Finite element simulation of the influence of fretting wear on fretting crack initiation in press-fitted shaft under rotating bending

A Finite element based methodology for fretting wear and fretting fatigue prediction in press-fitted shaft is developed. This methodology integrates wear modelling with fretting fatigue analysis to quantitatively predict of the effects of stress redistribution and material removal induced by the fretting wear on fretting crack initiation properties. The fretting wear-induced evolutions of mean normal stress, a mean correction multiaxial damage parameter and accumulated fatigue damage are predicted by this methodology. The results show that the fretting crack initiation at the contact edge is significantly suppressed by the severe fretting wear, since the server stress concentration is relieved and the surface material with high accumulated fatigue damage is grinded off. While, the fretting crack initiation at the inner surface of the contact area is greatly promoted by the slight wear by introducing the large stress concentration near the edge of fretted wear scar.