Experimental and numerical analysis of fretting crack formation based on 3D X-FEM frictional contact fatigue crack model

Nowadays, numerical simulation of 3D fatigue crack growth is easily handled using the eXtended Finite Element Method coupled with level set techniques. The finite element mesh does not need to conform to the crack geometry. Most difficulties associated to complex mesh generation around the crack and the re-meshing steps during the possible propagation are hence avoided. A 3D two-scale frictional contact fatigue crack model developed within the X-FEM framework is presented in this article. It allows the use of a refined discretization of the crack interface independent from the underlying finite element mesh and adapted to the frictional contact crack scale. A stabilized three-field weak formulation is also proposed to avoid possible oscillations in the local solution linked to the LBB condition when tangential slip is occurring. Two basic three-dimensional numerical examples are presented. They aim at illustrating the capacities and the high level of accuracy of the proposed X-FEM model. Stress intensity factors are computed along the crack front. Finally an experimental 3D ball/plate fretting fatigue test with running conditions inducing crack nucleation and propagation is modeled. 3D crack shapes defined from actual experimental ones and fretting loading cycle are considered. This latter numerical simulation demonstrates the model ability to deal with challenging actual complex problems and the possibility to achieve tribological fatigue prediction at a design stage based on the fatigue crack modeling.     

Modeling quasi-static crack growth with the extended finite element method Part II: Numerical applications

In Part I [Int. J. Solids Struct., 2003], we described the implementation of the extended finite element method (X-FEM) within Dynaflow™, a standard finite element package. In our implementation, we focused on two-dimensional crack modeling in linear elasticity. For crack modeling in the X-FEM, a discontinuous function and the near-tip asymptotic functions are added to the finite element approximation using the framework of partition of unity. This permits the crack to be represented without explicitly meshing the crack surfaces and crack propagation simulations can be carried out without the need for any remeshing. In this paper, we present numerical solutions for the stress intensity factor for crack problems, and also conduct crack growth simulations with the X-FEM. Numerical examples are presented with a two-fold objective: first to show the efficacy of the X-FEM implementation in Dynaflow™; and second to demonstrate the accuracy and versatility of the method to solve challenging problems in computational failure mechanics.     

Modeling quasi-static crack growth with the extended finite element method Part I: Computer implementation

The extended finite element method (X-FEM) is a numerical method for modeling strong (displacement) as well as weak (strain) discontinuities within a standard finite element framework. In the X-FEM, special functions are added to the finite element approximation using the framework of partition of unity. For crack modeling in isotropic linear elasticity, a discontinuous function and the two-dimensional asymptotic crack-tip displacement fields are used to account for the crack. This enables the domain to be modeled by finite elements without explicitly meshing the crack surfaces, and hence quasi-static crack propagation simulations can be carried out without remeshing. In this paper, we discuss some of the key issues in the X-FEM and describe its implementation within a general-purpose finite element code. The finite element program Dynaflow™ is considered in this study and the implementation for modeling 2-d cracks in isotropic and bimaterial media is described. In particular, the array-allocation for enriched degrees of freedom, use of geometric-based queries for carrying out nodal enrichment and mesh partitioning, and the assembly procedure for the discrete equations are presented. We place particular emphasis on the design of a computer code to enable the modeling of discontinuous phenomena within a finite element framework.     

微动磨损对过盈配合结构微动疲劳性能的影响

在考虑微动磨损的前提下,基于SWT临界平面法和线性累计损伤模型建立了过盈配合结构微动疲劳的寿命预测模型,并详细研究了微动磨损对过盈配合结构微动疲劳性能的影响.结果表明:考虑微动磨损的作用时,微动疲劳的预测结果更加准确;微动磨损显著降低了配合边缘处的应力集中现象,提高了过盈配合结构的微动疲劳寿命;由于微动磨损的作用,配合边缘处的SWT参数逐渐降低,且其最大值出现的位置由配合最边缘逐渐向着配合内部移动,与此同时,临界平面上的法向应力平均值逐渐增大,两者的变化共同导致微动疲劳裂纹萌生位置向着配合内部移动.     

New approach based on continuum damage mechanics with simple parameter identification to fretting fatigue life prediction

A new continuum damage mechanics model for fretting fatigue life prediction is established. In this model, the damage evolution rate is described by two kinds of quantities. One is associated with the cyclic stress characteristics obtained by the finite element(FE) analysis, and the other is associated with the material fatigue property identified from the fatigue test data of standard specimens. The wear is modeled by the energy wear law to simulate the contact geometry evolution. A two-dimensional(2D) plane strain FE implementation of the damage mechanics model and the energy wear model is presented in the platform of ABAQUS to simulate the evolutions of the fatigue damage and the wear scar. The effect of the specimen thickness is also investigated. The predicted results of the crack initiation site and the fretting fatigue life agree well with available experimental data. Comparisons are made with the critical plane SmithWatson-Topper(SWT) method.     

