微动摩擦接触面上力学参数的数值分析

本文采用边界元法分析微动摩擦接触面上的力学参数，对平面与平面接触和圈柱面与平面接触的两种情况作了计算分析，由于几何的因素，两种接触中的力学参数分布是不相同的。外加载荷的改变将引起力学参数的相应改变；摩擦系数的改变对边界向应力有影响，但对接触压力没有明显的影响；滑动幅度的改变对力学参数滑影响，在微动过程中，边界切向应力是一压循环，计算结果初步地揭示了微动摩擦接触面上力学参数的某些规律。     

微动疲劳裂纹萌生位置及形成方式研究

着重研究了微动桥足不同几何形状——方足(r=0mm)及带不同半径r(0.3mm、0.6mm、0.9mm)对微动区接触应力的影响,用不同的r值模拟微动桥足在微动疲劳中的磨损状况。采用ANSYS有限元分析软件详细计算了接触表面的应力分布和磨损区、粘着区、滑动区及张开区的大小,进而讨论裂纹的萌生位置,并建立了不同的r大小即磨损状况与裂纹萌生位置的关系。同时针对方足微动桥/平面试件的接触几何,计算了不同名义接触压力分布形式对接触面上应力分布的影响。此外,还对方足微动桥/平面试件接触几何进行了三维有限元分析,证明了萌生裂纹通常是以多源方式同时出现。计算结果与实验结果吻合很好。     

60Si_2Mn钢的低周拉扭复合微动疲劳特性

测量60Si_2Mn钢在拉扭复合载荷作用下的低周微动疲劳特性,研究了不同轴向循环拉伸应力幅值对微动疲劳寿命、循环软化特性以及摩擦磨损表面和断口形貌的影响.结果表明,随着循环拉伸应力幅值的提高,60Si_2Mn钢的微动疲劳寿命降低幅度不同,发生循环软化的时期不断提前,完成循环软化的疲劳周期也不断缩短。同时,微动摩擦副产生的氧化物磨屑对微动磨损性能有重要影响,在疲劳前期加剧摩擦磨损,在疲劳后期减轻摩擦磨损。微动疲劳裂纹源形成于试样发生微动摩擦磨损的表面,并出现疲劳台阶。在扭矩产生的切向剪切应力作用下,疲劳裂纹沿着与轴向45°角的方向扩展,最终在断口上留下显著的舌状凸起,拉应力的幅值越大舌状凸起越明显。     

TA1钛合金自冲铆接头力学性能及微动行为

本工作以TA1自冲铆接头为研究对象,基于拉伸-剪切和疲劳试验分析了接头的力学性能,并采用扫描电镜从微观层面研究了接头的拉伸-剪切失效机理、疲劳失效机理及微动行为。结果表明:拉伸-剪切失效模式为铆钉腿部从下板拉脱,铆钉颈部存在不同程度的断裂。疲劳失效模式主要为上板断裂失效,其疲劳极限约为1.18 kN。疲劳裂纹从上板与铆钉头接触部位萌生,在持续微动磨损及疲劳循环应力作用下,沿板厚和板宽方向不断扩展,直至接头疲劳断裂。微动磨损的剧烈程度直接影响接头疲劳失效模式。上板与铆钉头接触区的微动磨损源于板宽W区域,随着微动过程的不断进行,逐步向板长L区域扩展。     

椭圆形路径载荷下的微动疲劳失效特征

为了解微动疲劳失效机理,通过柱面对柱面的接触方式,研究了60Si2Mn钢在椭圆形路径、拉扭耦合作用下的多轴低周微动疲劳特性,深入分析讨论了不同轴向循环拉伸应力幅值对摩擦磨损表面和断口形貌的影响.结果认为：磨损区产生的氧化物磨屑对微动区磨擦损伤行为具有显著影响;微动摩擦磨损对试样表面的影响深度只有数十微米;微动疲劳裂纹源...     

