Finite Element Analysis of Localized Plasticity in Al 2024-T3 Subjected to Fretting Fatigue

Fretting fatigue is a combination of two complex mechanical phenomena, namely, fretting and fatigue. Fretting appears between components that are subjected to small relative oscillatory motion. Once these components undergo cyclic fatigue load at the same time, fretting fatigue occurs. Fretting fatigue is an important issue in aerospace structural design. Many studies have investigated fretting fatigue behavior; however, the majority have assumed elastic deformation and very few have considered the effect of plasticity. The main goal of this study is to monitor the effect of different fretting fatigue primary variables on localized plasticity in an aluminum alloy (Al 2024-T3) test specimen. In order to extract the stress distribution at the contact interface under elasto-plastic conditions, a modified finite element contact model was used. The contact model was verified through comparison with an elastic analytical solution. Then, a bilinear elasto-plastic isotropic hardening model with a von Mises yield surface was implemented to simulate the material behavior of the aluminum alloy. The effect of different fretting fatigue primary variables, such as axial stress, contact geometry, and coefficient of friction, on localized plasticity was investigated. Finally, the relationship between the location of maximum localized plasticity and Ruiz fretting damage parameter with the crack initiation site is discussed.