This work employs a three-dimensional (3D) finite element analysis (FEA) to investigate the fretting metallic contact between a deformable hemisphere and a deformable flat block. Fretting is governed by displacement-controlled action where the materials of the two contacting bodies are set to have identical properties; studied first is steel-on-steel and then copper-on-copper. At contact onset, a normal interference (indentation) is applied, which is then followed by transverse cyclic oscillations. A large range of coefficients of friction (COFs) is imposed at the interface. The results show that the maximum von Mises stress is confined under the contacting surface for small COFs; however, that maximum reaches the contacting surface when the COFs are sufficiently large. It is also shown that fretting under sufficiently large COFs forms large plastic strains in “ring” like patterns at the contacting surfaces. Junction growth is found where the contacting region is being stretched in the direction of the fretting motion. At large COFs, pileups show up at the edges of the contact. The fretting loops of the initial cycles are found along with the total work invested into the system. At certain interference, there exists a certain COF, which results in the largest work consumption. The magnitude of the COF is found to produce either partial slip (prone for fretting fatigue) or gross slip (prone for fretting wear). A scheme of normalization is proposed, and it is shown to be effective for the two said materials that have vastly different material properties. Hence, the normalized results may well characterize a range of contact scales (from micro to macro) of various ductile material pairs that behave in an elastic–plastic manner with strain hardening.

References

References
1.
Varenberg
,
M.
,
Etsion
,
I.
, and
Halperin
,
G.
,
2005
, “
Nanoscale Fretting Wear Study by Scanning Probe Microscopy
,”
Tribol. Lett.
,
18
(
4
), pp.
493
498
.
2.
Li
,
G.
,
Ding
,
S.
,
Bao
,
M.
, and
Sun
,
H.
,
2017
, “
Effect of Actively Managed Thermal-Loading in Optimal Design of an Aeroengine Turbine Disk
,”
Int. Commun. Heat Mass Transfer
,
81
, pp.
257
268
.
3.
Yang
,
Q.
,
Zhou
,
W.
,
Gai
,
P.
,
Zhang
,
X.
,
Fu
,
X.
,
Chen
,
G.
, and
Li
,
Z.
,
2017
, “
Investigation on the Fretting Fatigue Behaviors of Ti–6Al–4V Dovetail Joint Specimens Treated With Shot-Peening
,”
Wear
,
372–373
, pp.
81
90
.https://www.sciencedirect.com/science/article/pii/S0043164816307372
4.
Shi
,
L.
,
Wei
,
D-S.
,
Wang
,
Y-R.
,
Tian
,
A-M.
, and
Li
,
D.
,
2016
, “
An Investigation of Fretting Fatigue in a Circular Arc Dovetail Assembly
,”
Int. J. Fatigue
,
82
, pp.
226
237
.
5.
Chan
,
K. S.
,
Enright
,
M. P.
,
Moody
,
J. P.
,
Golden
,
P. J.
,
Chandra
,
R.
, and
Pentz
,
A. C.
,
2010
, “
Residual Stress Profiles for Mitigating Fretting Fatigue in Gas Turbine Engine Disks
,”
Int. J. Fatigue
,
32
(
5
), pp.
815
823
.
6.
Vingsbo
,
O.
, and
Söderberg
,
S.
,
1988
, “
On Fretting Maps
,”
Wear
,
126
(
2
), pp.
131
147
.
7.
Varenberg
,
M.
,
Etsion
,
I.
, and
Halperin
,
G.
,
2004
, “
Slip Index: A New Unified Approach to Fretting
,”
Tribol. Lett.
,
17
(
3
), pp.
569
573
.
8.
Hoeppner
,
D.
,
Adibnazari
,
S.
, and
Moesser
,
M. W.
,
1994
, “
Literature Review and Preliminary Studies of Fretting and Fretting Fatigue Including Special Applications to Aircraft Joints
,” Utah University, Salt Lake City, UT, Report No.
DOT/FAA/CT-93/2
.http://www.dtic.mil/docs/citations/ADA280310
9.
Chivers
,
T.
, and
Gordelier
,
S.
,
1985
, “
Fretting Fatigue and Contact Conditions: A Rational Explanation of Palliative Behaviour
,”
Proc. Inst. Mech. Eng., Part C
,
199
(
4
), pp.
