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Research Papers: Contact Mechanics

Analysis of Displacement-Controlled Fretting Between a Hemisphere and a Flat Block in Elasto-Plastic Contacts

[+] Author and Article Information
Huaidong Yang

G. W. Woodruff School of Mechanical
Engineering,
Georgia Institute of Technology,
Atlanta, GA 30332-0405
e-mail: hyang380@gatech.edu

Itzhak Green

G. W. Woodruff School of Mechanical
Engineering,
Georgia Institute of Technology,
Atlanta, GA 30332-0405
e-mail: green@gatech.edu

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received June 21, 2018; final manuscript received September 15, 2018; published online November 1, 2018. Assoc. Editor: Wenzhong Wang.

J. Tribol 141(3), 031401 (Nov 01, 2018) (11 pages) Paper No: TRIB-18-1241; doi: 10.1115/1.4041535 History: Received June 21, 2018; Revised September 15, 2018

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.

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Figures

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Fig. 1

Schematic of a ¼ sphere in contact with a flat block, along with the loading definitions

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Fig. 2

Finite element model in ANSYS 17.1

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Fig. 3

Three cycles of oscillatory horizontal displacement

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Fig. 4

The evolution of von Mises stresses during three cycles of horizontal loading at 1* ωc interference with μ = 0.3: (a) Front view, 0*ωc at A1-B1, (b) front view, 0.2*ωc at A1-B1, (c) front view, 1*ωc at A1-B1, (d) front view, 0.8*ωc at B1-C1, (e) front view, 0*ωc at B1-C1, (f) front view, −1*ωc at C1-D1, (g) front view, −0.8*ωc at D1-A2, (h) front view, 0*ωc at A2, and (i) bottom view, 0*ωc at A4

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Fig. 5

The evolution of von Mises stresses during three cycles of horizontal loading at 1* ωc interference with μ = 1: (a) Front view, 0*ωc at A4, (b) bottom view, 0*ωc at A1, (c) bottom view, 0.4*ωc at A1-B1, (d) bottom view, 1*ωc at A1-B1, (e) bottom view, 0.8*ωc at B1-C1, (f) bottom view, 0.6*ωc at B1-C1, (g) bottom view, 0.4*ωc at B1-C1, (h) bottom view, 0.2*ωc at B1-C1, (i) bottom view, −1*ωc at C1-D1, (j) bottom view, −0.6*ωc at C1-D1, (k) bottom view, 0*ωc at A2, and (l) bottom view, 0*ωc at A4

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Fig. 6

The evolution of equivalent plastic strain during three cycles of horizontal loading at 1* ωc interference with μ = 1: (a) Front view, 0*ωc at A4, (b) bottom view, 0.4*ωc at A1-B1, (c) bottom view, 0.6*ωc at A1-B1, (d) bottom view, 0.8*ωc at A1-B1, (e) bottom view, 1*ωc at B1, (f) bottom view, 0*ωc at A2, (g) bottom view, 0*ωc at A3, and (h) bottom view, 0*ωc at A4

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Fig. 7

The schematics of the contact zone at the beginning and ending of the three cycles (A4) of loading at 1*ωc with μ = 1

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Fig. 8

The evolution of junction growth at 1*ωc with μ = 0.3 and μ = 1 during three cycles of horizontal loading

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Fig. 9

The surface profile of the contacting region of the block at 1*ωc after three cycles of horizontal loading with μ = 1

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Fig. 10

The surface profile of the contacting region of the block at 1*ωc after three cycles of horizontal loading with μ = 0.3

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Fig. 11

The surface profile of the contacting region of the block at 3*ωc after three cycles of horizontal loading with μ = 1

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Fig. 12

The evolution of the tangential force during three cycles of horizontal loading at 1*ωc with μ = 1

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Fig. 13

The evolution of the tangential force during three cycles of horizontal loading at 1*ωc with μ = 0.3 and μ = 0

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Fig. 14

The evolution of the total work done to the system at 3*ωc during three cycles of loading with different COFs

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Fig. 15

The evolution of the normalized contact area during three cycles of horizontal displacement at 1*ωc interference with the same normalized displacement input, μ = 1. Note that Ac and ωc are taken from Table 2 corresponding to steel and copper.

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Fig. 16

The evolution of the tangential force during three cycles of horizontal displacement at 1*ωc interference with the same normalized displacement input, μ = 1. Note that Pc, and ωc are taken from Table 2 corresponding to steel and copper.

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