• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 추계학술대회 논문집
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• pp.1033-1036
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• 2005

The effect of surface roughness on the contact fatigue was investigated in this study. To accomplish this goal, contact analysis based on the influence functions and the rectangular patch solution was performed to obtain the subsurface stress. Mesoscopic multiaxial fatigue criterion is then applied to predict fatigue damage. Suitable counting method and damage rule were used to evaluate the fatigue life of random loading caused by rough surface. As a result of the analysis, relationship between the life and roughness as well as the creack initiation depth was revealed. Below the critical roughness, It is observed that the fatigue life has hardly changed and creack is initiated around the depth at which the maximum shear stress occurs. Different behavior, however, is observed in case that the roughness is above the critical value.

• 대한기계학회논문집A
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• 제28권9호
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• pp.1391-1398
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• 2004

Railway wheels and axles belong to the most critical components in railway vehicles. The service conditions of railway vehicles became more severe in recent years due to the increase of speed. Therefore, a more precise evaluation of wheelset life and safety has been requested. Wheel/rail contact fatigue and thermal cracks due to braking heat are two main mechanisms of the railway wheel failure. In this paper, an evaluation procedure for the contact fatigue life of railway wheel is proposed. One of the main sources of the contact zone failure is the residual stress. The residual stress on wheel is formed during the manufacturing process which includes a heat treatment, and then is changed by contact stress developed by wheel/rail contact and thermal stress induced by braking. Also, the cyclic stress history for fatigue analysis is determined by applying finite elements analysis for the moving contact load. The objective of this paper is to estimate fatigue life by considering residual stress due to heat treatment, braking and repeated contact load, respectively.

• 한국철도학회논문집
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• 제10권5호
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• pp.546-553
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• 2007

본 연구는 압입축에 프레팅이 발생할 경우 프레팅 마모에 의한 접촉형상의 변화가 접촉응력의 분포, 균열발생 위치에 미치는 영향을 분석하고자 하였다. 압입축의 프레팅 피로실험시 측정한 접촉면의 프로파일을 이용하여 유한요소 해석을 수행하고 피로 사이클별 마모형상 변화에 따른 접촉면의 응력 변화를 분석하였다. 접촉면의 응력 해석결과를 이용하여 프레팅 피로손상 파라미터와 다축 피로이론를 적용하여 마모에 따른 균열발생위치의 변화를 해석하고 실험과 비교, 분석하였다. 프레팅 마모에 의해 접촉 끝단의 응력집중은 초기에 급격하게 감소하며, 마모가 진행될수록 응력집중의 위치는 접촉끝단에서 안쪽으로 이동한다. 따라서 프레팅 마모에 의한 접촉응력의 변화가 균열발생 위치의 변차와 다중균열발생의 주요원인임을 명확히 하였다.

• 열처리공학회지
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• 제13권5호
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• pp.355-359
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• 2000

Ion beam assisted deposition system was used to deposit CNx coatings with various thickness on the substrates of high-frequency induction hardened steels. Rolling contact fatigue tests were performed using Polymet RCF-1 machine with a constant supply of lubricant. Rolling contact fatigue life was substantially different in the steels with various thickness of CNx coatings. The optimum thickness of CNx coating was found to be $8.9{\mu}m$, showing the longest fatigue life, mainly caused by higher resistance to initiation of cracks and protective overcoat remaining to the surface failure during rolling contact fatigue. Cracks were initiated in the substrates under the surface of wear track and propagated to the surface, which eventually resulted in the failure. The reduction of fatigue life observed in the specimen with elimination of CNx coating during rolling contact fatigue was explained by the substrates deformation.

• 한국산업융합학회 논문집
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• 제20권2호
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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.

• 한국자동차공학회논문집
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• 제18권2호
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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.

• Tribology and Lubricants
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• 제19권1호
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• pp.26-30
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• 2003

The stresses of surface and substrate under the rough surface contact are irregular. Using rainflow counting method for irregular stresses, the fatigue surface crack initiation lift was calculated. With the surface generated by computer, this paper figures out the random load generated by contacting to the rough surface, analyzes the stress of its subsurface, and calculates the fatigue crack initiation life of the rough surface fatigue theory.

• 한국정밀공학회지
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• 제29권12호
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• pp.1346-1350
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• 2012

Contact wire is one of the most important components supplying electricity to railroad cars. At the beginning of the research on contact wire, wear problem caused by friction between contact wire and pantograph was considered even more important issue for the failure of contact wire. However, since several fatigue fractures were reported from Shinkansen in Japan, fatigue fracture has become another important issue for the failure of contact wire. Despite of its importance, standard of the fatigue test of contact wire has not been established yet. Thus, fatigue characteristics of contact wire is very difficult issue to evaluate quantitatively. Hence, in this study, test method simulating operating conditions of contact wire by Minsung Kang and etc. is used to evaluate the fatigue characteristics of copper alloy contact wire. Also, test results is compared with the result of Minsung Kang's research on pure copper contact wire.

• 한국정밀공학회지
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• 제25권6호
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• pp.116-125
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• 2008

In general, fretting is a contact damage process due to micro-slip associated with small amplitude oscillatory movement between two surfaces in contact. Previous studies in fretting fatigue have observed a contact size effect related to contact width. The volume-averaging method of theoretically predicted contact stress fields was required to emulate experimental trends and to predict the observed contact size effects. This contact size effect is captured by the mean values of stresses and strains at the element integration points of FE model and two critical plane models (SWT, FS) in the present paper. It is shown that crack nucleation and fretting fatigue life can be predicted by the FE-based critical plane models.

• 한국윤활학회:학술대회논문집
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• 한국윤활학회 2004년도 학술대회지
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• pp.53-59
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• 2004

Rough surfaces are taking into account to estimate the contact fatigue life. A computational methodology and the theoretical basis in this case is presented in this paper. Displacement solution technique by Cho and Love is applied to calculate the stress history beneath the surface subjected to loading. Mesoscopic multiaxial fatigue criterion is then applied to predict fatigue life. This fatigue criterion yields satisfactory results for non-proportional loading and can satisfactorily describe the physical mechanisms of crack initiation as well. As a result of analysis the relation between the life and the roughness as well as the most probable depth of the crack nucleation is discussed.