Proceedings of the 7th International Conference on Fracture Fatigue and Wear (eBook)

Preface 6
Organisation 8
Organising Committee 8
Chairman 8
Co-chairman 8
International Scientific Committee 8
Contents 10
Fracture 17
Failure Analysis of a Removable Support of a Cockpit Seat in a STOL Airplane 18
Abstract 18
1 Introduction 18
2 Results and Discussion 20
2.1 Macro Examination 20
2.2 SEM 22
2.3 Microstructure 25
2.4 Micro Hardness Test 26
2.5 Estimated Maximum Forces 27
3 Conclusions 31
4 Recommendations 31
Acknowledgments 32
References 32
Spot Welding Joint’s Fracture Behavior and Fundamental 33
Abstract 33
1 Introduction 33
2 Fracture Mechanics of Spot Welds 34
3 Modeling and Simulation 35
3.1 Specimen Modeling 35
3.2 Material Properties 35
3.3 Finite Element Analysis Code 35
3.4 Mesh Generation and Boundary Conditions 36
4 Results and Discussion 36
4.1 Maximum Stresses and Crack Propagation 36
5 Conclusions 41
Acknowledgments 41
References 41
Failure and Fracture Analysis of Al-alloy Wheel Rim of a Vehicle 43
Abstract 43
1 Introduction and Background Information 43
2 Experimental Procedure 44
3 Results and Discussion 45
3.1 Visual Examination and Stereomicroscopy 45
3.2 SEM Fractographic Evaluation 45
3.3 Optical Metallography 45
3.4 SEM/EDS Analysis 47
3.5 Charpy Impact Testing 49
4 Conclusions 54
References 55
Key Parameters for Fracture Toughness of Particle/Polymer Nanocomposites Sensitivity Analysis via XFEM Modeling Approach
1 Introduction 56
2 Numerical Modeling for Fracture of Particle/PNCs 57
3 Sensitivity Analysis Methods 60
3.1 Regression Method 60
3.2 Elementary Effects 60
3.3 Sobol' Method 60
3.4 Extended Fourier Amplitude Sensitivity Test 61
4 Results 62
5 Conclusion 64
References 64
A Criterion for Crack Initiation at Blunt Notches Based on the Concept of Local Strength 67
Abstract 67
1 Introduction 67
2 Problem Statement 69
3 Fracture Criterion 70
4 Examples of Fracture Criterion Application 71
4.1 Plate with an Elliptic Hole Under Tension 71
4.2 Infinite Body with Ellipsoidal Hollow Under Tension 72
5 Comparison Between Predicted and Experimental Data 73
5.1 Plate with a Circular Hole Under Tension 73
5.2 Plate with Lateral Notches Under Tension 73
5.3 Bar with a Circumferential Notch Under Tension 74
5.4 Plate with a Circular Hole Under Compression 75
6 Conclusions 75
Acknowledgments 76
References 76
Effect of Friction Coefficient and Maximum Contact Pressure on the Spalling Depth of Gear Teeth Flank 78
Abstract 78
1 Introduction 78
2 Numerical Simulation 79
3 Results and Discussion 79
4 Conclusion 82
References 82
Transient Analysis of Multiple Interface Cracks in Two Bonded Elastic and Piezoelectric Layers 84
Abstract 84
1 Introduction 84
2 Formulation of the Problem 85
3 Derivation of the Integral Equations 88
4 Results and Discussions 89
5 Concluding Remarks 91
References 91
A Study on the Constitutive Equation Effects in the Fracture Initiation of AA5450 Sheets 93
Abstract 93
1 Introduction 93
2 Experiments 94
3 Finite Element Model 94
4 Results and Discussions 95
5 Conclusions 97
References 97
Predicting the Failure Type of Liquid Hydrocarbon Pipeline Using Fuzzy Expert System 99
Abstract 99
1 Introduction 99
2 Fuzzy Expert Systems 100
3 Development of a Fuzzy Logic-Based Failure Model 101
3.1 Data Collection, Filtering and Classification 101
3.2 Fuzzy of Variables and Define Membership Functions 101
3.3 Establishing a Fuzzy Rule Base for FES 103
3.4 Model Implementation 104
3.5 Model Validation 104
4 Conclusion 104
