Fretting Fatigue Failure Simulation with Scripting in Abaqus

Introduction to Fretting Fatigue Failure

Finite Element Method (FEM) simulations are indispensable for understanding and predicting fatigue behavior in mechanical systems. This tutorial package, on Fretting Fatigue failure Simulation, equips researchers and engineers with tools to model, analyze, and automate simulations of Fretting Fatigue failure phenomena. By combining step-by-step guidance with theoretical insights, the package bridges the gap between academic knowledge and practical application.

The main objective is to develop a 2D Fretting Fatigue configuration in Abaqus, focusing on creating models, refining mesh methodologies, and obtaining accurate contact stress data. A unique feature of this package is its emphasis on the use of the command prompt for automating post-processing tasks. You can use this tool to extract Field Outputs and create custom Field Output parameters based on simulation results. Additionally, users will learn automation techniques to modify key simulation parameters, such as the Coefficient of Friction (CoF), submit different simulation scenarios, and extract Output data from every simulation.

FEM is an indispensable complement for Fretting Fatigue since it is a robust tool for solving complex engineering problems involving stress, strain, and fatigue. On the other hand, Fretting Fatigue Failure is a phenomenon developed from small oscillatory movements between contacting surfaces. It creates a unique challenge in predicting crack nucleation. This package emphasizes understanding this challenge and applying advanced FEM techniques to address them. This makes it a valuable resource for anyone working in materials science, mechanical design, or structural integrity analysis.

Lesson 1: Package Overview

The first lesson introduces the Fretting Fatigue Failure Simulation Package and provides a foundation for the topics developed in posterior lessons and workshops. It covers key concepts such as the Fretting phenomenon, its causes, failure modes, its impact on engineering components, and the available techniques to predict crack nucleation on the components. The roadmap of the simulation workflow guides users through geometry and material definition, loading steps and boundary condition setup, meshing techniques, and various methods to automate simulation parameters and results extraction using Python scripting. This overview prepares users to explore the theoretical and practical aspects in the following sections.

Lesson 2: Fretting Fatigue Failure Phenomenon

The second lesson deepens into the fundamentals of Fretting Fatigue failure and its implications for mechanical components. We analyze the phenomenon of fretting in detail, examining the conditions under which it occurs and its associated failure mechanisms. For instance, we commonly observe fretting in aerospace components, where cyclic loading and micromovements degrade contact surfaces.

Key parameters influencing Fretting Fatigue failure severity, such as contact pressure, slip amplitude, and the Coefficient of Friction are thoroughly discussed. Real world examples, like the failure of dovetail joints in turbine blades, illustrate these principles.

Additionally, we will provide students with an exploration of the different methods and parameters used to predict Fretting Fatigue crack nucleation. We introduce users to Critical Plane (CP) parameters, emphasizing their unique characteristics that make them indispensable in Fretting Fatigue Failure analysis. We explain the diverse types of CP parameters and their applications in predicting crack nucleation.