Finite element modelling of damage fracture and fretting fatigue

This paper summarises the research carried out to develop Finite Element (FE) modelling and predictive techniques for damage, fracture, fatigue and fretting fatigue problems. A damage model is developed based on Continuum Damage Mechanics and integrated within FE code. It is then used to predict the number of cycles to crack initiation in adhesively bonded joints. Furthermore, crack propagation algorithm is programmed within FE code using the principles of Fracture Mechanics and Paris law. The effect of mode mixity on crack propagation is taken into account using a Double Cantilever Beam (DCB) test specimen. Moreover, FE model of fretting fatigue aluminium test specimen is carried out in order to study the stress distribution and predict the crack propagation fatigue lifetime. Fretting fatigue problems involve two types of analyses; namely contact mechanics analysis and damage/fracture mechanics analysis. Both analyses are performed in FE code and the stress distribution along the contact surface between the two bodies is obtained and analysed. Furthermore, crack propagation analysis under fretting fatigue condition is presented. In most cases, the numerical results are compared to experimental ones

Numerical estimation of fretting fatigue lifetime using damage and fracture mechanics

Fretting fatigue is a complex tribological phenomenon that can cause premature failure of connected components that have small relative oscillatory movement. The fraction of fretting fatigue lifetime spent in crack initiation and in crack propagation depends on many factors, e.g., contact stresses, amount of slip, frequency, environmental conditions, etc., and varies from one application to another. Therefore, both crack initiation and propagation phases are important in analysing fretting fatigue. In this investigation, a numerical approach is used to predict these two portions and estimate fretting fatigue failure lifetime under a conformal contact configuration. For this purpose, an uncoupled damage evolution law based on principles of continuum damage mechanics is developed for modelling crack initiation. The extended finite element method approach is used for calculating crack propagation lifetimes. The estimated results are validated with previously reported experimental data and compared with other available methods in the literature.The authors wish to thank the Ghent University for the financial support received by the Special Funding of Ghent University, BOF (Bijzonder Onderzoeksfonds), in the framework of project (BOF 01N02410) and gratefully acknowledge the financial support provided by the Spanish Ministry of Economics and Competitiveness through the project DPI2010-20990.Hojjati-Talemi, R.; Wahab, MA.; Giner Maravilla, E.; Sabsabi, M. (2013). Numerical estimation of fretting fatigue lifetime using damage and fracture mechanics. Tribology Letters. 52(1):11-25. https://doi.org/10.1007/s11249-013-0189-8S1125521Hills, D.A., Nowell, D.: Mechanics of Fretting Fatigue. Solid Mechanics and its Applications vol. 30. Kluwer Academic Publishers, Dordrecht (1994)Smith, K.N., Watson, P., Topper, T.H.: A stress-strain function for the fatigue of metals. J Mater. 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Fatigue life analysis of un-repaired and repaired metallic substrate using FRANC2D

We present numerical investigations on fatigue life analysis of un-re-paired and repaired metallic substrate. Most of the engineering structures fail due to fatigue under dynamic loading. While research is mostly focused in experi-mental fatigue analysis, only few numerical approaches are found in the litera-ture. In this paper, fatigue life analysis of metallic substrate with two types of repairs is presented. One type of repair is with mechanical fasteners, which is most commonly used technique, and the other one is adhesive bonding. 2D nu-merical fatigue analysis is performed on un-repaired, repaired-riveted and re-paired-bonded joints of metallic substrate in FRANC2D/L (Fracture Analysis 2D Layered). Fatigue life curves showed that the repaired-bonded joint has 14 times higher life expectation than un-repaired and repaired-riveted joints.Peer ReviewedPostprint (published version