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A new fretting fatigue testing machine design, utilizing rotating–bending

principle approach

Article  in  The International Journal of Advanced Manufacturing Technology · February 2014

DOI: 10.1007/s00170-013-5457-0

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A new fretting fatigue testing machine
design, utilizing rotating–bending principle
approach

E. Zalnezhad, Ahmed A. D. Sarhan &

P. Jahanshahi

The International Journal of

Advanced Manufacturing Technology

ISSN 0268-3768

Int J Adv Manuf Technol

DOI 10.1007/s00170-013-5457-0

1 23
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1 23
 Author's personal copy
Int J Adv Manuf Technol
DOI 10.1007/s00170-013-5457-0

ORIGINAL ARTICLE

A new fretting fatigue testing machine design, utilizing

rotating–bending principle approach
E. Zalnezhad & Ahmed A. D. Sarhan & P. Jahanshahi

Received: 5 February 2012 / Accepted: 24 October 2013

# Springer-Verlag London 2013

Abstract Fretting fatigue is a phenomenon which occurs 1 Introduction

when two parts are contacted to each other and one of those
parts or both are subjected to cyclic load. Fretting decreases Fretting is the surface damage that occurs when contacting
fatigue life of materials drastically by half or even more. surfaces between mating bodies experience an oscillatory mo-
Therefore, investigation of fretting fatigue life of materials is tion of small amplitude. When fretting occurs under fluctuating
an important subject. Fretting fatigue tests are usually per- loading condition, the process is termed fretting fatigue.
formed using universal hydraulic testing devices. In this work, Fretting fatigue increases the tensile and shear stresses at the
a rotating bending apparatus for fretting fatigue test is intro- contact surface producing surface defects which can act as
duced in which the cyclic load is provided by an adjustable stress concentration sites [1]. Fretting fatigue is a common
eccentric load. The apparatus called RBFF machine which is occurrence in multitude of components or structures involving
the abbreviation of rotating bending fretting fatigue. The riveted joints, bolted joints, wire ropes, and dovetail joints of
eccentric load is measured by load cell. The coefficient of gas turbine engine [2–4]. Fretting decrease fatigue life of
friction and fretting load are measured by foil strain gauges materials drastically. When fretting is applied on the surface
using a Wheatstone bridge configuration. The performance of of materials, the stress concentration at fretting region is in-
the machine is verified with doing a comparison between creased and micro crack appears and starts to grow. Cracks may
fatigue lives of a number of AL7075-T6 alloy samples on a assert in some cases, while in others, they may propagate,
Shimadzu rotating bending fatigue testing machine and RBFF. eventually causing failure. Regions such as in the dovetail joint
The results shows very close assent between the operations of in a turbine engine, where the blade and disk are in contact and
the two testing rigs. The main privileges of RBFF are its undergo vibratory stresses, are especially susceptible to fretting
simplicity with respect to universal devices, cheapness and, fatigue and have been subject of studies for a number of years
coefficient of friction (between pads and specimen) evaluation [5, 6]. Structural members at macro- or micro-size scales by
during the test. The RBFF also has the capability of being used design or default involve contact between similar or dissimilar
for any other soft and hard metals. It can be advanced further materials. Normally, the contacting surfaces are pressed togeth-
for high and low temperature. er by a normal load, P and when one of the contacting bodies is
subjected to an externally applied cyclic load, σ a a small
Keywords Fretting fatigue . Al7075-T6 alloy . Rotating amount of relative displacement takes place at the contact
bending fatigue interface and induces frictional force, f f at the contact zone.
The combination of normal load, frictional force, and cyclic
axial load develops a localized stress field at the contact inter-
E. Zalnezhad (*) : A. A. D. Sarhan
face, which leads to early nucleation of micro-cracks. The
Department of Mechanical Engineering, Faculty of Engineering,
University of Malaya, Kuala Lumpur 50603, Malaysia process of crack initiation at the contact interface with fretting
e-mail: [email protected] due to the cyclic axial loading is termed as fretting fatigue. The
fretting has been observed in riveted and flanged joints, steam
P. Jahanshahi
and gas turbines, wire ropes, biomedical implants,
Photonics Research Group, Department of Electrical Engineering,
Faculty of Engineering, University of Malaya, Kuala Lumpur 50603, micromechanical devices, ball bearings, and springs [7, 8].
Malaysia Arora et al. [5, 9] designed a fretting fatigue test rig in such a
 Author's personal copy
Int J Adv Manuf Technol

