This dissertation aims to contribute towards the understanding and modeling of tribological phenomena of contact, friction, and wear in viscoelastic materials with application in rubber compounds. Tribiological properties of rubber compounds are important for many applications such as tires, shoe heels and soles, wiper blades, artificial joints, O-ring seals, and so on. In all these applications, the objective is to maximize the friction coefficient to avoid slipping and reduce the wear rate to improve the life expectancy and performance of the products. The first topic in this study focuses on a novel multiscale contact theory proposed by Persson and explains the advantages of this theory over other classical contact theories. The shortcomings of this theory are also investigated, and three methods are proposed to improve Persson's original contact model by correcting the approximation of deformation in the contact area. The first method is based on the original Greenwood and Williamson (GW) contact theory, which neglects the effect of elastic coupling between asperities. The second method is based on an improved version of GW theory, which considers the elastic coupling effect of asperities in an approximate way. The third method is based on the distribution of local peaks of asperities, which is particularly suitable to determine the fraction of a skewed height profile involved in tribological processes. This method can be implemented within the framework of other proposed methods. Since the height profiles of rough surfaces studied in this dissertation are approximately normally distributed, the second correction method is applied to the original contact model to calculate the real contact area and friction coefficient. The second topic addresses the theoretical model of hysteresis friction in viscoelastic materials. The multiscale temperature rise of the rubber surface due to hysteresis friction is also modeled and the effect of flash temperature on the real contact area and friction coefficient is studied. Since the hysteresis friction is not the only mechanism involved in the rubber friction, a semi-empirical model is added to the hysteresis model to include the contribution of adhesion and other processes on the real contact area. Based on the improved multiscale contact theory, a pressure-dependent friction model is also developed for viscoelastic materials, which is in good agreement with experimental results. The third topic deals with the theory of stationary crack propagation in viscoelastic materials and the effect of crack tip flash temperature on the instability of crack propagation observed in some experimental results in the literature. Initially, a theoretical model is developed to calculate the tearing energy vs crack tip velocity in a Kelvin-Voigt rubber model. Besides, two coupled iterative algorithms are developed to calculate the temperature field around the crack tip in addition to the tearing energy as a function of crack tip velocity. In this model, the effect of crack tip flash temperature on the tearing energy is considered to update the relation between tearing energy vs crack tip velocity, which also affects the flash temperature. A theoretical model is also developed to calculate the contribution of the hysteresis effect to the tearing energy vs crack tip velocity using the dynamic modulus master curve of a rubber compound. Then, the low-frequency fatigue test results are compared with the theoretical predictions and used in the framework of powdery rubber wear theory to calculate the stationary rubber wear rate due to fatigue crack propagation. Moreover, a sliding friction and wear test set-up, with both indoor and outdoor testing capability, is developed to validate the theoretical models. The experimental results confirm that the theoretical model can successfully predict the friction coefficient when there is no trace of thermochemical degradation on the rubber surface. Investigating the wear mechanism of rubber samples on three different surfaces reveals that the contribution of fatigue wear rate is less important than other wear mechanisms such as abrasive wear due to sharp asperities or thermochemical degradation due to a significant rise of temperature on the contact area. Finally, the correlation between friction coefficient and wear rate on different surfaces is studied, and it is found that the relation between friction and wear rate strongly depends on the dominant wear mechanism, which is determined by the surface characteristics, sliding velocity, normal load, and contact flash temperature. / PHD / The objective of this dissertation is to understand and develop models for contact, friction, and wear in rubber-like materials. Friction and wear of rubber-like materials are important in many applications such as tires, shoe heels and soles, wiper blades, artificial joints, O-ring seals, and so on. In all these applications, it is desired to maximize the friction to avoid slipping and reduce the mass loss due to abrasion to improve the life expectancy of the products. The first topic in this dissertation focuses on a novel multiscale contact theory proposed by Persson and different approaches proposed in this work to improve this theory. Then, the real contact area is calculated using an improved version of the contact model. The second topic addresses the theoretical model of rubber friction due to hysteresis energy dissipation and the effect of frictional heating on the real contact area. Since the hysteresis friction is not the only mechanism involved in the rubber friction, a semi-empirical model is also used to include the contribution of adhesion and other processes on the real contact area. Based on the improved contact theory, a pressure-dependent friction model is also developed for rubber-like materials, which is in good agreement with the experimental results. The third topic deals with the theory of stationary crack propagation in rubberlike materials and the effect of crack tip temperature rise on the instability of crack propagation observed in some experimental results in the literature. The low-frequency fatigue test results are compared with the theoretical predictions, and the results are used in the framework of powdery rubber wear theory to calculate the rubber wear rate due to slow crack propagation. A sliding friction and wear test set-up is also developed to validate the theoretical models. The theoretical model of the friction coefficient is successfully validated by experimental results. Investigating the rubber wear on different surfaces reveals that the contribution of fatigue wear rate is less important than the other wear mechanisms. The correlation between friction coefficient and wear rate on different surfaces reveals that relation between friction and wear rate strongly depends on the dominant wear mechanism, which is determined by the surface characteristics, sliding velocity, normal load, and temperature rise on the contact surface.

