Numerical Simulation Of Fretting Wear In Press-fitted Shaft

The fretting fatigue occurring in press-fitted shaft is one of the most common damage behaviors for the axles. The stress distribution near the matching surface would change largely with the varying of worn surface profile against number of fretting fatigue cycles caused by fretting wear. As a result, the fretting wear has an important effect on the properties of fretting fatigue and it is necessary to propose a method to numerically simulate the fretting wear. So the research on the fretting fatigue will be much more scientific and reasonable, when the effect of fretting wear is considered.In this study, the Archard method and dissipated energy method are modified to the forms which are suitable for finite element analysis. The numerical simulation method is developed based on the modified forms and the Arbitrary Lagrangian-Eulerian adaptive meshing(ALE adaptive meshing) within the Abaqus. The fretting wear of a cylinder-on-flat specimen arrangement is investigated based on the numerical method. The following conclusions are obtained:for the gross slip case, the predicted wear scar width is well accordance with the experiment results, but the maximum predicted depth is shallower than the measured value; for the partial slip case, the maximum wear depth is under-predicted, however the stick zone width, the slip zone width and the scar width show reasonably good agreement with the experiment results; the distribution of contact parameters and the stress of sub-surface vary largely caused by the change of the worn surface profile, and the impact of fretting wear on the fretting fatigue can be confirmed.The fretting wear of the press-fitted shaft is studied based on the numerical method. It is found that, for the edge of the press-fitted shaft, the predicted wear depth is in good agreement with the measured value, although the wear depth for the internal zone of the press-fitted shaft is slightly over-predicted. The stress concentration at the edge is mitigated by the fretting wear. Meanwhile, the distributions of contact parameters and the nominal bending stress of the matching surface change obviously against the number of fretting wear cycles. As a result, the effect of fretting wear cannot be ignored when the researches of fretting fatigue are conducted.