Fig. 1 Schematic of rotating– Fretting ring Electrical rotating

bending fretting fatigue test A pair of springs connector
machine from different views. a 7 to apply the load
3Dview of RBFF. b Front and
side views of RBFF

8 Chuck

4 3
2

6
5

(a) 3Dview of RBFF

Compressive
Load cell for Pulley for applying the
measuring the bending load
bending load
Adjustable bearing for
applying the load

Compressive
load cell

(b) Front and side views of RBFF

way that the initiated small cracks at the contact edge could be remote cyclic load that leads to eventual specimen cracking
directly observed and the crack propagation could be recorded and failure. The main motivation behind the development of
using the video microscope. The fretting fatigue test jig is this device was to determine conditions that cause fretting-
mounted on an 810 MTS material test system of 100 kN induced cracks to form in advanced turbine engine materials
capacity. On the loading jig, two frictional force load cells are
mounted. Normal force to the specimen–pad interface is ap-
plied through the normal force load cell by turning the loading
bolt [10, 11] studied the crack growth in a shrink-fit assembly
subjected to rotating bending. They observed a significant
reduction in the fatigue crack propagation life, up to 50 %, as
compared to an equivalent pure bending case. Rajasekaran and Digital microscope
Nowell [12, 13] developed a biaxial fatigue experiment capable Load cell displayer
of simulating the loading experienced by a dovetail blade root RPM displayer
in an aircraft gas turbine. The device can simulate the effects of
centrifugal loading, disk expansion force, and blade vibration
[14]. Ebara and Fujimura [15–17] used a fretting fatigue spec-
imen with bolt-tightened shoe on both sides of the plate. The
contact load was gained from the strain measured by a strain
gauge fixed at the bolt center. A fretting test apparatus has been
designed at Purdue University in USA to study fretting fatigue
at elevated temperature. The fretting fatigue specimen is Cutoff switch
clamped between two contact pads and then loaded with a Fig. 2 Rotating bending fretting fatigue test machine
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Int J Adv Manuf Technol

such as the rash of high cycle fatigue engine failures that led to Additionally, the frequency of these types of machines is low
the grounding of many aircrafts. and, consequently, the fatigue tests are time consuming [7, 10].
Fretting fatigue may reduce the endurance limit of a compo- In this work, a new design of rotating bending fretting
nent by half or more, in comparison to the normal fatigue fatigue test apparatus is introduced. The design and construc-
conditions. Unfortunately, there is not a universal machine avail- tion are much simpler and more economical than the fatigue
able in the market for fretting fatigue testing. Generally, the test machines described above. A rotatable fretting ring ac-
universal hydraulic fatigue testing devices are used for this sort companies with friction pads and strain gauges are designed to
of testing. However, these universal machines require accesso- evaluate the friction coefficient between friction pads and
ries for producing contact pressure needed for fretting fatigue. specimens during fatigue test. Furthermore, the performance

Fig. 3 Schematic of parallel

specimen with two points loading
accompanies with moment, stress
graphs at slender region, and
analysis of stress in different
situation. a Schematic of
specimen-two points loading. b
Distribution of stress in the
narrow part of specimen. c Stress
concentration under friction pads
without applying loads (F). d
Combination of stress distribution
and concentration on specimen

Pulley for applying

the bending load

(a) Schematic of specimen-two points loading

(b) Distribution of stress in the narrow part of specimen

Friction pads

(c) Stress concentration under friction pads without applying loads (F)

Friction pads

(d) Combination of stress distribution and concentration on specimen

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Int J Adv Manuf Technol

Strain gauge Fretting load adjusting

Strain gauges for
friction pads

Fretting fatigue specimen

Electrical rotating
connector

Fretting pads (strain gauge) Fretting ring

(a)

Strain gauges for

Data Acquisition fretting ring

Fig. 6 The schematic of the strain gauges connections with electrical

rotating connector accompany with Wheatstone bridge circuits

mounted to the base for generating rotational movement

means, a pair of motor couplings (3) connecting a motor shaft
(4) to the motor, a plurality of first bearings (5) mounted to the
base for holding the motor shaft, a chuck (6) connected to the
(b) motor shaft for gripping a fretting fatigue specimen, a frame
Fig. 4 a Schematic and b real images of the fretting fatigue test rig including a plurality of rods and holders, a second bearing
coupled to a bearing holder for supporting the test specimen, a
of the new design (rotating bending fretting fatigue; RBFF) pulley including a lead screw (7), a load cell (8) connected to
was examined by comparative investigation on fatigue life of
Al7075-T6 alloy using Shimadzu fatigue test machine. 400
350
300
Force (N)