325
337
.
10.
Courtney-Pratt
,
J.
, and
Eisner
,
E.
,
1957
, “
The Effect of a Tangential Force on the Contact of Metallic Bodies
,”
Proc. R. Soc. London A
,
238
(
1215
), pp.
529
550
.
11.
Parker
,
R.
, and
Hatch
,
D.
,
1950
, “
The Static Coefficient of Friction and the Area of Contact
,”
Proc. Phys. Soc. Sect. B
,
63
(
3
), p.
185
.
12.
Tabor
,
D.
,
1959
, “
Junction Growth in Metallic Friction: The Role of Combined Stresses and Surface Contamination
,”
Proc. R. Soc. London A: Math., Phys. Eng. Sci.
,
251
(
1266
), pp.
378
393
.
13.
Leonard
,
B. D.
,
Sadeghi
,
F.
,
Evans
,
R. D.
,
Doll
,
G. L.
, and
Shiller
,
P. J.
,
2009
, “
Fretting of WC/aC: H and Cr2N Coatings Under Grease-Lubricated and Unlubricated Conditions
,”
Tribol. Trans.
,
53
(
1
), pp.
145
153
.
14.
Leonard
,
B. D.
,
Sadeghi
,
F.
,
Shinde
,
S.
, and
Mittelbach
,
M.
,
2012
, “
A Novel Modular Fretting Wear Test Rig
,”
Wear
,
274–275
, pp.
313
325
.
15.
Warhadpande
,
A.
,
Leonard
,
B.
, and
Sadeghi
,
F.
,
2008
, “
Effects of Fretting Wear on Rolling Contact Fatigue Life of M50 Bearing Steel
,”
Proc. Inst. Mech. Eng., Part J
,
222
(
2
), pp.
69
80
.
16.
Zhu
,
M.
,
Zhou
,
Z.
,
Kapsa
,
P.
, and
Vincent
,
L.
,
2001
, “
Radial Fretting Fatigue Damage of Surface Coatings
,”
Wear
,
250
(
1–12
), pp.
650
657
.
17.
Xu
,
J.
,
Zhu
,
M.
,
Zhou
,
Z.
,
Kapsa
,
P.
, and
Vincent
,
L.
,
2003
, “
An Investigation on Fretting Wear Life of Bonded MoS2 Solid Lubricant Coatings in Complex Conditions
,”
Wear
,
255
(
1–6
), pp.
253
258
.
18.
Jin
,
X.
,
Sun
,
W.
, and
Shipway
,
P.
,
2016
, “
Derivation of a Wear Scar Geometry-Independent Coefficient of Friction From Fretting Loops Exhibiting non-Coulomb Frictional Behaviour
,”
Tribol. Int.
,
102
, pp.
561
568
.
19.
Eriten
,
M.
,
Polycarpou
,
A.
, and
Bergman
,
L.
,
2010
, “
Physics-Based Modeling for Partial Slip Behavior of Spherical Contacts
,”
Int. J. Solids Struct.
,
47
(
18–19
), pp.
2554
2567
.
20.
Eriten
,
M.
,
Polycarpou
,
A.
, and
Bergman
,
L.
,
2011
, “
Physics-Based Modeling for Fretting Behavior of Nominally Flat Rough Surfaces
,”
Int. J. Solids Struct.
,
48
(
10
), pp.
1436
1450
.
21.
Kogut
,
L.
, and
E
,
I.
,
2002
, “
Elastic–Plastic Contact Analysis of a Sphere and a Rigid Flat
,”
ASME J. Appl. Mech.
,
69
(
5
), pp.
657
662
.
22.
Jackson
,
R. L.
, and
Green
,
I.
,
2005
, “
A Finite Element Study of Elasto-Plastic Hemispherical Contact Against a Rigid Flat
,”
ASME J. Tribol.
,
127
(
2
), pp.
343
354
.
23.
Tsukizoe
,
T.
, and
Hisakado
,
T.
,
1968
, “
On the Mechanism of Contact Between Metal Surfaces—Part 2: The Real Area and the Number of the Contact Points
,”
ASME J. Lubr. Technol.
,
90
(
1
), pp.