A Newton method for three-dimensional fretting problems

The present paper concerns the numerical treatment of fretting problems using a finite element analysis. The governing equations resulting from a formal finite element discretization of an elastic body with a potential contact surface are considered in a quasi-static setting. The constitutive equations of the potential contact surface are Signorinis contact conditions, Coulombs law of friction and Archards law of wear. Using a backward Euler time discretization and an approach based on projections, the governing equations are written as an augmented Lagrangian formulation which is implemented and solved using a Newton algorithm for three-dimensional fretting problems of didactic nature. Details concerning the implementation are provided.     

考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测研究

微动疲劳是矿井提升钢丝绳主要失效形式之一,在钢丝微动疲劳过程中,微动磨损严重影响钢丝微动疲劳裂纹扩展特性,进而制约钢丝微动疲劳断裂机制,故开展考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测研究至关重要. 运用自制钢丝微动疲劳试验机开展钢丝微动疲劳试验和拉伸断裂试验,通过高速度数码显微系统揭示微动疲劳过程中钢丝微动磨损演化、裂纹萌生和扩展及断裂特性,基于摩擦学和断裂力学理论,运用有限元法、循环迭代法和虚拟裂纹闭合技术建立了考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测模型,并进行试验验证. 结果表明:采用微动疲劳过程稳定阶段磨损系数预测钢丝微动磨损演化可保证预测正确性,微动疲劳过程中钢丝主要为I型裂纹扩展模式,考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测值和试验值吻合较好,验证了预测模型正确性.      

微动磨损与微动疲劳寿命的计算与分析方法

微动损伤常见于工程中,可使紧固件松动,疲劳寿命减少和腐蚀增加,造成较大的安全隐患和经济损失．微动损伤的试验耗时耗力,还不宜损伤的直接观察,辅以计算模拟和分析十分必要．本文重点介绍微动磨损和微动疲劳寿命计算的一些方法和分析准则．其中,微动磨损计算主要介绍基于Archard公式,结合有限元计算的分析方法,以及相应的多层节点更新方法．对于微动疲劳寿命的计算和分析,主要介绍基于多轴疲劳临界面准则的判别准则,尤其是基于能量准则的Smith-Watson-Topper参数．重点介绍如何在微动条件下实现磨损与疲劳寿命的耦合求解,以及损伤的累积和破坏的判定．通过一个简单算例说明了微动磨损对其疲劳寿命可有很大的影响．     

数值方法在微动疲劳研究中的应用进展

对近年来数值方法在微动疲劳机理研究中的应用进展进行了评述,概述了微动疲劳裂纹萌生和扩展的机理,指出接触区域的应力分布对微动疲劳性能起决定作用,详细介绍了目前接触问题的各种数值计算方法,分析了当前微动疲劳区域应力场计算的问题和难点。     

Fatigue crack growth simulation in coated materials using X-FEM

In the present work, the eXtended Finite Element Method (XFEM) is used to study the effect of bi-material interfaces on fatigue life in galvanised panels. X-FEM and Paris law are implemented in ABAQUS software using Python code. The XFEM method proved to be an adequate method for stress intensity factor computation, and, furthermore, no remeshing is required for crack growth simulations. A study of fatigue crack growth is conducted for several substrate materials, and the influence of the initial crack angle is ascertained. This study also compares the crack growth rate between three types of bi-materials alloys zinc/steel, zinc/aluminium, and zinc/zinc. The interaction between two cracks and fatigue life, in the presence of bi-material interface, is investigated as well.     

A finite element finite-strain formulation for modeling colliding blocks of Gent materials

The present paper is devoted to the analysis of the contact/impact problems with Coulomb friction and large deformation between two hyperelastic bodies of Gent model. The total Lagrangian formulation is adopted to describe the geometrically non-linear behavior. For the finite element implementation, the explicit expression of the incremental law of Gent model is derived. A first order algorithm is applied for the numerical integration of the time-discretized equation of motion. Efficiency and accuracy of the resulting method is illustrated on a two-dimensional static contact problem and a three-dimensional dynamic contact problem as compared with ANSYS simulations.     