References 105
Simulation of Loading Rate Effects on Dynamic Brittle Failure of Concrete Structures Using a Two-Scale Damage Model 106
1 Introduction 106
2 Dynamic Damage Model 107
3 Compact Tension Test 108
4 L-Shaped Specimen Test 110
5 Conclusions 112
References 112
Deformation Behavior and Fracture of Al-CuZr Nano-Laminates: A Molecular Dynamics Simulation Study 114
Abstract 114
1 Introduction 114
2 Simulation Methodology 115
3 Results and Discussions 116
4 Conclusions 119
References 120
Model of Damaged Medium for Describing Fatigue Fracture of Materials and Structures 122
Abstract 122
1 Introduction 122
2 Defining Relations of Mechanics of Damaged Media 124
3 The Investigation Results 127
4 Conclusion 137
Acknowledgements 138
References 138
Modeling of Fatigue Fracture of Coatings in Multi-cycle Friction Contact 140
Abstract 140
1 Introduction 140
2 Problem Formulation and the Method of Solution 141
2.1 Contact Problem Solution 141
2.2 Calculation of Internal Stresses 143
2.3 Model of the Contact Fatigue at the Layer-Substrate Interface 143
3 Results and Discussion 145
4 Conclusions 148
Acknowledgments 148
References 148
Research and Modeling of Stress-Strain State and Fracture Strength of Triplexes at Temperatures 293–213 K 150
Abstract 150
1 Introduction 150
2 Materials and Methods 153
2.1 Test Samples and Materials 153
2.2 Modeling of the Adhesion Processes and the Triplex Separate Layers Fracture in the Presence of Crack-Like Defects 154
2.3 Measurements 156
2.4 Methodology to Determine Stresses 157
3 Experimental Results 158
4 Analysis of the Experimental Results of Studies of Stress-Strain and Boundary States of the Triplex in the Temperature Range 293–213 K 160
5 Numerical Modeling of the Framing Influence on the SIF of Surface Cracks 161
5.1 Modeling Conditions 161
5.2 Numerical Results and Discussion 162
6 Conclusions 163
References 164
Influence of Low Temperature on Mechanical Properties of Carbon Steel P110 Estimated by Means of Small Punch Test 166
Abstract 166
1 Introduction 166
2 Experimental Methodology 168
3 Results and Discussion 170
4 Summary 176
Acknowledgements 177
References 177
Crack Propagation in Various Double Cantilever Beam Geometric Configurations 179
Abstract 179
1 Introduction 179
2 Procedures and Methodology Used 180
2.1 Williams Power Series 180
2.2 Over-Deterministic Method (ODM) 180
3 Cracked Geometry, Numerical Model, ODM, MTS Criterion 181
3.1 Investigated Cracked Geometry 181
3.2 Numerical Model in ANSYS 181
3.3 ODM Procedure 182
3.4 MTS Criterion Evaluation 182
4 Results and Discussion 182
5 Conclusion 184
Acknowledgements 184
References 184
Lateral Indentation and Impact Analyses on Curved Composite Shells 186
1 Introduction 186
2 Materials and Methods 187
2.1 Experimental Setup and Testing 188
2.2 Numerical Analyses 189
3 Results and Discussion 191
3.1 Sensitivity Analysis on the Hashin Parameters 193
4 Conclusions 197
References 198
Structured Learning-Based Sinusoidal Modelling for Gear Diagnosis and Prognosis 199
Abstract 199
1 Introduction 199
2 Problem Formulation 200
3 The Structured Learning Based Sinusoidal Modelling 203
4 Performance Investigation 204
5 Conclusion 207
References 207
Singular Stress Field of Interfacial Small Crack in Orthotropic Bonded Plate 209
Abstract 209
1 Introduction 209
2 Singular Stress Field of Interface Edge 210
2.1 Definition of Stress Intensity Factor 210
3 Method of Analysis 211
3.1 Analysis Condition 211
3.2 Determination of Stress Intensity Factor 212