81
88
.
24.
Holmberg
,
K.
,
Laukkanen
,
A.
,
Ronkainen
,
H.
,
Wallin
,
K.
,
Varjus
,
S.
, and
Koskinen
,
J.
,
2006
, “
Tribological Contact Analysis of a Rigid Ball Sliding on a Hard Coated Surface—Part I: Modelling Stresses and Strains
,”
Surf. Coat. Technol.
,
200
(
12–13
), pp.
3793
3809
.
25.
Moody
,
J. J.
,
2007
, “
A Finite Element Analysis of Elastic-Plastic Sliding of Hemispherical Contacts
,”
M.S. thesis
, Georgia Institute of Technology, Atlanta, GA.https://smartech.gatech.edu/handle/1853/31992
26.
Green
,
I.
,
2018
, “
An Elastic-Plastic Finite Element Analysis of Two Interfering Hemispheres Sliding in Frictionless Contact
,”
Phys. Sci. Int. J.
,
19
(
1
), pp.
1
34
.http://www.sciencedomain.org/abstract/25624
27.
Boucly
,
V.
,
Nelias
,
D.
, and
Green
,
I.
,
2007
, “
Modeling of the Rolling and Sliding Contact Between Two Asperities
,”
ASME J. Tribol.
,
129
(
2
), pp.
235
245
.
28.
Gupta
,
V.
,
Bastias
,
P.
,
Hahn
,
G. T.
, and
Rubin
,
C. A.
,
1993
, “
Elasto-Plastic Finite-Element Analysis of 2-D Rolling-Plus-Sliding Contact With Temperature-Dependent Bearing Steel Material Properties
,”
Wear
,
169
(
2
), pp.
251
256
.
29.
Ghosh
,
A.
,
Leonard
,
B.
, and
Sadeghi
,
F.
,
2013
, “
A Stress Based Damage Mechanics Model to Simulate Fretting Wear of Hertzian Line Contact in Partial Slip
,”
Wear
,
307
(
1–2
), pp.
87
99
.
30.
Yang
,
H.
, and
Green
,
I.
,
2018
, “
An Elastoplastic Finite Element Study of Displacement-Controlled Fretting in a Plane-Strain Cylindrical Contact
,”
ASME J. Tribol.
,
140
(
4
), p.
041401
.
31.
Yang
,
H.
, and
Green
,
I.
,
2018
, “
A Fretting Finite Element Investigation of a Plane-Strain Cylindrical Contact of Inconel 617/Incoloy 800H at Room and High Temperature
,”
Proc. Inst. Mech. Eng. Part J
(epub).
32.
Zolotarevskiy
,
V.
,
Kligerman
,
Y.
, and
Etsion
,
I.
,
2011
, “
Elastic–Plastic Spherical Contact Under Cyclic Tangential Loading in Pre-Sliding
,”
Wear
,
270
(
11–12
), pp.
888
894
.
33.
Shi
,
X.
,
Wu
,
A.
,
Zhu
,
C.
, and
Qu
,
S.
,
2013
, “
Effects of Load Configuration on Partial Slip Contact Between an Elastic Plastic Sphere and a Rigid Flat
,”
Tribol. Int.
,
61
, pp.
120
128
.
34.
Johnson
,
K. L.
,
1987
,
Contact Mechanics
,
Cambridge University Press
,
Cambridge, UK
.
35.
Green
,
I.
,
2005
, “
Poisson Ratio Effects and Critical Valus in Spherical and Cylindrical Hertzian Contacts
,”
Appl. Mech. Eng.
,
10
(
3
), p.
451
.http://itzhak.green.gatech.edu/rotordynamics/Poisson_ratio_and_critical_values.pdf
36.
Peterson
,
M. B.
, and
Winer
,
W. O.
,
1980
,
Wear Control Handbook
,
American Society of Mechanical Engineers
, New York.
37.
Walvekar
,
A. A.
,
Leonard
,
B. D.
,
Sadeghi
,
F.
,
Jalalahmadi
,
B.
, and
Bolander
,
N.
,
2014
, “
An Experimental Study and Fatigue Damage Model for Fretting Fatigue
,”
Tribol. Int.
,
79
, pp.
183
196
.
You do not currently have access to this content.