Axisymmetric fretting analysis in coated cylinder

Fretting is essentially a contact fatigue phenomenon, although bulk stresses and material properties contribute to final failure. The near surface state of stress developed under oscillatory contact between machine elements plays a major role in deciding the severity of fretting. It is possible to enhance tribological properties by coating the surface. There is rather scanty literature available on fretting analysis of coated components. Presence of such coatings has a large influence on the near surface state of stress. The effect of coatings on the severity of fretting is the focus of this paper. Results obtained for both hard and soft coatings are compared with the results obtained for the homogeneous case. The component geometry and loading are chosen to be cylindrical to enable 3D elastic axisymmetric fretting analysis. The results are compared with 2D models (strip and half-plane) to examine their utility and validity for understanding axisymmetric fretting. Contact pressure and frictional shear loading cases are solved separately and superposed appropriately depending on the coefficient of friction considered. Results for different values of coefficient of friction and elastic mismatch are illustrated through contour plots of stresses and strains. These results are expected to be helpful for identifying fretting failure zones and fracture mechanisms in coated components. Analytical results presented here could serve as useful benchmarks for calibrating numerical codes and experimental techniques.