4 Numerical Results and Discussions 212
4.1 Expression of Stress Intensity Factor of Small Edge Interface Crack 212
4.2 Effect of Material Combination 213
5 Conclusions 215
References 216
Comparative Research on Calculation Methods of Stress Intensity Factors and Crack Propagation Criterion 217
Abstract 217
1 Introduction 217
2 Calculation Methods of Stress Intensity Factor 218
3 Calculation Methods of Crack Propagation Criterion 220
4 Conclusions 224
Acknowledgements 224
References 224
Crack Identification Using eXtended IsoGeometric Analysis and Particle Swarm Optimization 225
Abstract 225
1 Introduction 225
2 Motivation and X-IGA Approach in Forward Problem 226
2.1 A Brief of B-Spline/NURBS Functions 227
2.2 XIGA Implementation 227
3 Particle Swarm Optimization (PSO) 229
4 Numerical Results 231
4.1 Cracked Plate - Scenario 1 231
4.2 Cracked Plate - Scenario 2 231
4.3 Cracked Plate - Scenario 3 233
4.4 Cracked Plate - Scenario 4 234
5 Conclusion 236
References 236
Fatigue 238
PWR Fatigue Testing at SCK•CEN in the Framework of INCEFA+ 239
Abstract 239
1 Introduction 239
2 Material 240
3 Specimen 240
4 Environment 242
5 Fatigue Testing 242
6 Extensometers 244
7 Test Result 244
8 Discussion of Test Results 252
9 Conclusion 253
Acknowledgments 254
References 254
The Effect of Technological and Structural Factors on the Strength of Polyethylene Adhesive Joints 255
Abstract 255
1 Introduction 256
2 Methodology 257
2.1 Adherend 257
2.2 Surface Treatment 257
2.3 Adhesives 258
2.4 Adhesive Joints 259
2.5 Strength Tests and Statistical Analysis 260
3 Results 261
3.1 Results of Adhesive Joints Strength 261
3.2 Statistical Results of Adhesive Joints Strength 262
3.3 Elongation at Break of Adhesive Joints 264
3.4 Failure Patterns of Adhesive Joints 266
3.5 Results Discussion 268
4 Conclusions 269
References 270
Compression of Strain Load History Using Holder Exponents of Continuous Wavelet Transform 272
Abstract 272
1 Introduction 273
2 Theoretical Background 274
2.1 Singularities Detection with Holder Exponents 274
3 Methodology 275
3.1 Strain Signal Acquisition 276
3.2 Continuous Wavelet Transform and Lipschitz Regularity Analysis 276
3.3 Compression of Strain Time Histories and Fatigue Life Prediction 278
4 Results and Discussion 280
4.1 Continuous Wavelet Transform of Time History 280
4.2 Comparison of Lipschitz-Based and Time-Domain-Based FDE Techniques 281
5 Conclusions 285
Acknowledgements 286
References 286
Structural Optimization for the Gusset Plate in the Boom Structure of Concrete Pump Truck 287
Abstract 287
1 Introduction 287
2 General Introduction of CPT 288
2.1 Configuration of CPT 288
2.2 Loading Characterization 289
2.3 Gusset Plate 290
2.4 Representative of Region and Loading for Optimization 292
3 Design Of Experiment (DOE) 294
3.1 Design Process 294
3.2 Conceptual Design 294
3.3 Detailed Design 296
4 Conclusion 298
Acknowledgement 299
References 299
Failure Analysis of Prematurely Failed Hip Joint Implant Inside the Femur Bone 300
Abstract 300
1 Introduction 300
2 Experimental 302
2.1 Material 302
2.2 Method 303
3 Results and Discussion 304
3.1 Hardness and Bend Test 304
3.2 Chemical Analysis Test 304
3.3 Stereo Zoom and Optical Microscopy 305
3.4 SEM-EDS Analysis 306
4 Conclusions 308
Acknowledgements 308
References 309
Comparative Study of Defect-Based and Plastic Damage-Based Approaches for Fatigue Lifetime Calculation of Selective Laser-Melted AlSi12 311
Abstract 311
1 Introduction 311
2 Materials and Methods 314
