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The distributions of other contact variables were also found to be considerably different. Considering
the fact that the circumferential fretting fatigue crack observed in Axle B almost entirely encircled
the axle, a ring-shaped crack was also used in the FE models. In Figure 32, the normalization
equation is reported where NTS is the normalized tangential stress range with respect to the tensile
strength, NCS is the normalized compressive stress range with respect to the tensile strength, and
0.28 is the critical stress parameter (CSP) at a fatigue limit of 10 7 cycles. Computational approach
to contact fatigue damage initiation and deformation a. If material is not included in the article's
Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds
the permitted use, you will need to obtain permission directly from the copyright holder. After the
fatigue test, the axle was disassembled from the wheel, and an MPI was performed to further detect
the fretting fatigue cracks. Fig. 3 Strain gauges and their positions on test axles (unit: mm) Full size
image After the MPI, specimens for detailed observations were cut out using a wire electrical
discharge machine, and then ultrasonically cleaned with acetone for 20 min. This article is an open
access article distributed under the terms and conditions of the Creative Commons Attribution (CC
BY) license ( ). In particular, they found that adding a stress relief groove in electric passenger car
axles could improve the fatigue life of the axle by up to 50% ( Figure 8 ). They also evaluated
subsurface stresses using this approach, successfully predicting the failure lives of fretting fatigue
specimens. Barrow Motor Ability Test - TEST, MEASUREMENT AND EVALUATION IN
PHYSICAL EDUC. The singular integral equation (SIE) method was then applied using the output
of the coarse finite element mesh and compared to results obtained using the fine mesh. They then
retrieved the TSR-CSR diagram by testing conventional laboratory-type S355mc specimens on a
bridge-type fretting fatigue test rig. Download Free PDF View PDF David C Barton John D
Fieldhouse Automotive Chassis Engineer Saif Ali Download Free PDF View PDF INDIAN
RAILWAY TRACKS a TRACK ENGINEERING COMPENDIUM SAMI ENIS ARIOGLU The
following collection of chapters is based on a revision of the drafts of J.S. Mundrey, Rail Consult
India, for the forthcoming 5thEdition of RAILWAY TRACK ENGINEERING. The Generalized
Cattaneo Partial Slip Plane Contact Problem. THERCAST: A new 3D simulation model for complete
chaining casted and forged i. They consequently proposed a design parameter, “fretting damage” (
FD ), by multiplying the highest surface tangential stress with the maximum frictional work. Figure
13 shows the evolution of the equivalent plastic strain PEEQ at the wheel seat edge with the loading
cycles. The behaviour of the joints was found to be strongly dependent on both applied tightening
torque and maximum alternating load. Furthermore, the nominal bending stress applied in a 13 mm
diameter press-fitted axle was far greater than the actual stress on a railway axle. Firstly, they tested
different shape shaft specimens on a rotating-bending machine in order to replicate a classical
fretting situation. Funding This research received no external funding. It also predicted a fretting
fatigue life identical to test results: nonetheless, a single calibration point was used. Due improved
computational efficiency, the authors recommended using the Augmented Lagrange algorithm.
Fretting fatigue can occur in press-fitted shafts subjected to rotating bending such as railway axles.
SEM micrographs showing the types of damage of wheel and rail rollers at room temperature. ( a )
D1; ( b ) D2. Zones of microslip develop along the contact surface where sliding occurs, leading to
considerable surface damage. The FE pre-processor HYPERMESH was employed to create a starting
2D solid mesh of the test axle without considering fretting wear (models 1 and 3), as shown in Fig.
9 a. A highly refined mesh size of 0.05 mm was selected in the areas of interest, including the regions
near the wheel seat edge and transition fillet. Coupling the bionic surface friction contact
performance and wear resistance. They observed that mesh refinement was a key point in achieving
convergence, while all the contact algorithms that were used gave accurate results. Effect of Large
Hydrostatic Pressures on the Torsional Fatigue Strength of an Alloy Steel.
They then carried out an analysis for each different force acting on the dovetail, another analysis
with the application of both centrifugal force and aerodynamic force, and, lastly, an analysis in
which all the loads were applied at the same time. Metallographic microscopy and surface and
subsurface damages were inspected using scanning electronic microscopy (SEM) (QUANTA200
FEI, Eindhoven, Netherlands). The combined effect of press-fitting and stress concentration causes
S xx,max to decrease near the mating surface, and then increase with an increase in depth.