多轴复杂应力形式下TB6高强钛合金耳片的微动疲劳断裂研究

本实验研究了TB6高强钛合金在拉-扭多轴应力条件下的微动疲劳断裂机理,并结合宏微观观察、残余应力测试、计算机模拟分析了不同工艺条件的耳片在拉-扭疲劳试验应力下的微动疲劳寿命差异,研究了微动疲劳裂纹的萌生及扩展特性,揭示了耳片裂纹萌生机制。结果表明:二次挤压耳片的断口扩展区面积比例较大,说明其拉-扭疲劳扩展更为充分。经二次挤压后,耳片的拉-扭微动疲劳总寿命得到延长,且裂纹萌生寿命均占总寿命的95%以上;二次挤压后耳片的裂纹萌生驱动力较低,呈现较高的裂纹萌生抗力。各断口均起源于耳片内孔微动磨损印迹较重处,大面积连续片状的微动磨损印迹表明二次挤压后的钛合金微动疲劳敏感性大大降低。经挤压强化后,孔壁形成了较高幅值的残余压应力层和组织强化层,可以有效地抑制裂纹的萌生和扩展。耳片内孔微动磨损层的形成是机械诱导机制和热诱导机制共同作用的结果,其最终磨损形式为疲劳磨损。     

铝合金自冲铆接微动行为研究

选择两组不同厚度铝合金板制成SA15和SA25自冲铆接头并进行疲劳实验,用威布尔分布验证实验数据有效性,用疲劳三参数经验公式拟合接头S-N曲线并对比分析接头疲劳性能,用扫描电子显微镜研究接头微动行为以探索疲劳失效与微动磨损的关系。实验数据服从威布尔分布,表明数据可靠。三参数经验公式较好地拟合接头S-N曲线,SA25接头疲劳性能优于SA15接头,且在中低疲劳寿命区域SA25接头疲劳性能的优越性更为突出。SA15接头失效于上板靠铆钉头,而SA25接头失效于下板沿纽扣。SA15接头在铆接区两板间微动磨损较严重,SA25接头在下板与铆钉腿部微动磨损较严重。疲劳失效部位与微动磨损剧烈部位重合,表明微动磨损是导致接头疲劳失效的重要因素之一。     

用应变能密度法分析纤维金属层板的微动疲劳特性

为研究纤维金属层板的微动疲劳特性,首先,基于三维坐标系下的临界平面法求解了纤维金属层板铝层临界平面上的应力和应变分量,并进一步求解了Smith-Watson-Topper （SWT）和I型Nita-Ogatta-Kuwabara （NOK）应变能密度参数;然后,建立了应变能密度参数-微动疲劳寿命关系式,并通过实验数据得到了寿命预测公式中的待定参数;最后,采用I型NOK应变能密度准则分析了铝层厚度、纤维层厚度、各层相对厚度和桥足圆角半径等对微动疲劳损伤位置和寿命的影响,并为纤维金属层板抗微动疲劳设计提出了一些合理化建议。结果表明:增加铝层厚度可以延长微动疲劳寿命,但增加纤维层厚度和桥足圆角半径不会改善微动疲劳特性。提出的方法可为分析纤维金属层板铆接和螺栓连接中的微动疲劳问题提供理论依据。      

微动损伤对复合材料螺栓连接预紧力松弛的影响

开展了横向循环载荷下复合材料螺栓连接件预紧力松弛试验,探究了材料疲劳损伤与接触面微动磨损联合作用下螺栓连接预紧力松弛过程。基于有限元软件ABAQUS,采用Archard磨损模型和ALE（Arbitrary Lagrangian-Eulerian）自适应网格技术,编制了适用于连接结构微动磨损的UMESHMOTION子程序,建立了分析连接支承面微动磨损的计算模型;利用子程序UMAT编制了Shokrieh和Lessard提出的疲劳累积损伤定量分析程序。在此基础上分析了复合材料疲劳损伤、螺孔伸长及接触磨损的耦合作用下预紧力随循环周次变化的机制,与实验结果进行对比,验证了所提出的预测方法的合理性、有效性。      