2.1 Experimental Setup 314
2.2 Theory and Calculations 319
3 Results and Discussion 321
4 Conclusions and Outlook 324
Acknowledgements 325
References 325
Fatigue Damage of Waterwall Tubes in a 1000 MW USC Boiler 328
Abstract 328
1 Introduction 328
2 Description of the Boiler 329
3 Results and Discussion 330
3.1 Visual Observation 330
3.2 Chemical Analysis 330
3.3 Mechanical Properties 330
3.4 Microstructural Observation 331
3.5 Cracks and Fracture Analysis 331
3.6 EDS and XRD Phase Analysis 333
3.7 Root Cause Analysis 336
4 Conclusions and Recommendations 337
Acknowledgements 338
References 338
Fatigue of Steels Used in the Manufacture of Components for Heavy Load Vehicles 339
Abstract 339
1 Introduction 339
2 Experimental Procedure 341
3 Results and Discussion 343
4 Conclusions 348
Acknowledgements 348
References 349
Specimen Thickness Effects on Front Edge Shape of Fatigue Crack in Al7075-T6 Alloy 350
Abstract 350
1 Introduction 350
2 Material, Specimen and Experimental Procedures 351
3 Results and Discussion 352
3.1 Curvature Radius of Fatigue Crack Front Edge 352
3.2 Change in the Plastic Zone Size in the Specimen Thickness Direction 354
4 Conclusion 357
References 357
Finite Lifetime Estimation of Mechanical Assemblies Subjected to Fretting Fatigue Loading 359
Abstract 359
1 Introduction 359
2 The MWCM to Estimate Fatigue Life Under CA Multiaxial Fatigue Loading 360
3 The TCD Approach 362
4 Estimation of Stress Quantities Relative to the Critical Plane Under CA Multiaxial Loading 363
5 Formalization of the Design Methodology to Estimate Finite Lifetime of Mechanical Assemblies Under CA Fretting Fatigue Loading 364
6 Validation with Experimental Data 366
7 Results and Discussion 369
8 Conclusion 370
Acknowledgment 370
References 371
Probabilistic Modeling of Coating Delamination 373
Abstract 373
1 Problem Formulation and Resulting Equations 374
1.1 Discontinuous Solutions for Coated Half-Plane with Interface Cracks 375
1.2 J-Integrals and Stress Intensity Factors at Interface Crack Tips 377
2 Probabilistic Model of Cyclic Coating Delamination 378
3 Some Numerical Results 380
4 Conclusions 383
References 384
Failure of Giant Wheel Ride at an Amusement Park 385
Abstract 385
1 Introduction 385
2 The Parameters of the Central Shaft 387
3 Metallurgical Analysis 387
4 Structural/Stress Analysis 389
5 Conclusions 391
References 391
Thermal-Mechanical Fatigue Analysis of a Main Steam Isolation Valve of a Boiling Water Reactor-5 393
Abstract 393
1 Introduction 393
2 Statement of the Problem 394
3 Materials and Methods 395
4 Results 399
5 Conclusions 401
Acknowledgement 402
References 402
Influence of Soft Particle Peening Treatment on Fatigue Strength of Aluminum Alloy A5052 404
Abstract 404
1 Introduction 404
2 Influence of Hardness on Surface Modification Effect [13] 405
2.1 Experimental Method 405
2.2 Result of Extent of Wear and Vickers Hardness 406
3 Influence of Soft Resin Particle Peening on Fatigue Strength Characteristics of Aluminum Alloy A5052 407
3.1 Material and Experimental Procedure 407
3.2 Influence on Hardness Distribution, Surface Roughness and Residual Stress 408
3.3 Influence on Fatigue Strength 410
3.4 Consideration by Impact Energy 411
4 Conclusions 413
References 413
Fatigue Life Calculation of Load-Adapted Hybrid Angular Contact Ball Bearings 415
Abstract 415
1 Introduction 415
2 Method of Calculation 416
2.1 Input Parameters 417
2.2 FE Model 420
2.3 Calculation of Bearing Fatigue Life 421
3 Calculational Results 423
