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TECHNICAL PAPERS

A Predictive Rolling Contact Fatigue Crack Growth Model: Onset of Branching, Direction, and Growth—Role of Dry and Lubricated Conditions on Crack Patterns

[+] Author and Article Information
M. C. Dubourg

Laboratoire de Mécanique des Contacts, UMR CNRS 5514, INSA de Lyon, Ba⁁timent 113, 20, Av. A. Einstein, 69621 Villeurbanne Cédex, France

V. Lamacq

G.E. Energy Products France SNC, Zone Industrielle du Port, F-90140 Bourogne

J. Tribol 124(4), 680-688 (Sep 24, 2002) (9 pages) doi:10.1115/1.1479698 History: Received March 07, 2001; Revised March 07, 2002; Online September 24, 2002
Copyright © 2002 by ASME
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References

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Lamacq,  V., and Dubourg,  M.-C., 1999, “Modelling of Initial Fatigue Crack Growth and Crack Branching Conditions Under Fretting Conditions,” Fatigue Fract. Eng. Mater. Struct., 22, pp. 535–542.
Dubourg, M.-C., and Lamacq, V., 2000, “Stage II Crack Propagation Direction Under Fretting Fatigue Loading. A New Approach in Accordance with Experimental Observations,” in Fretting Fatigue: Current Technology and Practices, ASTM, 1367, D. W. Hoeppner, V. Chandrasekaran and C. B. Elliot, eds., American Society for Testing and Materials, Baltimore, MD, pp. 436–450.
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Figures

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Schematic definition of KI and KII before branching and k1 and k2 after branching at the tip of an infinitesimal segment of length s inclined at an angle θ to the initial crack direction (θ: positive when measured clockwise, negative when measured anti-clockwise)
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Definition of waveform parameters for a sequential load history of stress history intensity factors. ϕ=overlap; ΔK=Kmax−Kmin;R=Kmin/Kmax;S=Kdwell/Kmax18.
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KI and KII evolutions during a rolling contact cycle for a 6 mm long crack, inclined to the surface at α=15 deg; fi=0.1,fr=0.4, 3 phases
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An example of the evolution of the maximum crack growth rate for a 4 mm long crack as a function of the crack growth direction according to two crack growth laws: fr=0.2,fi=0.1
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Crack propagation modeling according to mixed-mode Paris law. Determination of crack length to branching and crack growth direction after branching. fr=0.2 for water lubricated conditions and fi=0.1 for lubricated conditions.
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ΔKIeff and ΔKIIeff versus the crack length: fr=0.2,fi=0.1
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ΔKIeff/ΔKIIeff versus the crack length: fr=0.2,fi=0.1
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A crack after branching: adding of a segment
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RCF crack after branching ΔKI and ΔKII evolutions versus c/a ratio, c being variable. fr=0.2 for water lubricated conditions and fi=0.1 for lubricated conditions. α=15 deg.
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RCF crack after branching: Coplanar crack growth rate versus c/a.fr=0.2 for water lubricated conditions and fi=0.1 for lubricated conditions. α=15 deg, θ=75 deg.
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Influence of positive residual stresses (200 MPa) on crack propagation under RCF in a rail: fr=0.2,fi=0.1, α=15 deg, θ=75 deg
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Influence of negative residual stresses (−200 MPa) on crack propagation under RCF in a rail: fr=0.2,fi=0.1, α=15 deg, θ=75 deg
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Schematic representatiion of the effect of residual stress on crack morphology under RCF
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Influence of fr on KI variations for a 6 mm crack inclined at α=15, fi=0.1
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Influence of fr on KII for a 6 mm crack inclined at α=15, fi=0.1
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Influence of fr on crack growth rates for a 6 mm crack inclined at α=15 deg; fi=0.1
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Influence of fi on KII for a 6 mm long crack inclined at α=15; fr=0.2
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Influence of fi on crack growth rates for a 6 mm long crack inclined at 15 deg; fr=0.2
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Opposite effects of similar contact conditions in the contact zone and along crack faces on KII
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Schematic representation of damage under dry conditions and water lubrication conditions under RCF
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Interactions between two cracks during a rolling loading cycle. Normal force=9000 N/mm, fr=0.2 (water lubricated). No residual stress, fi=0.1 (lubricated conditions).
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Influence of neighboring crack on crack network—schematic representation

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