Fretting is a surface damage phenomenon and is typically observed at the contact
interfaces such as bolted, gasketed joints, and the like. It occurs due to the
combined effect of normal and tangential loads, which produces a small-amplitude
relative sliding between two components that are held together using clamping
forces. Fretting-related failures are also observed in multiple components of an
internal combustion engine. This article presents the fretting fatigue damage
evaluation of a single layer head gasket using a relative new approach, i.e.,
deviatoric strain amplitude-based method, further combined with the Ding’s
empirical parameter D
fret2.
Corresponding fretting damage results are compared with the traditional approach
based on the Ruiz’s parameter F1. To evaluate the consistency
in the predicted results, the correlation study is carried out for three head
gaskets of three different high horsepower engine platforms and very good
correlation is observed between F1 damage results, fatigue life
results obtained using the deviatoric strain amplitude-based parameter corrected
for Ding’s parameter, D
fret2, and the actual fretting damage observed on the
actual head gasket. Stabilized stress-strain results obtained using multilinear
kinematic hardening model (MKIN) are considered for the fatigue life
evaluation.
Further, alternative approach based on the “fretting limit line” is also proposed
for simpler absolute and comparative fretting fatigue damage evaluation across
the different designs. Overall, as demonstrated in this work, deviatoric strain
amplitude-based parameter combined with Ding’s parameter, D
fret2, is an effective approach toward the absolute
and comparative fretting fatigue damage and associated life evaluation of actual
engine components.
