Finite element analysis of fretting fatigue behavior of steel wires and crack initiation characteristics

The effects of fretting parameters on stress distributions of contacting wires during the initial stage of fretting–fatigue of steel wires were investigated using the finite element method. The roles of fretting parameters on crack initiation characteristics were discussed employing the multiaxial fatigue criteria of Fatemi–Socie and Smith–Watson–Topper, and three-dimensional coordinate transformation. Non-uniform stress distributions on contact surfaces and ring-shaped stress distributions near the contact zone on the symmetric plane are observed. Different fretting parameters induce distinct fretting regimes, stress distributions and abrupt changes of stress near the trailing edge. Crack initiation becomes more difficult with increasing contact load as compared to the increased possibility of crack initiation with increasing relative displacement.

► Finite element method is employed to investigate fretting–fatigue of steel wires.
► Effects of fretting parameters on stress distributions of contacting wires are explored.
► Multiaxial fatigue criteria and three-dimensional coordinate transformation are applied.
► Effects of fretting parameters on crack initiation characteristics are investigated.