International Journal of Environmental Research and Public Health (IJERPH). In particular, for more
complex contact geometries, such as dovetail joints, it is necessary to determine point or line contact
loads by numerical methods. Tests were carried out on a rotating bending machine using the shaft
and hub specimens showed in Figure 14. They observed that the modified SWT model was more
precise in terms of the nucleation zone prediction with respect to the plain SWT model. Fig. 1 A
schematic plot of normal load against According to Melan’s theorem when shakedown occurs. Dang
Van combined with a simple model to predict New Multiaxial Fatigue Limit Criterion: Theory. The
SWT parameter is determined by the peak normal stress. It can be seen that pearlite composed of
cementite and ferrite presents a lamellar structure, and the Pearlite lamellar spacing in D1 is larger
than that in D2. 3. Results 3.1. Wear Loss Figure 6 shows the wear loss of wheel and rail rollers
under different temperatures. Then, three-dimensional finite element (FE) models were established
based on the obtained wear profiles. As shown in Fig. 5 a, the rough surface of zone I indicates the
occurrence of severe abrasive wear. Plastic deformation of wheel and rail rollers at room temperature:
( a ) D1 wheel; ( b ) rail of D1 friction pair; ( c ) D2 wheel; ( d ) rail of D2 friction pair. A torsional
vibration was applied to the two different types of specimen by means of the test rig showed in
Figure 9. Then, multi-axial fatigue parameters and a linear elastic fracture mechanics-based approach
were used to investigate the fretting fatigue crack initiation and propagation, respectively, in which
the role of the fretting wear was taken into account. Computational approach to contact fatigue
damage initiation and deformation a. Effect of Large Hydrostatic Pressures on the Torsional Fatigue
Strength of an Alloy Steel. The type D specimen displayed the maximum increase in the fatigue
limit. After the fatigue test, the axle was disassembled from the wheel, and an MPI was performed
to further detect the fretting fatigue cracks. Fig. 3 Strain gauges and their positions on test axles
(unit: mm) Full size image After the MPI, specimens for detailed observations were cut out using a
wire electrical discharge machine, and then ultrasonically cleaned with acetone for 20 min. They then
run an FE analysis (the model is shown in Figure 54 ) on ABAQUS in order to develop a tool to
estimate fretting fatigue crack initiation lifetime. In the rotating components like axle-shaft
arrangements, the friction and slip are important factors. At low and high temperatures, wear loss,
plastic deformation, and subsurface damage were more severe than at room temperature; they were
the greatest at low temperature. The data point retrieved from the bolted specimens agreed with the
TSR-CSR diagram retrieved by testing the laboratory type specimens ( Figure 45 ). All articles
published by MDPI are made immediately available worldwide under an open access license. No
special. They observed that the shot-peening treatment increased the fretting fatigue life of the
specimens by 100% (from an average of 189,574 cycles to an average 379,646 cycles) as shown in
Figure 37. The specimen was loaded under biaxial tension in a fatigue testing machine in which two
hydraulic actuators, acting on sheet and blades, respectively, were controlled to operate between any
two independent loads, displacements or strains, in-phase or out-of-phase. This is explicable with the
consequent lowering of sliding happening in the contact area; It has also been highlighted that, for
low tightening torques, fretting fatigue does not occur. Cracks were found to start in a high stress
region, next to the edge of the contact, and to propagate obliquely under the contact during the
initial phase of growth. Furthermore, in this regime of partial slip, the tangential force and the
amount of slip were dependent variables, so that a greater tangential force caused larger amounts of
slip.
The pre-defined cracks with different depths shown in Fig. 18 a were modelled as shown in Fig. 18
b. The number of contours along the crack front was set as 15, and the maximum tangential stress
(MTS) criterion was adopted. Especially in high-speed railways operating in extremely hot and cold
climates, the mechanical properties of temperature-sensitive wheel and rail materials will change at
certain extreme temperatures. This second phenomenon is perhaps more dangerous because it has
been responsible for many critical service failures of components, leading sometimes to tragic
accidents. The study sets out with a review of predictive models of fretting fatigue with an emphasis
on computer-based numerical methods of relevance to wheel-axle assemblies. When external forces
or displacements are applied, the two elastic bodies deform and therefore the contact zone becomes a
definite contact area whose shape depends on the load magnitude. They still assumed that the
dovetail was symmetric, and that the moment was negligible. It also predicted a fretting fatigue life
identical to test results: nonetheless, a single calibration point was used. The specimen was loaded
under biaxial tension in a fatigue testing machine in which two hydraulic actuators, acting on sheet
and blades, respectively, were controlled to operate between any two independent loads,
displacements or strains, in-phase or out-of-phase. Journal of Cardiovascular Development and
Disease (JCDD). Both simplified models turned out to accurately predict the material fretting
response, and were therefore validated ( Figure 59 a). In spite of considerable differences in strength
and alloying of tested bars, differences in the mean value of the fatigue limit were not significant
Therefore, no significant increase in fatigue strength under press fit can be expected using a higher
strength steel. Fretting fatigue design is of primary importance in the fan assembly and in the low-
pressure stages of the compressor where the operating temperature is low enough to exclude creep
damage. Fixture C instead showed a stress intensity factor field that allowed for cracks to nucleate
and arrest until the load required to exceed the long crack growth threshold was surpassed. They also
provided the extension for the evaluation of frictional damage. The visible circumferential stripes
observed on zone III were formed during the machining process for the axle, whilst the diagonal
stripes were formed during the process of assembling and disassembling the axle. Because of the
fretting wear, the stress and strain states beneath the press-fitted region change with the evolution of
the wear profile. Study on Wear and Fatigue Performance of Two Types of High-Speed Railway
Wheel Materials at Different Ambient Temperatures. Effect of stress relief groove on fretting fatigue
life of the axle. They also pointed out how, based on their model, a smaller punch radius is expected
to improve the fretting fatigue behavior, however, more studies were needed in order to define
whether the benefit still holds true for a vanishing small radius. Ciavarella G. Macina Engineering,
Materials Science 2003 20 PDF Save On a New Methodology for Quantitative Modeling of Fretting
Fatigue K. D. Van H. Maitournam Engineering, Materials Science 2000 A new intrinsic methodology
for the prediction of fretting fatigue failure of a structure is presented. Farris Materials Science,
Engineering 1998 226 Save The analysis and prevention of failure in railway axles K. Hirakawa K.
