Prediction of fretting fatigue crack initiation in double lap bolted joint using Continuum Damage Mechanics

•Finite Element Analysis of fretting fatigue in Double Bolted Lap Joint.•Continuum Damage Mechanics.•High cycle fatigue.•Crack initiation analysis.•Effect of contact regime on fretting fatigue crack initiation and propagation.

In fretting fatigue, the combination of small oscillatory motion, normal pressure and cyclic axial loading develops a noticeable stress concentration at the contact zone leading to accumulation of damage in fretted region, which produces micro cracks, and consequently forms a leading crack that can lead to failure. In fretting fatigue experiments, it is very difficult to detect the crack initiation phase. Damages and cracks are always hidden between the counterpart surfaces. Therefore, numerical modeling techniques for analyzing fretting fatigue crack initiation provide a precious tool to study this phenomenon. This article gives an insight in fretting fatigue crack initiation. This is done by means of an experimental set up and numerical models developed with the Finite Element Analysis (FEA) software package ABAQUS. Using Continuum Damage Mechanics (CDM) approach in conjunction with FEA, an uncoupled damage evolution law is used to model fretting fatigue crack initiation lifetime of Double Bolted Lap Joint (DBLJ). The predicted fatigue lifetimes are in good agreement with the experimentally measured ones. This comparison provides insight to the contribution of damage initiation and crack propagation in the total fatigue lifetime of DBLJ test specimens.