Fretting fatigue is a damage process that may arise in engineering applications where small cyclic relative displacements develop inside contacts leading to detrimental effects on the material fatigue properties. Fretting is located in regions not easily accessible, which makes it a dangerous phenomenon. It is therefore important to be able to make reliable predictions of the fretting fatigue lives. The work presented in this thesis has its focus on different aspects related to fretting fatigue in the titanium alloy Ti-17. A fretting experiment was developed which allowed for separate control of the three main fretting loads. Initially, the evolution of the coefficient of friction inside the slip region was investigated experimentally and analytically. Subsequently, 28 fretting tests were performed in which large fatigue cracks developed. The fretting tests were firstly evaluated with respect to fatigue crack initiation through five multiaxial fatigue criteria. The criteria predicted a too high fretting fatigue limit. A possible clue to the discrepancy was found in the fretting induced surface roughness with the asperity-pit interactions. The fatigue growth of the large fretting cracks was numerically modelled through a parametric crack growth procedure. The predicted lives were compared to the experimental outcome. The numerical simulations showed that linear elastic fracture mechanics was an appropriate tool for the prediction of fretting fatigue propagation lives in the long crack regime. Fatigue cracks spend most of their propagation life in the small crack regime. The possibility of modelling the small crack behaviour is therefore very important from the engineering point of view. The fatigue growth of through thickness short cracks was studied experimentally and numerically in the four-point bend configuration. It was found that linear elastic fracture mechanics and closure-free material growth data furnished conservative estimates for cracks longer than 50 μm. One method to improve fretting fatigue life is to shot peen the contact surfaces. Experimental results on fretting life with or without shot peening were simulated. The fatigue life enhancement in shot peened specimens could be explained by slower crack growth in the surface material layer with residual compressive stresses. / QC 20100827

Die Dissertation beschäftigt sich mit der grundlagenorientierten Untersuchung reibdauerbeanspruchter Stahl-Kontakte und deren Festigkeitsbewertung. Die Besonderheit bei der Bewertung reibdauerbeanspruchter Kontakte stellt die zusätzlich zur spannungsmechanischen Beanspruchung vorliegende tribologische Beanspruchung des Werkstoffes dar. Die ursächlich auf eine Anrissinitiierung in der Bauteiloberfläche zurückzuführende niedrigere Ermüdungsfestigkeit reibdauerbeanspruchter Bauteilverbindungen, zeigt sich in Abhängigkeit des Fugendrucks, des Schlupfes und des Werkstoffes. Basierend auf den genannten Einflussgrößen konnte in der vorliegenden Arbeit ein Berechnungsverfahren erarbeitet werden, welches eine betriebssichere Auslegung reibdauerbeanspruchter Fügeverbindungen ermöglicht. Das Verfahren basiert auf dem örtlichen Konzept der FKM-Richtlinie „Rechnerischer Festigkeitsnachweis für Maschinenbauteile“ und implementiert den Schadenfall der Reibdauerermüdung durch einen Oberflächeneinflussfaktor, dem sogenannten Reibkorrosionsfaktor. Die tribologischen Beanspruchungsparameter Schlupf und Fugendruck werden dabei über eine Worst-Case-Betrachtung berücksichtigt. Durch eine von der Zugfestigkeit des Grundwerkstoffes abhängige Darstellung des Reibkorrosionsfaktors, konnte darüber hinaus eine systemspezifische Berechnung der Ermüdungsfestigkeit erreicht werden. Die Validierung des Berechnungsverfahrens erfolgte an einer Pleuelverbindung. / The doctoral thesis investigates basically the fretting fatigue strength of steel contacts and their strength assessment. Especially the tribological loading conditions which are present at the contact surface cause a specific method of the strength assessment of joined contacts. In this context, the lower fatigue strength of component connections under tribological loading conditions, which is the result of crack nucleation at the component surface, depends on the contact pressure, the slip and the basic-material. Based on these parameters, a calculation method was developed in the present study which allows a reliable design of component connections under fretting conditions. This method is based on the local concept of the FKM-guideline 'Rechnerischer Festigkeitsnachweis für Maschinenbauteile' and introduces the fretting fatigue failure mechanism by a surface factor, the so-called fretting factor. These fretting factors are calculated empirically and based on a worst-case approach of the tribological parameters slip and contact pressure. Furthermore it is possible to determine the fretting factor according to the tensile strength of the basic-material. As a result of this, it is possible to calculate the system-specific fretting fatigue strength of joined steel-components. The improved calculation accuracy of the strength assessment was validated on connecting rods.

