Analysis of fretting fatigue in aircraft structures: Stresses, stress intensity factors, and life predictions
Abstract
Clamped contacts subjected to cyclic loading are prone to fretting fatigue, a mechanism of crack nucleation and propagation. In aircraft, fretting fatigue occurs at the rivet/hole interface on the fuselage skin and at the dovetail joint in engine hardware where disk and blade meet. The ability to predict the lives of such components would be a great aid in preventing failures. Finite element models appropriate for the calculation of fretting fatigue stresses and stress intensity factors are developed for two different contact geometries. In addition, several less computationally expensive numerical methods are also studied. Agreement between the various solutions is good. A severe increase in the mode I stress intensity factor near the surface is discovered in both geometries. Mode II stress intensity factors are also detailed, illustrating the complex non-proportional loading of fretting-induced cracks. A comparison is made between results obtained from actual surface profiles and those generated from prescribed surface profiles; the differences are significant. Equivalent initial flaw sizes are calculated for two different metals using an approach which ignores the effect of mode II stress intensity factors. Life predictions based on the equivalent initial flaw size approach are found to agree reasonably well with those measured in the laboratory for contact geometries similar to the rivet/hole interface. More data is needed before a judgment can be made about life correlations for the dovetail joint contact geometry. The analysis methods described throughout can be easily implemented and integrated into a system aimed at designing against fretting fatigue.
Degree
Ph.D.
Advisors
Farris, Purdue University.
Subject Area
Aerospace materials
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