Numerical and experimental investigations on fretting fatigue: Relative slip, crack path, and fatigue life

•Methods for fretting-fatigue crack path and life prediction are proposed.•Crack initiates at the location of maximum relative slip amplitude.•Crack path can be estimated based on the maximum tangential stress range criterion.•Fatigue life can be predicted based on the tangential stress intensity factor range.•Experimental and predicted results under small-scale yielding are in good agreement.

Finite element analysis was carried out to evaluate the stress and strain on flat-on-flat contact interface as well as around crack tip in fretting fatigue at various contact pressures. The crack path in fretting fatigue could be successfully estimated based on the maximum tangential stress range criterion. While, the fretting-fatigue lives could be successfully predicted by using the effective maximum tangential stress intensity factor range. At stress amplitudes higher than 300 MPa, the predicted lives tended to become longer than the experimental results due to the large plastic zone at crack tip.