18CrNiMo7-6合金钢的弯曲微动疲劳特性

对18CrNiMo7-6合金钢进行弯曲微动疲劳实验,建立弯曲微动疲劳S-N曲线,并对实验结果进行分析。结果表明:该合金钢的弯曲微动疲劳S-N曲线不同于中碳钢材料,也不同于常规弯曲疲劳,而是呈"ε"型曲线特征。随着弯曲疲劳应力的增加,微动运行区域由部分滑移区向混合区和滑移区转变,损伤区的磨损机制以剥层、磨粒磨损和氧化磨损为主。在混合区内,裂纹最易萌生和扩展,且裂纹均萌生于材料接触区次表面。受接触应力和弯曲疲劳应力影响,弯曲微动疲劳裂纹的萌生和扩展可分为三个阶段:初期,在接触应力控制下,裂纹萌生于次表面;随后,裂纹受接触应力和弯曲疲劳应力共同控制,转向更大角度方向扩展;最后,裂纹完全受弯曲疲劳应力控制而垂直于接触表面扩展,直至断裂失效。     

THE APPLICATION OF FRACTURE MECHANICS TO FRETTING FATIGUE

Abstract— A fracture mechanics model of fretting fatigue has been developed. This enables the calculation of the critical size of defect which can grow under fretting conditions. The model has been applied to the fretting of aluminium alloy 2014A fatigue specimens in contact with 3.5NiCrMoV steel fretting contact pads. The input parameters to the model include externally applied stresses, contact pressure between pad and specimen and frictional forces between the two contacting surfaces. The latter have been measured using a strain gauge technique. Small fretting defects in the fatigue specimens have been investigated metallographically and fractographically. There is good agreement between their size and critical defect sizes calculated using the fretting model.     

Experimental results in fretting fatigue with shot and laser peened Al 7075-T651 specimens

This work focuses on determining the effect of shot and laser peening on fretting fatigue in the Al 7075-T651 alloy. These surface treatments generate a residual compressive stress field near the treated surface where contact under fretting fatigue produces high stress levels. The fretting fatigue resistance of shot and laser peened specimens was assessed in a series of tests involving measurements of the residual stress field, residual stress relaxation under the action of cyclic loads, the friction coefficient, surface roughness and material hardness. The obtained results are compared with those for untreated specimens. The tests show the beneficial effect of the compressive residual stresses and the improvement that surface roughness causes in fretting fatigue life, especially in shot peened specimens. Another important effect observed, is the partial residual stress relaxation produced during the fretting fatigue tests.     

THE EFFECT OF HARDNESS ON THE FRETTING FATIGUE OF ALLOY STEELS

The fretting fatigue behaviour of several alloy steels is reported in this paper. Fretting fatigue experiments were conducted on flat fretting junctions in axial tension at a stress ratio of 0.1. In all cases the same materials were fretted against each other. The fretting fatigue strength at a slip amplitude of 45 μ is rather insensitive to the hardness of the materials. The fretting fatigue strength at the slip amplitude of 10 μ increases with increase in hardness. As the slip amplitude increases the fretting fatigue life of 3SCrMo steel decreases, the depth of wear scars increases and the wear damage becomes more severe. The reason for similarity of fretting fatigue to the fatigue of notched specimens is that the effect of wear scars is similar to that of notches.     

FRETTING FATIGUE AT ELEVATED TEMPERATURES IN TWO STEAM TURBINE STEELS

Abstract— —Fatigue tests and fretting fatigue tests of two steam turbine steels at room temperature and 773 K were carried out. The reduction of fatigue life and strength in the fretting test were significant at 773 K as well as at room temperature. The values of the friction coefficient at 773 K was almost equal to those at room temperature. The geometry of the fretting fatigue crack was flat in the early stage of fatigue life where a significant effect of fretting was observed. With increasing crack length and with a reducing effect of fretting, the fatigue crack shape changed to a semi-circular form. The fretting fatigue lives predicted on the basis of elastic-plastic fracture mechanics analysis, with the frictional force between the fretting pad and the specimen taken into consideration, agreed well with experimental results at both temperatures.     

