Analysis of complete contacts subject to fatigue

Engineering assemblies are very frequently subject to fretting fatigue, which is a damage process that results when very small slip displacements arise at nominally stationary frictional interfaces. Fretting accelerates the initiation and early propagation of fatigue cracks, thereby causing significant reductions in the fatigue performance of many critical engineering components. A majority of the previous research on fretting fatigue has focused on incomplete (i.e. smooth-edged) contacts, while complete (i.e. sharp-edged) contacts have received less attention. The aim of this thesis is to contribute to the theoretical understanding of complete contacts, especially when they are subject to fatigue conditions. This problem is addressed in two separate ways. First, because fretting failures almost invariably initiate from the edge of contact, a detailed understanding of the conditions in this region should enable more accurate assessments of fatigue performance to be made. Thus, an asymptotic analysis is presented, which provides an accurate description of the contact edge under many conditions. This is done by using the elasticity solution for a semi-infinite notch to represent the state of stress near the contact edge in an asymptotic sense. Attention is then placed on the fact that cyclically loaded frictional contacts tend toward a steady-state response in which less frictional slip (and energy dissipation) occurs than in the first few load cycles. To investigate this effect, a numerical sub-structuring procedure is described, which significantly reduces the number of degrees of freedom in finite element models of frictional contact. This reduced model is then used to calculate the shakedown limit, i.e. the amplitude of cyclic load above which frictional slip is guaranteed to persist in the steady state. The sensitivity of the steady-state solution to the initial residual displacement state is then investigated, and it is shown that initial conditions can have a large influence on the steady-state behaviour of complete contacts.