Design based on damage tolerance concepts has become mandatory in high technology structures. These concepts are also essential for evaluating life extension of aged structures which are in service beyond originally stipulated life. Fracture analysis of such structures in the presence of single or multiple three-dimensional flaws is essential for this approach. Surface cracks are the most commonly occurring flaws and development of accurate methods of analysis for such cracks is essential for structural integrity evaluation of newly designed or aged structures. The crack fronts of these surface flaws are usually approximated mathematically to be of either part-elliptical or part-circular in geometry. In this thesis, some of the issues related to fatigue crack growth of single and multiple surface cracks are studied in detail. Here emphasis is given to the development of simple and accurate post-processing techniques to estimate stress intensity factors for surface cracks, development and/or implementation of simple numerical methods to simulate three-dimensional single and multiple cracks in fatigue and their experimental verification. Modified virtual crack closure integral (MVCCI) technique for estimation of strain energy release rates has been improved (chapter II) to deal with curved crack front and unequal elements across the crack front. The accuracy of this method is evaluated and presented in this chapter for certain benchmark surface flaw problems. The improved MVCCI is used in the investigation of interaction between multiple surface cracks in three-dimensional solids. The interaction effects are studied for both interacting and coalescing phases as observed to occur in the growth of multiple surface cracks. Extensive numerical work is performed to study the effects of various parameters such as aspect ratio, thickness ratio, interspacing on the interaction factors. These solutions are used in formulating empirical equations to estimate interaction factors. This facilitated the development of a simple semi-analytical method to study fatigue crack growth of multiple cracks. The growth of surface cracks under fatigue loading in the finite width specimens of an aero-engine superalloy has been studied experimentally (presented in chapter III). Four configurations for single semi-elliptical cracks are considered. Fatigue crack growth is simulated by two models viz. two degrees of freedom and "multi degrees of freedom with ellipse fit'. These models are sometimes referred to as semi-analytical models as the crack growth is predicted by numerical integration combining Paris equation with an empirical form of stress intensity factor solution. In order to use two degrees of freedom model for fatigue crack growth prediction of semi-elliptical cracks, empirical solution for the Ml range of geometric parameters for stress intensity factor is required for the considered configurations. The available Newman-Raju solution is useful for this purpose within a limited range of surface crack length to width (c/W) of the specimen. Based on the present finite element results, the empirical equations are developed for extended values of c/W. It is well understood that the fatigue prediction for two-dimensional crack can be improved by inclusion of crack closure effects. Usually, in semi-analytical models for growth of surface cracks under fatigue loading, the crack closure is included as a ratio of crack closure factor at surface and depth locations of semi-elliptical crack. In the present work, this ratio for the considered material of specimens is obtained by an experimental study. The difference in characteristics of preferred propagation path between semi-elliptical crack in a finite width plate and a wide plate is clearly brought out. Current crack growth predictions for most of the structures are based on the presence of only a single crack. However, in structures several cracks may initiate simultaneously within a stress critical zone and may interact depending upon their geometry, spatial location, structure geometry and mode of loading. In this work various configurations of twin semi-elliptical cracks have been studied by experiments. The beachmarks created on the specimens during experiments are used in the investigation of crack shape progression during fatigue. A three degrees of freedom crack growth model for interacting and coalescing cracks has been proposed. The experimentally determined crack shape and lives have been compared with the corresponding values from numerical simulation. The correlation of experimental results with numerical predictions was carried out through improved MVCCI for eight-noded brick elements. This has worked well in the configurations analysed. However, it is known in literature that there are benefits of using 20-noded singular elements. There could be special situations where the regular elements could fail, and singular elements could be essential. For this purpose, further development of MVCCI were carried out using 20-noded quarter-point