2 Description of RBFF machine principles 250

200
The present apparatus relates to a fretting fatigue machine 150
using rotating–bending method are designed by the authors 100
in this work. A general view and a schematic of the device 50
(called in this paper as RBFF) are depicted in Figs. 1 and 2,
0
respectively. The device consists of a base (1), a motor (2) 0 50 100 150 200 250 300 350 400
Strain (µm)

(a)
160
140
120
Force (N)

100
80
60
40
20
0
0 30 60 90 120 150
8mm Strain (µm)

(b)
Fig. 5 The fretting pads Fig. 7 Calibration curves for (a) fretting ring and (b) friction pads
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Int J Adv Manuf Technol

the lead screw for measuring the force applied from the lead 2.1 Variable load and eccentric system
screw to the test specimen, the instrumentation which consists
of load cell for measuring the axial forces imposed on the The bending load is applied to the specimen by a pulley,
specimens, the inverter for varying the frequency, and fatigue which has the capability of being variable in eccentric mech-
cycles counter. Also, there is an adjustable support between anism maximum 2 mm, shown in Fig. 3a. The mechanism
chuck and last bearing (it is placed at the end left side of consists mainly of a pulley, rod, and bearing. This amount of
machine). The support has two springs to balance the bending displacement is sufficient for most of fretting fatigue tests and
load. Another compressive load cell is located under the ball in particular if the deformations are supposed to remain within
bearing of support, to adjusting the loads (making the loads the elastic range.
equal) on the fretting fatigue specimen.
The basis functionality of this machine is applying equal 2.2 Contact loading system
opposite loads at different places on the specimen to get high
stress in the narrow part of it, so with adding the friction pads The pressure required to produce fretting is transmitted to the
which is located at the middle of the fretting parts, maximum contact area, via a calibrated proving ring, shown in Fig. 4, to the
stresses are placed under the friction pads. The three- contact area through the loading pads. Each pad (see Fig. 5) has
dimensional (3D) model of fretting fatigue specimen, pads, two bases (contacting surfaces) through which load are exerted
and bearing were modeled according to the ISO-1143:2010 on the specimen. The pad span which is defined as the distance
(E) in ABAQUS 6.10-1 (ABAQUS Inc., Providence, RI, between the centers of the fretting pad feet was chosen to be
USA). The specimen was meshed by 3D quadratic tetrahedral 7 mm. The pad's base has a width of 2 mm. The pads were made
element. Mesh sizes decreased in order to carry out the con- of stainless steel 410 with σult=700 MPa and σy=420 MPa.
vergence test and mesh independency to achieve the higher The pads are revolved accompanied with the specimen, as this
accuracy of results in ABAQUS. The fretting specimen was may affect the sliding oscillations between specimen and pads.
considered as linear elastic material with young modulus of The normal load is induced by an adjusting screw and is
72 GPa. The Poisson's ratio was considered constant and measured using a Wheatstone bridge circuit. Four strain
equal to 0.3. The bearing and pads were considered as rigid gauges were bonded to the proving ring and wired to create
material. Surface to surface contact with the small sliding was a Wheatstone bridge circuit to measure the elastic strains
considered between the pads and specimen, and bearings and induced by loading the ring through the load adjusting screw.
specimen. The friction coefficient of 0.3 was assigned to the Figure 6 shows the schematic of the strain gauges connections
interfaces of pads and specimen. However, the interaction in with electrical rotating connector accompanied with
the specimen and bearings was frictionless. The specimen Wheatstone bridge circuits. The calibration curve of load
movement was restricted in axial direction. Meanwhile, bear- versus strain was obtained by 10 N standard weights for the
ings and pads movement was limited in axial and perpendic- ring (see Fig. 7a). The normal load can be measured from the
ular directions. The loads magnitude which applied on the curve shown in Fig. 7a.
bearings and pads were 150 and 100 Mpa, respectively. The friction force, created by normal force and sliding
Figure 3a, b, c, d show the moment and stress graphs accom- movement between the specimen and pads, was calibrated
pany with finite element analysis using ABAQUS software before testing. Four strain gauges, two in direction of friction
for the unplaced and placed friction pads on the specimen. and two at right angle to this direction, were bonded to the
Figure 3d also shows that the maximum stress is under friction pads to measure the elastic strain induced by friction force.
pad when specimen is under bending loads. Combination of This type of strain gauge configuration would cancel out the
stress concentration and stress distribution can provide earlier effect of temperature rise due to the fatigue loading in contact
fatigue failure. area. The pads were clamped to the specimen by the same

