Prediction of Fretting Fatigue Crack Propagation Life of Steel Wire Considering Fretting Wear

Fretting fatigue is one of main failure modes of hoisting rope in coal mine. During fretting fatigue of steel wire, fretting wear seriously affects the fretting fatigue crack propagation characteristic of steel wire, and thereby restricts the fretting fatigue fracture mechanism of steel wire. Therefore, it is of great importance to carry out the research on prediction of fretting fatigue crack propagation life of steel wire considering fretting wear. Fretting fatigue and tensile fracture tests of steel wires were carried out by employing the self-made fretting fatigue test rig. Fretting wear evolution, crack initiation and propagation, and fracture characteristics of steel wire during fretting fatigue were revealed using the high-speed digital microscope system. The prediction model of fretting fatigue crack propagation life of steel wire considering fretting wear was established based on theories of tribology and fracture mechanics and applying the finite element method, iterative method and virtual crack closure technology, which was validated by fretting fatigue tests. The results showed that the prediction of fretting wear evolution of steel wire using the wear coefficient at the stabilized stage of fretting fatigue ensured the prediction accuracy. The mode I crack propagation was mainly present during fretting fatigue of steel wire. Predicted fretting fatigue crack propagation life of steel wire considering fretting wear was consistent with the experimental value, which validated the prediction model.