Effect of mean stress on fretting fatigue of Ti-6Al-4V on Ti-6Al-4V

Fretting fatigue tests of Ti‐6Al‐4V on Ti‐6Al‐4V have been conducted to determine the influence of stress amplitude and mean stress on life. The stress ratio was varied from R=−1 to 0.8. Both flat and cylindrical contacts were studied using a bridge‐type fretting fatigue test apparatus operating either in the partial slip or mixed fretting regimes. The fretting fatigue lives were correlated to a Walker equivalent stress relation. The influence of mean stress on fretting fatigue crack initiation, characterized by the value of the Walker exponent, is smaller compared with plain fatigue. The fretting fatigue knockdown factor based on the Walker equivalent stress is 4. Formation of fretting cracks is primarily associated with the tangential force amplitude at the contact interface. A simple fretting fatigue crack initiation metric that is based on the strength of the singular stress field at the edge of contact is evaluated. The metric has the advantage in that it is neither dependent on the coefficient of friction nor the location of the stick/slip boundary, both of which are often difficult to define with certainty a priori.     

TWO-PARAMETER MODEL OF FRETTING FATIGUE CRACK GROWTH

Abstract— A fretting fatigue crack growth model is proposed accounting for the effects of tribological parameters of the contacting materials and the biaxiality of contact together with bulk stresses, upon fretting fatigue crack growth rate and direction of growth in the fretting-zone subsurface layers. Based on this model a new technique is developed to determine fatigue life and predict the fatigue limit in an aluminium alloy, AMg6N, and a titanium alloy, VT9, under fretting conditions. For the above cases, fretting fatigue crack growth behaviour predicted by the proposed model is in good agreement with the experimental results.     

Plain fatigue and fretting fatigue behaviour of plasma nitrided Ti-6Al-4V

Fatigue tests with and without fretting against unnitrided fretting pads were conducted on unnitrided and plasma nitrided Ti-6Al-4V samples. Plasma nitrided samples exhibited higher surface hardness, higher surface compressive residual stress, lower surface roughness and reduced friction force compared with the unnitrided specimens. Plasma nitriding enhanced the lives of Ti-6Al-4V specimens under both plain fatigue and fretting fatigue loadings. This was explained in terms of the differences in surface hardness, surface residual stress, surface roughness and friction force between the unnitrided and nitrided samples.     

STATIC AND CYCLIC FRETTING FATIGUE BEHAVIOUR OF SILICON NITRIDE

A cyclic fretting fatigue test machine was constructed. The piezoelectric bimorphs were used as actuators for cyclic loading and fretting motion at the resonance frequency of the system. Fretting fatigue tests under static and cyclic loading conditions were carried out using HIP-sintered silicon nitride. From the experimental results, it was found that fretting fatigue strengths under the two test conditions were identical and hence the effect of cyclic loading on fretting fatigue strength of silicon nitride was almost negligible. A fretting crack initiated in a very early stage of the fatigue life at the position of the maximum frictional stress in the contact area. Fretting fatigue life prediction based on fracture mechanics was also carried out. The predicted lives were in good agreement with the experimental results.     

FRETTING FATIGUE OF AN AUSTENITIC STAINLESS STEEL IN SEAWATER

Abstract— Fretting fatigue tests of an austenitic stainless steel used for a propeller tail shaft were carried out in seawater and in air. In seawater, fretting significantly reduced the fatigue strength, however, the fretting fatigue lives at higher levels of stress were longer than those in air. The tangential force coefficient (defined as the ratio of the frictional force amplitude and the contact load) in seawater was much lower than that in air and varied in the range from 0.3 to 0.5 during the fretting fatigue tests. The lower tangential force coefficient in seawater seems to be the main reason for the longer fretting fatigue life in seawater. The prediction of fretting fatigue life was made on the basis of elastic-plastic fracture mechanics, where the frictional force between the specimen and the contact pad was taken into consideration. The predicted fatigue lives agreed well with the experimental results in both air and seawater.     

WAVEFORMS IN FRETTING FATIGUE

Abstract— The magnitudes and directions of the frictional forces must be considered in any fracture mechanics analysis of crack growth under fretting fatigue conditions. A simple nonlinear friction model has been developed which relates the waveforms of the frictional forces to those of the applied forces when fretting occurs. It is shown that the waveforms are different in shape and that periods of dwell and phase shifts may occur in the frictional forces. These differences can significantly affect the rate of growth of cracks and hence life prediction.