Author:

Keywords:

Science & Technology, Technology, Engineering, Mechanical, Engineering, Fretting fatigue, Additive manufacturing, Crack initiation, Crack propagation, XFEM, CRACK-GROWTH, INTENSITY FACTORS, CONTACT, FAILURE, PREDICTION, INITIATION, MECHANISM, WEAR, PATH, STG/18/010#54843755, 0910 Manufacturing Engineering, 0913 Mechanical Engineering, Mechanical Engineering & Transports, 4014 Manufacturing engineering, 4017 Mechanical engineering

Abstract:

Fretting fatigue failure occurs in shrink-fitted assemblies due to the combination of high stresses and relative displacements near the contact edge. Due to these high stresses, fatigue crack initiates followed by crack propagation until final rupture. Additive manufacturing (AM) is a game changing technology, which enables new component capabilities that cannot be manufactured with conventional techniques. This research work analyses numerically the influence of an artificial internal stress relief toroidal groove inside a shrink-fitted shaft, which could be manufactured using AM technology. Due to the toroidal void, the stress/strain fields are redistributed improving the fretting fatigue crack initiation and propagation lifetimes. To do so, 2D finite element models are created in Abaqus software with and without the internal groove. To estimate the fretting fatigue initiation and propagation lifetime and crack propagation direction, critical plane methods are used. In terms of the crack propagation, eXtended Finite Element Method (XFEM) is used to simulate mixed mode crack advancing in a single mesh structure. Finally, the obtained results with and without void were compared concluding with significant improvements in terms of total fatigue lifetime.