CrMoV合金钢的微动疲劳实验研究

本文利用一种自行设计的微动疲劳实验装置研究CrMoV合金钢的微动疲劳特性。作者研究了接触压力对材料微动疲劳寿命的影响规律,得到了研究条件下CrMoV合金钢的接触压力阈值。当接触压力较小时,微动桥压块与试件表面间有相对滑动,微动疲劳寿命随接触压力的增加快速下降;当接触压力达到或超过阈值62.5MPa时,微动疲劳寿命达到最低值并不再随接触压力的增加而下降。本文给出了CrMoV合金钢在接触压力为225MPa的微动疲劳曲线和零接触压力(纯)疲劳曲线,并给出微动疲劳强度与常规疲劳强度的关系,分析了微动疲劳破坏的微观机理。     

基于SWT方法的钢绞线索微动疲劳特性分析

为得到钢绞线索丝间接触区的应力场分布并预测微动疲劳裂纹萌生位置和微动疲劳寿命，本文利用参数化方法建立了精细化的钢绞线拉索有限元模型，包括整索模型和不同层丝间接触区域的局部精细化子模型．分析了钢绞线索在两种交变荷载工况下的应力场变化情况，并基于多轴疲劳SWT(Smith-Watson-Topper)临界平面法进行了疲劳特性分析和疲劳寿命预测．主要结论如下：钢绞线索内接触区边缘处的微动幅值较大，中心处几乎没有相对滑动，微动疲劳的初始裂纹萌生点位于接触区域边缘；经不同区域子模型分析比较，在轴向循环荷载作用下，外层钢丝的接触区域比内层钢丝更易发生微动疲劳损伤；在横向位移循环荷载作用下，同层钢丝因位置角度不同而产生了较大的疲劳特性差异，且相比轴向循环拉伸，该工况下最不利单丝的微动疲劳寿命更低；与非接触区域相比，接触区的疲劳寿命大幅降低，微动现象对钢绞线索的抗疲劳性能有明显降低作用．     

基于互补理论和扩展有限元法的摩擦接触裂纹应力强度因子计算

从虚功方程出发，结合扩展有限元离散技术与接触条件的非线性互补表述，建立了摩擦接触裂纹问题的扩展有限元非线性互补模型，将不等式接触条件转化为非线性互补类的非光滑方程组，并采用基于广义导数的非光滑阻尼牛顿法求解方程组，无需引入任何额外人工变量以及迭代求解。以含中心倾斜裂纹平板和边裂纹平板为例，运用相互作用积分法计算摩擦接触裂纹的应力强度因子，将其结果与理论解进行对比分析，该方法都能给出精确的计算结果；基于扩展有限元方法对单轴压缩作用下倾斜裂纹扩展过程进行了数值模拟，计算结果表明，受压裂纹数值结果与实验结果比较吻合，从而验证了本文方法的有效性与正确性。     

SGBEM modeling of fatigue crack growth in particulate composites

The symmetric-Galerkin boundary element method (SGBEM) has previously been employed to model 2-D crack growth in particulate composites under quasi-static loading conditions. In this paper, an initial attempt is made in extending the simulation technique to analyze the interaction between a growing crack and clusters of perfectly bonded particles in a brittle matrix under cyclic loading conditions. To this end, linear elastic fracture mechanics and no hysteresis are assumed. Of particular interest is the role clusters of inclusions play on the fatigue life of particulate composites. The simulations employ a fatigue crack growth prediction tool based upon the SGBEM for multiregions, a modified quarter-point crack-tip element, the displacement correlation technique for evaluating stress intensity factors, a Paris law for fatigue crack growth rates, and the maximum principal stress criterion for crack-growth direction. The numerical results suggest that this fatigue crack growth prediction tool is as robust as the quasi-static crack growth prediction tool previously developed. The simulations also show a complex interplay between a propagating crack and an inclusion cluster of different densities when it comes to predicting the fatigue life of particulate composites with various volume fractions.     

Finite element analysis of the fatigue crack growth rate in transformation toughening ceramics

The fatigue crack growth rate in the zirconia tetragonal polycrystal is analyzed through the finite element method. In order to achieve this purpose, a continuum based constitutive law for materials subjected to phase transformations has been suitably implemented into a commercial finite element code. The fatigue crack growth in a notched beam, subjected to a cyclic four points bending load, has been investigated through a sensitivity analyses with respect to the two most relevant constitutive parameters: one accounting for the amount of the transformation strain and one accounting for the activation energy threshold. The fatigue crack growth rate typical of transforming materials is characterized by two distinct stages: at the beginning of the crack propagation process, the crack growth rate exhibits a negative dependency on the applied stress intensity factor; thereafter, a linear positive dependency is observed. This two stage process is well caught by the finite element model presented in this paper. Moreover, the response of the computational analyses has shown that the strength of the transformation process is determinant for the crack growth process to be arrested.     