4 Conclusion and Outlook 427
Acknowledgments 427
References 427
The Influence of Hydrogen on Fatigue Fracture in Mooring Chain Steel 429
Abstract 429
1 Introduction 429
2 Experimental Procedure and Methods 430
2.1 Materials 430
2.2 Microscopic Observation 430
2.3 Mechanical Tests 431
2.4 Methods 431
3 Results 431
4 Discussion 436
5 Conclusions 439
Acknowledgements 439
References 439
Monitoring Micro-damage Evolution in Structural Steel S355 Using Speckle Interferometry 441
Abstract 441
1 Introduction 441
2 Basics on Fatigue Damage and Metrology 441
2.1 Stages of Cyclic Damage 441
2.2 Experimental Background on Damage Assessment 442
2.3 Fundamentals of Speckle Interferometry 443
3 Experimental Methods and Materials 444
4 Measurement Results 446
5 Summary and Outlook 450
Acknowledgment 450
References 450
On an Extension of the Fatemi and Socie Equation for Rolling Contact in Rolling Bearings 452
Abstract 452
1 Introduction 453
2 Theory and Description 455
2.1 Critical Plane Criterion of Fatemi and Socie 455
2.2 Determination of Shear Strain Amplitude and Normal Stress 457
3 Application to Rolling Contact 459
3.1 Configuration 459
3.2 Influence of the Normal Stress in the Critical Plane 461
4 Simulations Results 464
4.1 Critical Plane Orientation and Location 465
4.2 Crack Initiation Lifetime Calculation in the Approach A1 and A2 466
4.3 Comparison with Standard DIN ISO 281 468
5 Conclusion 469
References 470
Durability of Steel Joints with Ductile Adhesive Subjected to Fatigue Tests 472
Abstract 472
1 Introduction 472
2 Experimental 473
3 Results and Discussion 474
4 Conclusions 477
References 477
Effect of an Adhesive Bonding on the Fatigue Life of Advanced High Strength Steel Spot-Welds 478
Abstract 478
1 Introduction 478
2 Specimen Preparation 479
3 Test Results and Discussion 480
3.1 Thickness Dependence of the Joint Strength 480
3.2 Sheet Strength Dependence of the Joint Strength 486
4 Conclusions 492
Acknowledgement 493
References 493
Fatigue Life Predictions for L-Shaped Cracks 494
Abstract 494
1 Introduction 494
2 Methodology and Formulation 495
2.1 Normal Crack Front Advance 495
2.2 Length Advance 498
3 Results and Discussion 498
3.1 Normal Crack Front Advance 498
3.2 Length Advance 502
4 Conclusions 503
Acknowledgements 503
References 503
Modelling of Short Crack Arrest and Fatigue Propagation Using Non-local Fracture Criteria 505
Abstract 505
1 Introduction 505
2 Non-local Fracture Criteria 506
3 Dugdale’s Crack Model 507
4 Fatigue Growth of the Short Cracks 508
5 Arrest of the Short Cracks 510
6 Conclusions 512
References 512
Critical Analysis of Randomly Rough Surfaces for Contact Mechanics Through Statistical Simulation 514
Abstract 514
1 Introduction 514
2 Simulation Methods 516
3 Simulations and Simulation Results 519
4 Discussion 522
5 Conclusions 524
Acknowledgements 524
References 524
Panel Test for New Developed Airbus A321 ACF Overwing Door and Surrounding Structure 526
Abstract 526
1 Introduction into the A321neo ACF Project 526
2 Influence of Design on Verification and Validation Needs 527
3 Test Scenario 527
4 Description of Chosen Test Set-up 530
5 Specimen Adaptation to Test Needs 531
6 Test Program 531
7 Conclusion 533
Acknowledgement 534
References 534
Strain Rate Concentration Factor for Round and Flat Test Specimens 535
Abstract 535
1 Introduction 535
2 Definition of Strain Rate Concentration Factor 536
3 Strain Rate Concentration for the Round and Flat Specimen 537