Toyama M. Kubota Engineering, Materials Science 1998 131 Save Mechanisms of fretting fatigue Y.
However, it is by no means complete: it is very clear how solutions and evidence are sometimes not
univocal, and are sometimes even in contrast with each other. The study highlighted the importance
of many parameters, such as the distance of the bolts from the hub outer diameter, the bolt preload
and the equivalent bolt spring stiffness. The plastic deformation of wheel and rail rollers was
characterized using optical microscopy (OM) (OLYMPUS BX60M, Tokyo, Japan). Editor’s Choice
articles are based on recommendations by the scientific editors of MDPI journals from around the
world. At the same temperature, the fatigue crack damage generated on the subsurface of the D2
material was slightly less and shorter in length than that on D1, which indicated that the anti-fatigue
properties of D2 were slightly better than those of D1. Journal of Experimental and Theoretical
Analyses (JETA). The test axle was constrained using a clamp on one side, and an electric motor with
a rotating imbalanced exciter was fixed on the opposite side. Recently uploaded Barrow Motor
Ability Test - TEST, MEASUREMENT AND EVALUATION IN PHYSICAL EDUC. A numerical
study is an alternative method for investigating the fretting fatigue in press-fitted axles.
The research paths and main results have been presented but, as previously highlighted, further
research for the validation of all the identified criteria is still needed, since no complete and universal
description of the effects of fretting and design method has been produced. Coupling the bionic
surface friction contact performance and wear resistance. Fig. 1 A schematic plot of normal load
against According to Melan’s theorem when shakedown occurs. The dimensions of wheel roller
(upper specimen) and rail roller (lower specimen are shown in Figure 3 a. They found that it had little
effect on the initiation of cracks, but that a higher mean stress in the specimen reduced the fatigue
life. The results retrieved in terms of stresses along the contact surface and in the depth direction
showed that the cyclic stress characteristics were not the same for different nodes. Hence, fretting
was seen to be a central factor in the formation of micro-cracks. General arrangement of ( a ) test
piece and ( b ) dovetail profile. In particular, for more complex contact geometries, such as dovetail
joints, it is necessary to determine point or line contact loads by numerical methods. They tested both
shot-peened (SP) specimens and “as-received” (AR) specimens, bringing them to failure, applying an
average loading value of 5.5 kN, an amplitude value of 4.5 kN, a stress ratio of 0.1, and a sinusoidal
wave of 10Hz frequency. Fatigue tests were conducted on full-scale railway axles, and the fretting
wear and fretting fatigue in the fretted zone of the railway axles were analysed. Metallographic
microscopy images of D1 and D2 materials are shown in Figure 5. Paper should be a substantial
original Article that involves several techniques or approaches, provides an outlook for. These
simulation results indicate that the crack propagation in mode I plays a more critical role as the crack
propagates, which can be used to explain the observed phenomenon shown in Fig. 8 that the crack
propagation angle gradually decreases with an increase in the crack depth. The normal force P results
in a contact patch of width. Based on the review, a finite element (FE)-based numerical framework
to predict fretting fatigue of wheel-axle assemblies is outlined. He carried out a series of tests on an
aluminum 2024-T3 double lap joint specimen ( Figure 38 ) aiming at developing design methods in
order to reduce fretting on the joint. One very important aspect of this fixture design is that no post-
processing and filtering is needed to obtain the fretting response. As a result, two main effects can be
observed: Wear of the surfaces; A considerable reduction in fatigue life. Schematics of the used rig
are shown in Figure 23. Study on Wear and Fatigue Performance of Two Types of High-Speed
Railway Wheel Materials at Different Ambient Temperatures. Materials. 2020; 13(5):1152. In
agreement with the previous work, they observed that low friction coatings such as Diamond Like
Carbon (DLC) increased the number of cycles needed to nucleate a crack by reducing the magnitude
of the applied loading, whereas surface processing inducing compressive residual stresses (low
plasticity burnishing—LPB and laser shock processing—LSP) reduced the intensity factor range
resulting in either retarded crack growth or crack arrest. It was demonstrated that the bulk stresses in
the specimen introduced an eccentricity to the contact stick zone due to strain mismatch ( Figure 3 ).
