cyclic loading than that under plain fatigue condition. This can be observed in automobile and railway vehicle, fossil and nuclear power plant, aircraft etc. In the present study, railway axle material RSA1 used for evaluation of fretting fatigue life. Plain and fretting fatigue tests were carried out using rotary bending fatigue tester with proving ring and bridge type contact pad. Through these experiments, it is found that the fretting fatigue limit decreased about 37% compared to the plain fatigue limit. In fretting fatigue, the wear debris is observed on the contact surface, and oblique cracks at an earlier stage are initiated in contact area. These results can be used as useful data in a structural integrity evaluation of railway axle.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.11
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• pp.1083-1092
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• 2007

The objective of the present paper is to evaluate the effect of the evolution of contact surface profile caused by fretting wear on fatigue life of press-fitted shaft by means of an analytical method based on experimental data. A finite element analysis was performed to analyze the stress states of press-fitted shaft, considering the worn contact profiles of shaft. The fatigue lives of the press-fitted shaft reflecting the evolution of contact stress induced by fretting wear were evaluated by stress-life approach using fatigue notch factor. It is found that the stress concentration of contact edge in press-fitted shaft decreases rapidly at the initial stage of total fatigue life, and its location shifts from the contact edge to the inside with increasing number of fatigue cycles. Thus the change of crack nucleation position in press-fitted shaft is mainly caused by the stress change of contact edge due to the evolution of contact surface profile by fretting wear. Furthermore, the estimated fatigue lives by stress-life approach at the end of running-in period of the fretting wear process corresponded well to the experimental results. It is thus suggested that the effect of fretting wear on fatigue life in press fits is strongly related to the evolution of surface profile at the initial stage of total fatigue life.

• Tribology and Lubricants
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• v.32 no.3
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• pp.88-94
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• 2016

We conduct a series of fretting corrosion tests on tin-coated electric contact to evaluate the effects of lubricant on fretting corrosion behavior. We perform these tests with a constant contact force at 25℃ 50℃, 75°C, and 100℃. In the tests with a span amplitude of 30 μm, we could not determine the conventional behavior of the first, second, and third stages of the change in electric resistance during fretting corrosion and observed that the contact resistance continuously increases with the cycles. This behavior is due to the fact that the generation of oxides on the tin-coated contact is controlled and stabilized by the presence of lubricant. SEM observations on samples with a span amplitude of 77 μm at all testing temperatures confirm that there is less oxide debris on the fretting damaged surface. Hence, for tin-coated electric connector, the effect of lubrication on the lifetime of the electric contact increases as the fretting span decreases and testing temperature increases, compared to those for connector without lubricant. Especially, for a specimen with a span amplitude of 30 μm at 100℃, the increment in contact lifetime due to lubricant is found to be more than 20 times, compared to that without lubricant.

• International Journal of Automotive Technology
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• v.7 no.1
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• pp.75-82
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• 2006

Fretting corrosion widely known as a degradation mechanism refers to the combination of fretting wear and corrosion such as oxidation. This paper critically reviews the works published previously on fretting corrosion of electrical connectors. Various experimental approaches such as testing machines, material selection, testing environments, acceleration testing techniques and preventing methods are addressed. Future research prospects are suggested.

• Transactions of the Korean Society of Automotive Engineers
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• v.18 no.2
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• pp.74-82
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• 2010

Fretting damage can be observed in automobile and railway vehicle, fossil and nuclear power plant, aircraft etc. In the present study, railway axle material RSA1 used for evaluation of fretting fatigue life. Plain and fretting fatigue tests were carried out using rotary bending fatigue tester with proving ring and bridge type contact pad. Through these test, the following results are obtained: 1) it is found that the fretting fatigue limit of standard specimen decreased about 37% compared to the plain fatigue limit. 2) The early crack of Shinkansen type specimens initiated in contact area and final fractured below samp=214 MPa. 3) The early crack of all TGV type specimens initiated in rounded area and fractured. 4) Tire tracks and rubbed scars were observed in the oblique crack region and fatigue crack growth region of fracture surface. 5) The wear debris is observed on the contact surface, and oblique cracks at an earlier stage are initiated in contact area. These results can be used as useful data in a structural integrity evaluation of railway axle.

• Journal of the Korean Society for Aeronautical & Space Sciences
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• v.35 no.7
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• pp.601-611
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• 2007

Most of mechanically jointed aircraft structures are always encountered the fretting damages on the contact surfaces between two jointed structural members or at the edges of fastener holes. The partial slip and contact stresses associated with fretting contact can lead to severe reduction in service lifetime of aircraft structures. Thus a critical need exists for predicting fretting crack initiation in mechanically jointed aircraft structures, which requires characterizing both the near-surface mechanics and intimate relationship with fretting parameters. In this point of view, a series of fretting fatigue specimen tests for 2024-T351 Al-alloy, have been conducted to validate a mechanics-based model for predicting fretting fatigue life. And included in this investigaion were elasto-plastic contact stress analyses using commercial FEA code to quantify the stress and strain fields in subsurface to evaluate the fretting fatigue crack initiation.