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Research on fretting fatigue life estimation model considering plastic effect

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Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

The contact surface between the aero-engine turbine blade and the disk dovetail junction structure is small, which results in severe fretting fatigue. The fretting fatigue of the structure is sharply aggravated by the plastic effect under the action of alternating loads. The existing fatigue life estimation model may need to be improved in considering fretting and plastic effects, making the result greatly differ from those found in practice. Accordingly, this work intends to propose a fretting fatigue life estimation model based on plastic effects and standard surface-to-surface contact theory. The distribution of both the equivalent and contact stresses found in the contact area was analyzed using finite elements. The aim was to determine the fatigue critical point of the structure. The maximum cyclic load stress value was obtained through the fretting fatigue experiments to verify the model accuracy. The model applicability was verified and analyzed using dovetail experiments. The experimental results have shown that the error between the values obtained using the proposed estimation model and experiment is below 12%, meaning that the accuracy is high. Therefore, the estimation model is suitable for estimation the dovetail structure fretting fatigue life. This paper provides theoretical support for the design of the dovetail tenon structure. The contact surface between the aero-engine turbine blade and the dovetail junction structure is small, which results in severe fretting fatigue. The fretting fatigue of the structure is sharply aggravated by the plastic effect under the action of alternating loads. The existing fatigue life estimation model may need to be improved in considering fretting and plastic effects, making the result greatly differ from those found in practice. Accordingly, this work intends to propose a fretting fatigue life estimation model based on plastic effects and standard surface-to-surface contact theory. The finite element analysis is used to analyze the distribution of equivalent stress and contact stress in the contact area, in order to determine the fatigue risk point of the structure. The accuracy of the model is verified by obtaining the maximum cyclic load stress value through the fretting fatigue experiment. The universal applicability of the model is verified through the dovetail experiment analysis. The experimental results show that the error between the theory and experiment of the proposed estimation model is below 12%. Therefore, it is suitable for the estimation of the fretting fatigue life of the dovetail structure.

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Data availability

The data will be available on reasonable request to the corresponding author.

Abbreviations

D crit :

Critical damage

D :

Damage variable

A :

Undamaged surface cross-section area

à :

Effective load area (which is the actual area)

\(\sigma\) :

Axial stress

\(\tilde{\sigma }\) :

Effective stress

\(\varepsilon\) :

Strain

F :

Force

E :

Undamaged elastic modulus

Ẽ :

Damaged elastic modulus

σ fretting :

Fretting stress

N :

Life

N f :

Remaining life

σ 0 :

Peak axial stress

p h :

Maximum contact area load

μ :

Friction coefficient on the contact surface

F T :

Tangential load amplitude between standard sample and contact pad

F N :

Normal load

σ R :

Material resistance stress

m :

Material parameter

Δε_p :

The maximum plastic strain range

ω :

Is the fitting parameter

K N :

Generalized stress intensity factor of the normal stress distribution

a round :

Load contact area radius

t :

Horizontal contact edge coordinate

R :

Edge radius

E* :

Elastically similar materials

ρ :

Density

f :

Frequency

ν :

Poisson's ratio

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Funding

This work is supported by NSFC-Liaoning United Key Fund (Grant No. U1708255), National key R & D plan of China (Grant No. 2018YFB1306701), and National Natural Science Foundation of China (Grant No. 51875076).

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Authors and Affiliations

  1. School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, China

    Junzhou Huo, Bowen Yang & Rong Ren

  2. College of Biotechnology, Guilin Medical University, Guilin, 541100, Guangxi, China

    Junzhou Huo & Jianghui Dong

Authors
  1. Junzhou Huo
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  2. Bowen Yang
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  3. Rong Ren
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  4. Jianghui Dong
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Contributions

Study design: JH, BY, and JD. Study conduct: JH, BY, and RR. Data collection, analysis and interpretation: BY and RR. Drafting manuscript: JH, BY, and JD. Revising manuscript: JH, BY, and JD. All authors have read and approved the final submitted manuscript.

Corresponding authors

Correspondence to Bowen Yang or Jianghui Dong.

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The authors declare no competing interests.

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Technical Editor: João Marciano Laredo dos Reis.

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Huo, J., Yang, B., Ren, R. et al. Research on fretting fatigue life estimation model considering plastic effect. J Braz. Soc. Mech. Sci. Eng. 44, 112 (2022). https://doi.org/10.1007/s40430-022-03391-4

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