4 Relationship Between the Strain Rate Concentration Factor and the Stress Concentration Factor 538
5 Conclusion 541
References 542
A Comparison Between Critical-Plane and Stress-Invariant Approaches for the Prediction of Fretting Fatigue Crack Nucleation 544
Abstract 544
1 Introduction 544
2 Theoretical Background 545
2.1 Critical Plane Approach 545
2.2 Stress Invariant Approach 546
3 Experimental Data 546
4 Methodology 547
4.1 Nucleation Life 547
4.2 Propagation Life 548
5 Results 548
5.1 Comparison of Initiation Location 548
5.2 Comparison of Fretting Fatigue Life 549
6 Conclusions 550
Acknowledgement 551
References 551
Effect of Short Crack Behavior on the Propagation Life Prediction for a Fretting Cylindrical Pad Configuration 553
Abstract 553
1 Introduction 553
2 Numerical Analysis 554
2.1 Finite Element Model 554
2.2 Life Predictions 556
3 Results 557
4 Conclusions 559
Acknowledgements 559
References 559
Simulation of Cyclic Deformation Behavior of Ferritic P92 Steel Based on Unified Viscoplastic Model 561
Abstract 561
1 Introduction 561
2 Experimental Procedure 562
3 Experimental Results and Discussion 563
4 Simulation of LCF and CFI Deformation 565
4.1 Constitutive Model 565
4.2 Determination of Material Parameters 566
4.3 Simulation Results and Discussion 567
5 Conclusion 569
Acknowledgements 569
References 569
Fatigue Life Analysis of Un-repaired and Repaired Metallic Substrate Using FRANC2D 572
Abstract 572
1 Introduction 572
2 Materials and Methodology 573
2.1 Materials 573
2.2 Modelling in FRANC2D/L 574
3 Results and Discussion 575
4 Conclusions 578
Acknowledgements 578
References 578
Wear 580
Effect of Cryosoaking Period on Soft Tempering Temperature and Wear Mechanism in AISI H11 Tool Steel 581
Abstract 581
1 Introduction 581
2 Experimental Procedures 582
2.1 Material Selection 582
2.2 Heat Treatment and Cryogenic Treatment 582
2.3 Hardness Test 583
2.4 Wear Test 583
2.5 Metallography 584
3 Results and Discussion 584
3.1 Hardness Variation 584
3.2 Morphology of Carbides 584
3.3 Wear Mechanism 585
3.4 Standardization of Soft Tempering Temperature 589
4 Conclusions 592
References 592
Dry Wear Behavior of Basalt/Carbon-Reinforced Epoxy Composite by Taguchi Method 593
Abstract 593
1 Introduction 593
2 Materials 595
2.1 Experimental Design 595
2.2 Wear Tests 596
3 Results and Discussion 596
3.1 Analysis of Weight Loss 596
3.2 Anova 599
4 Conclusions 600
References 600
Wear Property of Epoxy Reinforced with Carbon Using a Response Surface Methodology 603
Abstract 603
1 Introduction 603
2 Materials 605
2.1 Experimental Design 605
2.2 Wear Tests 606
3 Results and Discussion 606
3.1 Weight Loss 606
3.2 Anova 608
3.3 Regression Analysis 611
3.4 Optimization of Responses 611
4 Conclusions 612
References 612
Microabrasive Wear of Titanium Chrome Plated 614
Abstract 614
1 Introduction 614
2 Methods 615
2.1 Electrolytic Chromium Deposit 615
2.2 Testing Equipment 615
2.3 Test Method 616
2.4 Characteristics of the Specimens 617
2.5 Hardness Evaluation 618
2.6 Wear Tests of the Uncoated Specimens of Titanium 618
2.7 Wear Tests of the Titanium Specimens Coated with Chrome 619
3 Discussion 621
4 Conclusions 624
References 625
Experimental Investigate of the Wear and Friction Performance Considering Effects of Surface Topography and Lubricant 627
Abstract 627
1 Introduction 627
2 Effects of Surface Topography 628
3 Effects of Lubricant Characteristics 629
4 Conclusion 631
Acknowledgments 632
References 632
Experimental Simulation and Analysis of Die Casting Mould Wear 633
Abstract 633
