Dual-crack failure behaviors of milled Ti-6Al-4V alloy in conformal contact fretting fatigue

Gu, Hairong; Li, Jiao; Pei, Yan; Song, Yan-Kui; Guo, Zhibo; Qiu, Tianyang; Wang, Xibin

doi:10.1016/j.msea.2021.142465

Cited by 8 publications

(12 citation statements)

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“…Predicted (A) location, (B,C) orientation of crack initiation with the FS method, (D) 21 the cracks observed in experiment, and (E) schematic diagram of material flow and variation of stress on the specimen surface. [Colour figure can be viewed at wileyonlinelibrary.com]…”

Section: Resultsmentioning

confidence: 99%

“…To comply with the widely presented conformal contact situations and the previous works, 19,21,29 the pin‐hole contact case is employed. Since the contact zone length is about 10 mm 21 while the thickness of the specimen is 2.5 mm, and the direction of load is perpendicular to the thickness of the specimen, the fretting fatigue test apparatus (Figure 1A) was simplified as the two‐dimensional (2D) plane stress pin‐hole contact finite element model as shown in Figure 1C. The materials of the pin and the specimen are 0Cr13Ni8Mo2Al and Ti‐6Al‐4V, respectively.…”

Section: Methodsmentioning

confidence: 99%

“…The materials of the pin and the specimen are 0Cr13Ni8Mo2Al and Ti‐6Al‐4V, respectively. Since no obvious elastic deformation of the pin was observed during the experiment, 19,21,29 the pin was regarded as a rigid body in the finite element model. The mechanical properties of the Ti‐6Al‐4V were obtained by the tensile test and were fitted by Johnson–Cook material model (Equation 1), 30 as shown in Figure 1D.…”

Section: Methodsmentioning

confidence: 99%

“…(A) 21 Schematic of the fretting fatigue test apparatus, (B) dimensions of the finite element model, (C) the boundary conditions, and (D) Ti‐6Al‐4V tensile test curve and its fitted curve. [Colour figure can be viewed at wileyonlinelibrary.com]…”

Section: Methodsmentioning

confidence: 99%

“…Different contact forms result in different contact mechanics and stress distributions, which are highly correlated to the nucleation behaviors of fretting crack 20 . Our previous studies investigated the fretting crack behaviors in conformal contact fretting fatigue compared with non‐conformal contact fretting fatigue 19,21 . The results showed that the conformal nature could accelerate the accumulation of debris and redistribute the contact stress, resulting in the exacerbation of crack nucleation conditions.…”

Section: Introductionmentioning

confidence: 99%

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Numerical simulation of the effect of surface microgeometry and residual stress on conformal contact fretting fatigue crack initiation behavior

Song

Pei

et al. 2023

Fatigue Fract Eng Mat Struct

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Conformal contact is a commonly presented contact form in assemblies. Nonproportional loading is the main characteristics of conformal contact, which leads to prominent difficulty in revealing fretting crack behavior. In this paper, a finite element prediction model for Ti-6Al-4V pin-hole contact fretting fatigue crack initiation was developed, which simultaneously considered the effect of fretting wear, surface roughness, surface skewness, surface kurtosis, and residual stress. The results show that phase differences of stress component, change in direction of principal stress, and high stress gradient are the main reasons for the initiation of fretting fatigue under conformal contact condition. The model based on the Fatemi-Socie (FS) parameter successfully predicted the location, orientation, and fatigue life of crack initiation, which agrees well with the experimental results. Additionally, machining-induced residual stress can effectively inhibit mode I crack initiation at valleys. Moreover, ignoring the surface microgeometry characteristics reduces the prediction accuracy of the crack behavior.

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Section: Resultsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%