Pressverbindungen gehören zu den klassischen Maschinenelementen und werden insbesondere in der Antriebstechnik häufig eingesetzt. Zur sicheren und zugleich wirtschaftlichen Auslegung derartiger Verbindungen unter zyklischen Lasten fehlen generell gültige sowie abgesicherte normative Vorgaben bzw. Richtlinien für den Anwender. Insbesondere ist dies dann zutreffend, wenn Geometrien vorkommen, für welche keine Tabellen- bzw. Erfahrungswerte existieren. In dieser Arbeit werden ausführliche experimentelle Untersuchungen zur Ermüdungsfestigkeit von Pressverbindungen einer Standardgeometrie vorgestellt. Im Fokus der Untersuchungen steht die Dauer-, Zeit- und Betriebsfestigkeit der biege- sowie torsionsbelasteten Verbindung. Auf Basis der erzielten Festigkeiten und Lebensdauerwerte erfolgt die Ableitung normspezifischer Kennwerte für die Praxis. Weiterhin steht die Übertragung der erzielten Ergebnisse auf andere Pressverbindungs-Geometrien, wie beispielsweise die Verbindung mit Wellenabsatz, im Vordergrund. Hierbei wird das Verhalten hinsichtlich der Kerbwirkung im Vergleich zu gekerbten Wellen sowie zu anderen reibdauerbeanspruchten Verbindungen untersucht. Zudem erfolgt eine ausführliche Analyse simulationsspezifischer Einflussgrößen auf die Beanspruchungshöhe der Pressverbindung. Auf Grundlage dieser Erkenntnisse wird ein neues Auslegungskonzept erarbeitet und an Ergebnissen aus der Literatur gespiegelt.

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[pt] Esta dissertação revisita quatro modelos multiaxiais de dano por fadiga (SWTD, SWT, Findley e Crossland) e discute a sua aplicação na previsão do risco de nucleação de trinca sob solicitações de fadiga por fretting segundo as abordagens local e não-local. As previsões do risco de nucleação de trinca obtidas através dos modelos estudados foram confrontadas com dados experimentais disponíveis na literatura para o contato cilindro/plano em aços AISI 52100 e AISI 1034 respectivamente. As melhores previsões foram obtidas através da versão desviadora SWTD. Segundo a abordagem local, o modelo SWTD fez previsões menos conservativas que os demais, sendo estas com erros conservativos inferiores a 15 porcento. Segundo a abordagem não-local, os quatro modelos geram previsões com erros inferiores a 15 porcento se os mesmos forem calibrados de forma independente. É importante mencionar que as melhores previsões obtidas através da abordagem não-local (que requer a calibração de um parâmetro adicional) são similares àquelas obtidas por SWTD local. Especificamente para os testes de fadiga por fretting com carga remota, o modelo SWTD não-local gerou previsões com 100 porcento de acertos (13 testes). Segundo a abordagem não-local, foi verificado que, para o conjunto de testes estudado, a precisão nas previsões é mais influenciada pela dimensão característica (que deve ser calibrada) que pelo modelo de fadiga multiaxial ou método de integração considerado. Por fim, verificou-se que previsões não conservativas podem ser obtidas ao se considerar uma dimensão característica assumida como parâmetro material (sem calibração) tal qual a distância crítica proposta por Taylor, definida em termos do método do ponto. / [en] This work presents and discusses four multiaxial fatigue damage models (SWTD, SWT, Findley and Crossland) applied to crack nucleation prediction under fretting fatigue loadings according to the local and the non-local approaches. The predictions have been compared with experimental data available in the literature for the cylinder on flat configuration made of 52100 and 1034 AISI steel s respectively. In particular, for the data set analyzed, SWTD parameter (deviatoric version of SWT model) predictions were less conservative than the ones made by the other three models and have better correlated the experimental results. Considering the local approach, the error observed on the SWTD predictions was lower than 15 percent. On the other hand, for the non-local approach, it has been demonstrated that the four multiaxial fatigue models can provide crack nucleation predictions with similar level of accuracy (error lower than 15 percent) if the characteristic dimension is calibrated model-by-model. Note that this same level of accuracy was obtained with SWTD parameter defined in terms of the local approach, which requires one less parameter to be calibrated (characteristic dimension). In particular, considering only the fretting fatigue tests with bulk stresses, SWTD non-local (area method) prediction accuracy was 100 percent (13 tests). For the material studied, it has also been concluded that the non-local predictions accuracy depends more on the calibrated characteristic dimension than on the multiaxial model or integration method considered. Moreover, it has been verified that non-conservative predictions can be made if the characteristic dimension is assumed as a material property as proposed by Taylor on the critical distances theory (point method).