In these cases, the normal pressure distribution remains unchanged, but shear tractions are developed
to sustain the tangential force. Fretting fatigue design is of primary importance in the fan assembly
and in the low-pressure stages of the compressor where the operating temperature is low enough to
exclude creep damage. He divided the fatigue tests into two groups, for the first one, grooved hubs
were used while, for the second one, plain hubs were used. Except for the ploughing damage on the
surface of the D2 wheel roller at room temperature, surface damage type and degree of the two kinds
of wheel materials were basically the same. We need to non-dimensional regarding the semi-axis (a)
of. It was found that the fatigue behavior of the notched specimens was worse than the plain ones.
They found that the application of the coating provided resistance to fretting fatigue crack initiation,
probably because of the reduction in the coefficient of friction, and therefore reducing contact
stresses.
Schematics of the used rig are shown in Figure 23. THERCAST: A new 3D simulation model for
complete chaining casted and forged i. Find support for a specific problem in the support section of
our website. Please let us know what you think of our products and services. Fretting fatigue can
occur in press-fitted shafts subjected to rotating bending such as railway axles. The averaged SWT
parameter is expressed as follows. However, the parameter did not give any indication of the
location of the crack. Next Article in Journal Comparative Study of Rheological Effects of Vegetable
Oil-Lubricant, TiO 2, MWCNTs Nano-Lubricants, and Machining Parameters’ Influence on Cutting
Force for Sustainable Metal Cutting Process. The fixture uses a piezo actuator (PZT in the picture)
that imposed the fretting motion, while the tri-axial load cell measured the tangential force and the
possible misalignment forces. This includes the incorporation of several new modern aspects, updated
information, illustrating and delineating pictures, many redesigned and glossed-up graphs and
figures as well corrected and re-arranged tables. They tested both shot-peened (SP) specimens and
“as-received” (AR) specimens, bringing them to failure, applying an average loading value of 5.5 kN,
an amplitude value of 4.5 kN, a stress ratio of 0.1, and a sinusoidal wave of 10Hz frequency.
Furthermore, the nominal bending stress applied in a 13 mm diameter press-fitted axle was far greater
than the actual stress on a railway axle. Xie Engineering, Materials Science 2011 In this paper, aimed
at wheel-axle with axle load of 30 ton, the three dimensional finite element model was established,
and the interference fit between wheel and axle was considered. Thereafter, the axle was machined
to the final shape as shown in Fig. 1. The mechanical properties of the axle and wheel materials are
listed in Table 1. In order to visually describe and analyse the different experimental conditions, they
built a MRFM (shown in Figure 50 ) that highlighted how the mechanism of fretting fatigue not only
depended on local stress but also strongly depended on relative displacement. This article is an open
access article distributed under the terms and conditions of the Creative Commons Attribution (CC
BY) license ( ). K eq calculated for the worn axle is greater than that for the unworn axle. In this
paper contact stresses were extracted along a longitudinal path at the top surface of the shaft through
finite element method. The generalized TSR-CSR diagram could then be used to predict which
cyclic load will be critical for fretting fatigue failure. However, all contacts are bearing mounted in a
ring. The test results show that the fretting causes the fatigue limit to decrease significantly and all
of the fracture sections occur at the contact edges of the fitting zone with the sleeve. They also
provided the extension for the evaluation of frictional damage. When the mesh size is less than 0.05
mm, the contact pressure almost remained unchanged, whilst the computational time increased
rapidly. It can be seen that the distributions of the contact pressure were similar even if these two test
axles were subjected to different loads. Computational approach to contact fatigue damage initiation
and deformation a. However, the role of fretting wear in the fretting fatigue crack propagation in
railway axles has not yet been studied. Gout, Urate, and Crystal Deposition Disease (GUCDD).
Metallographic microscope images of wheel materials. ( a ) D1; ( b ) D2. Star Web Maker Services
Pvt. Ltd. Similar to Unlock 8.-simulation of fretting fatigue-d. It is suggested that a multi-variable
parametric study is necessary in order to correctly design this type of connection.