1 Introduction 633
2 Prototype Wear Testing Equipment 633
3 Experimental Work 635
3.1 Samples 635
3.2 Experiment Parameters 635
3.3 Results and Analysis 636
4 Conclusion 638
Acknowledgements 638
References 638
Structure and Properties of the New Antifriction Composite Materials for High-Temperature Friction Units 640
Abstract 640
1 Introduction 640
2 Experimental Procedure 642
3 Conclusion 648
References 648
Comprehension of Thermomechanical Phenomena and Material Behavior During High Speed Contact 650
Abstract 650
1 Introduction 650
2 Contact Interaction at ENIT 652
2.1 Presentation of the Test Device 652
2.2 Test Device Instrumentation 653
2.3 Contact Pieces and Contact Geometry 653
2.4 Test Procedure 654
2.5 Presented Tests 655
3 Data Analysis 656
3.1 Force Analysis 656
3.2 Friction Analysis 658
3.3 Temperature Analysis 660
3.4 Wear Analysis 662
4 Discussion 666
5 Conclusion 670
References 671
An Investigation into the Early Life Cycle Wear-Induced Failure of an All-Terrain Vehicle Ball Joint Cotter Pin 673
Abstract 673
1 Cotter Pin and Castle Nut Discussion 673
2 Accident Summary and Investigation 674
2.1 Accident Facts and Summary 674
2.2 Accident Vehicle Investigation 674
2.3 Subsequent Research and Investigation 675
3 Ball Joint Analysis 677
4 Exemplar Parts Testing, Results, and Comparisons with the Subject Cotter Pin Pieces 678
5 Conclusions 682
References 682
In-manufacture Running-in of Engine Components by Using the Triboconditioning® Process 683
Abstract 683
1 Introduction 683
2 Part Preparation and Testing 685
3 Results and Discussion 685
3.1 Effect of Triboconditioning® on Valve Train Friction and Wear 685
3.2 Effect of Triboconditioning® on Piston-Bore Friction and Wear 689
3.3 Development of Bushingless Connecting Rods via Triboconditioning® 691
4 Conclusions 692
References 692
Wear Behavior of ZrO2 Particle Reinforced (Fe,Ni) Matrix Composite 694
Abstract 694
1 Introduction 694
2 Experimental 695
3 Results and Discussion 696
3.1 X-Ray Diffraction (XRD) 696
3.2 Density 696
3.3 Wear Properties 697
3.4 Corrosion Behavior 700
4 Conclusion 701
References 701
Nanoscale Wear of Carbon Overcoat Subjected to Laser Heating in an Inert Gas Environment 703
Abstract 703
1 Introduction 703
2 Experimental 704
2.1 Test Pin and Disk 704
2.2 Experimental Setup [11] 705
2.3 Evaluation Method of DLC Wear on the Pin and Magnetic Disk Surfaces 706
3 Experimental Results and Discussion 706
3.1 In the Case Without Laser Heating 706
3.2 In the Case with Laser Heating 708
3.3 Observation of the DLC Thin Film on the Magnetic Disk Surface After Friction Wear Test 713
4 Conclusion 715
Acknowledgment 715
References 715
Wear Simulation Method for Mechanical Seals Under Mixed Lubrication Using Flow Factors 717
Abstract 717
1 Introduction 717
2 Mixed TEHD Lubrication Model 719
2.1 Fluid Mechanics Analysis 719
2.2 Asperity Contact Mechanics Analysis 720
2.3 Thermomechanics Analysis 721
2.4 Force Balance Mechanisms Analysis 721
2.5 Coupling Relationship 722
3 Wear Mechanisms Analysis and Numerical Algorithm 722
3.1 Wear Mechanisms Analysis 722
3.2 Numerical Algorithm 723
4 Simulation Studies and Discussions 724
4.1 Effects of Sealed Fluid Pressure 724
4.2 Effects of Rotating Speed 726
4.3 Effects of Roughness 727
5 Conclusions and Future Work 729
Acknowledgments 729
References 729
Boride Coating on Titanium Alloys as Biomaterial in Wear and Fretting Applications 731
Abstract 731
1 Introduction 731
2 Materials and Methods 732
3 Results and Discussion 734