CRACK FACE CONTACT PROBLEM ANALYSIS USING THE SCALED BOUNDARY FINITE ELEMENT METHOD

比例边界有限元侧面上有任意荷载时,将侧面载荷分解成关于径向方向局部坐标的多项式函数的和,推导给出了考虑侧面载荷存在的新型形函数,并基于该形函数推导了刚度矩阵和等效节点载荷列阵.首次对比例边界有限元法求解裂纹面接触问题进行了研究,运用Lagrange乘子引入接触界面约束条件,推导给出了比例边界有限元求解裂纹面接触问题的控制方程.将裂纹面单元分为非裂尖单元和含有侧面的裂尖单元.在非裂尖单元中的裂纹面,裂纹面作为多边形单元的边界,边界上的接触力可等效到节点上,通过在节点上构造Lagrange乘子,采用点对点接触约束进行处理.对于含有侧面的裂尖单元,在整个侧面上构造Lagrange乘子的插值场,采用边对边接触约束进行处理.对三个不同的接触约束状态下的算例进行了数值计算,通过与解析解及有限元软件ABAQUS计算结果的对比,验证了本文提出的比例边界有限元点对点和边对边接触求解裂纹面接触问题的精确性与有效性.     

微动频率对钢丝拉扭复合微动腐蚀疲劳行为影响研究

拉扭复合微动腐蚀疲劳是深井提升钢丝绳主要失效形式之一,深井提升钢丝绳振动频率决定钢丝间微动频率,直接影响钢丝拉扭复合微动腐蚀疲劳机理和损伤程度,进而制约深井提升钢丝绳服役安全性. 本文作者通过自制钢丝拉扭复合微动腐蚀疲劳试验机开展了酸性电解质溶液中钢丝拉扭复合微动腐蚀疲劳试验,通过钢丝切向力-位移幅值和扭矩-扭转角滞后回线分析了拉扭复合微动腐蚀疲劳过程中钢丝间接触状态及轴向和扭转方向钢丝耗散能,运用扫描电子显微镜和三维白光干涉表面形貌仪考察了拉扭复合微动腐蚀疲劳过程中钢丝磨痕形貌和磨损深度轮廓特性,采用X射线三维成像系统揭示了钢丝拉扭复合微动腐蚀疲劳裂纹扩展演化规律,通过电化学分析仪分析试验后钢丝Tafel极化曲线和阻抗谱以探究钢丝电化学腐蚀倾向和耐腐蚀性,揭示了微动频率对拉扭复合微动腐蚀疲劳过程中钢丝间接触状态、钢丝耗散能、微动磨损机理、疲劳裂纹扩展演化和疲劳寿命、电化学腐蚀倾向和耐腐蚀性的影响规律. 结果表明:在拉扭复合微动腐蚀疲劳过程中,随着微动频率的增加,钢丝间由完全滑移和部分滑移混合状态变为完全滑移状态,钢丝扭矩-扭转角滞后现象削弱,钢丝切向力-位移幅值和扭矩-扭转角滞后回线对应的耗散能均总体降低,钢丝间摩擦系数和钢丝磨损深度均降低,钢丝磨损机理均为磨粒磨损、黏着磨损、疲劳磨损和腐蚀磨损,钢丝最大裂纹深度和裂纹扩展速率均降低,疲劳寿命增加,钢丝电化学腐蚀倾向下降和耐腐蚀性增强.      

Experimental Investigation and Finite Element Analysis of Fatigue Crack Growth in Pipes Containing a Circumferential Semi-elliptical Crack Subjected to Bending

In this paper, a circumferential external surface flaw in a metallic round pipe under cyclic bending loading is considered. Because of very rapid changes in the geometrical parameters around the crack front region, the mesh generation of this region must be done with great care. This may lead to an increase in the run time which makes it difficult to reach valid results and conclusions. Because of the advantages of the sub-modeling technique in problems which need very high mesh density, this method is used. Stress intensity factors in mode I condition are determined using three-dimensional finite element modeling with 20 node iso-parametric brick elements in the ANSYS 9.0 standard code and the singular form of these finite elements at the crack front. In order to estimate the analysis error, the structural parameter error in energy norm criterion was used. Because of the advantages of non-dimensional analysis, this method is employed, and the stress intensity factors are normalized. For the analysis of the fatigue crack growth, the Paris law is used. The propagation path of the surface flaw is obtained from the diagram of aspect ratio versus relative crack depth. The fatigue crack growth analysis (the relative crack depth against loading cycles diagram) of different initial crack aspect ratio under cyclic loading is also considered. Fatigue shape development of initially semi-elliptical external surface defects is illustrated. The effect of the Paris exponent (material constant) on fatigue crack propagation is shown as well. Moreover, the fatigue crack growth of several specimens is assessed experimentally using a manually-constructed experimental set up. Finally, the experimental results obtained by cyclic bending loading tests are compared with the numerical results. The experimental results show good conformity with the finite element results.