elements (presented in chapter IV). Also a novel technique of decomposed crack closure integral (DCCI) was developed (presented in chapter V) for both regular and singular elements to represent the variation of MVCCI more accurately along the crack front. It is well known that quarter-point elements at crack front produce the required singularity at the crack tip and give accurate stress distribution with fewer degrees of freedom than conventional elements. Thus to develop more efficient post-processing tools, the MVCCI expressions are formulated for 20-noded singular quarter-point element for various assumptions regarding stress and displacement distributions in the elements across the crack front. A comprehensive study is presented (chapter IV) on MVCCI for 20-noded singular brick element including various simplified expressions for three-dimensional part-through cracks in pure and mixed-mode state of deformation of fracture. The developed MVCCI expressions are also valid for 15-noded quarter-point Penta elements. The reduction in model size can further be obtained if 12-noded three-dimensional singular element is employed at the crack front and eight-noded elements are used away from the crack front. The MVCCI expressions are also developed for 12-noded singular element and their accuracy is evaluated by numerical solutions. Presently, MVCCI, estimates the average stress intensity factor at the center of each element along the crack front. In this thesis, a Decomposed Crack Closure Integral (DCCI) is formulated to represent an assumed variation of stress intensity factor along the crack front in each element. The DCCI is formulated for 8-noded brick, 20-noded conventional brick and 20-noded singular brick elements. The numerical examples presented here deal with three-dimensional problems of patch repair technology and part-through cracks. The technique showed a major advantage for the patch repair problems where SIF variations along the crack front are of significance and large mesh sizes are computationally expensive. This along with MVCCI for 12-noded and 20-noded singular elements formed a part of the work on development of accurate and effective post-processing tools. It is expected that the present work will be helpful in damage tolerance design and assessment of aerospace structures and the experimental work performed as a part of this thesis will enhance confidence in the damage tolerance analysis. The thesis is concluded in chapter VI presenting the contributions of this thesis and projecting future lines of work possible in this area.

Crack propagation in structures when subjected to fatigue loading, follows three different phases namely - short crack growth, stable crack growth and unstable crack growth. Accurate fatigue life prediction demands the consideration of every crack propagation phase rather than only the stable crack growth stage. Further, the use of existing crack growth laws in structures with small cracks under-predicts the growth rate compared to experimentally observed ones, thereby leading to an unsafe design and keeping the structure in a potentially dangerous state. In the present work, an attempt is made to establish fatigue crack propagation laws for plain concrete, reinforced concrete and concrete-concrete jointed interfaces from first principles using the concepts of dimensional analysis and self-similarity. Different crack growth laws are proposed to understand the behavior in each of the three regimes of the fatigue crack growth curve. Important crack growth characterizing material and geometrical parameters for each zone are included in the proposed analytical models. In real life applications to structures, the amplitude of cyclic loading rarely remains constant and is subjected to a wide spectrum of load amplitudes. Furthermore, the crack growth behavior changes in the presence of high amplitude load spikes within a constant amplitude history and this is incorporated in the model formulation. Using scaling laws, an improved understanding of the scaling behavior on different parameters is achieved. The models describing different regimes of crack propagation are finally unified to obtain the entire crack growth curve and compute the total fatigue life. In addition, crack growth analysis is performed for a reinforced concrete member by modifying the model derived for plain concrete in the Paris regime. Energy dissipation occurring due to shake-down phenomenon in steel reinforcement is addressed. The bond-slip mechanism which is of serious concern in reinforced concrete members is included in the study and a method is proposed for the prediction of residual moment carrying capacity as a function of relative crack depth. The application of the proposed analytical model in the computation of fatigue crack growth is demonstrated on three practical problems – beam in flexure, concrete arch bridge and a patch repaired beam. Through a sensitivity study, the influence of different parameters on the crack growth behavior is highlighted.