3.1 Microstructure 734
3.2 Morphology and Thickness 734
3.3 Phase Composition 735
3.4 Hardness 736
3.5 Adhesion 736
3.6 Wear 738
4 Conclusions 741
Acknowledgments 742
References 742
Wear Behavior of ZTA Reinforced Iron Matrix Composites 744
Abstract 744
1 Introduction 744
2 Experimental Details 745
2.1 Composites Preparation 745
2.2 Sliding Wear Test 747
2.3 Three-Body Abrasive Wear Test 747
3 Results and Discussion 748
3.1 Microstructure and Properties 748
3.2 Sliding Wear 751
3.3 Three-Body Abrasive Wear Resistance 754
4 Conclusions 756
References 757
Friction and Wear of Mouthguard Material with a Laser-Textured Surface in Reciprocating Sliding Motion 759
Abstract 759
1 Introduction 759
2 Experimental Apparatus and Procedure 760
3 Results and Discussion 762
3.1 Effects of Pit Diameter 762
3.2 Effects of Pit Area Ratio 763
3.3 SEM Observations of Wear Processes 765
4 Conclusions 768
References 769
Effect of Prior Ratcheting Deformation on Low Cycle Fatigue Behaviour of AISI 4340 Steel 771
Abstract 771
1 Introduction 771
2 Experimental Details 772
2.1 Material Selection, Heat Treatment, Basic Metallography and Specimen Design 772
2.2 Ratcheting and Post-ratcheting Low Cycle Fatigue Tests 772
3 Results and Discussion 773
3.1 Microstructural Analysis 773
3.2 Hardness and Tensile Properties 774
3.3 Ratcheting Behavior Under Varying Stress Ratios 774
3.4 Effect of Previous Ratcheting Deformation on Low Cycle Fatigue Behaviour of the Steel 776
4 Conclusions 778
References 778
Finite Element Model in Abrasion Analysis for Single-Asperity Scratch Test 780
Abstract 780
1 Introduction 780
2 Material Characterization 781
2.1 Material 781
2.2 Experimental Characterization 781
2.3 Uniaxial Tensile Test 781
2.4 Fracture Tensile Test 783
3 Material Model Calibration 784
3.1 Finite-Element (FE) Model 784
3.2 Flow Curve Extrapolation 784
3.3 MBW Model Calibration 785
4 Model Application: Single Asperity Test 787
4.1 Experiments 787
4.2 Simulation 788
5 Conclusions 790
Acknowledgements 790
References 790
Analysis of the Fretting Wear Phenomenon on the Surface Coatings of Form-Wound Coil 792
Abstract 792
1 Introduction 792
2 Fretting Wear 793
2.1 Fretting Wear Mechanism 793
3 Experimental Setup 795
4 Experimental Results 796
4.1 Experimental Procedure 796
5 Discussion 799
6 Conclusions 800
References 800
Tribological and Mechanical Properties of Polyester Based Composites with SiC Particles 801
Abstract 801
1 Introduction 801
2 Experimental Procedure 802
2.1 Materials 802
2.2 Characterization Techniques 802
3 Results 803
4 Conclusions 806
Acknowledgments 806
References 806
Numerical Calculation of Local Adhesive Wear in Machine Elements Under Boundary Lubrication Considering the Surface Roughness 808
Abstract 808
1 Introduction 808
2 Numerical Wear Calculation 810
2.1 Wear Modelling 810
2.2 Local Wear Modelling 811
3 Calculation Results 812
3.1 Calculation of the Wear Coefficient 812
3.2 Calculation of Wear in Machine Elements 813
4 Validation 814
4.1 Test Results 814
4.2 Comparison 817
5 Summary and Outlook 818
References 818
Numerical Investigation and Optimization of Loosening Behavior of Wheel Nuts for Passenger Cars 820
Abstract 820
1 Introduction 820
2 Experiments and Simulations 821
3 Results and Discussions 822
4 Conclusions 825
Acknowledgement 825
References 825
Optimization of Rigidity of Aluminum Alloy Wheels 826
Abstract 826
1 Introduction 826
2 Simulation and Optimization 827
3 Results and Discussions 828
4 Conclusions 830
References 831