Modelling of crack growth under cyclic contact loading

The paper describes a general computational model for modelling of subsurface fatigue crack growth under cyclic contact loading of mechanical elements. The model assumes that the initial fatigue crack develops along the slip line in a single crystal grain at the point of the maximum equivalent stress. The position and magnitude of the maximum equivalent stress are determined with the Finite Element Analysis of the equivalent contact model, which is based on the Hertzian contact conditions with the addition of frictional forces. The Virtual Crack Extension method is then used for simulation of the fatigue crack propagation from the initial to the critical crack length, when the surface material layer breaks away and a pit appears on the surface. The pit shapes and relationships between the stress intensity factor and the crack length are determined for various combinations of contacting surface curvatures and contact loadings. The computational results show that the model reliably simulates the subsurface fatigue crack growth under contact loading and can be used for computational predictions of surface pitting for various contacting mechanical elements.