Bearings Coupling
Chuck

d
b

F
Fig. 8 Schematic of the main shaft accompany with the position of bending force and shaft's supports
 Author's personal copy
Int J Adv Manuf Technol

Table 1 Chemical composition of AL 7075-T6 (wt%) 3 Design of RBFF machine's parts

Al Cu Si Mg Cr Zn Mn
3.1 Design of the main shaft
90.94 1.85 0.47 1.8 0.28 4.6 0.06
The most important issues in designing of a shaft are stress
and deflection. With choosing proper material and calculation
of the shaft's diameter, this problem can be solved. A sche-
normal loads as was to be used in real experiments. The
matic of the main shaft, the supports, and the bending force
specimen was then pulled by constant load using INSTRON
accompanying their locations are depicted in Fig. 8. In order
tensile testing machine. The strain induced by this load was
to minimize deflections, steel is the logical choice for a shaft
measured by Wheatstone Circuit Bridge attached to the pads.
material because of its high modulus of elasticity [15]. In this
This procedure was repeated for different loads and the cali-
research work, the material of main shaft is selected SAE1020
bration curve of friction force versus strain was obtained. The
steel, which has σ ut =65 kpsi, S y =38 kpsi. The mean shaft's
calibration curve is depicted in Fig. 7b. The coefficient of
deflection was obtained by Eq. (1), where y is the deflection of
friction (μ ) can be determined by dividing the maximum
the shaft, E is the modulus of elasticity, and I is the momentum
measured friction force at a fretting pad foot by the contact
of inertia.
load at that foot.
F ðb þ c þ d Þ3
y¼− ð1Þ
3EI
2.3 Instrumentation
The shaft's diameters were obtained by Eq. (2), where d is
There are two load cells in RBFF machine for applying the
diameter of the shaft, N f is the safety factor, k f is the fatigue
equal loads on the specimen. The bending load is measured by
stress-concentration factor, M a is the alternating bending mo-
a SMSB type 50 kg load cell (see Fig. 1b). The variation of
ment, S f is the fatigue strength, k fsm is the fatigue factor for
load monitored by a digital displayer and can be transferred to
mean torsional stress, T m is the transmitted torque which was
a computer for further processing. The second load cell, which
calculated by Eq. (3), and S y yield stress [18].
is placed bellow the adjustable bearing (support), is used to
measure the load which is needed to convey the maximum ( "
2
2 #) 13
32N f Ma Tm
stress to the middle of the narrow part of the specimen. This d¼ kf þ k fsm ð2Þ
load should be equal to bending load for avoiding any shear π Sf Sy
force in specimen. The frequency of the device can vary using
an inverter up to a maximum of 50 Hz. The machine is
equipped with a cutoff switch which acts when specimen P
Tm ¼ ð3Þ
break down to avoid unnecessary revolution. There is a sta- ω
tionary microscope to see and capture an image from the
cracks and propagation of cracks under the friction pads on Where P is the power of motor which is 1 hp and ω is
the specimens when the RBFF machine is turned off. An angular velocity which is 2,800 rpm.
electrical slip ring is used to transfer data from rotating strain Equations (4) and (5) are state fatigue strength and endur-
gauges to stationary outlets. A data acquisition is utilized to ance limit of the material. Where Cs are correction factors; in
measure coefficient of friction (data come from strain gauges) this case, the amount are equal to one, except C surface , which
with a computer. is considered 0.84 for surface of steel [18].

Table 2 The plain fatigue and

fretting fatigue lives of Al7075- Stress (MPa) Shimadzu RBFF Plain fatigue
T6 alloy using RBFF and error %
Shimadzu fatigue test machines Plain fatigue Fretting fatigue

150 9751421 10311326 6456124 5.43

180 5847209 6343251 2784521 7.82
200 3461594 3346152 1788458 3.45
220 1294742 1356319 799564 4.54
250 560637 592076 473618 5.31
280 419304 387455 218579 8.22
 Author's personal copy
Int J Adv Manuf Technol

350 1000
Plain Fatigue Fretting Fatigue 2.78%
10000
Bending stress (MPa)

SHIMADZU RBFF
300

Number of cycle
8000
250 8.22%
6000
200
5.31%
4000
150
4.54%
2000
3.45% 7.82% 5.43%
100
1.00E+05 1.00E+06 1.00E+07 0
150 180 200 220 250 280 300
No. of cycle to failure
Bending stress (MPa)
Fig. 9 S/N curve of fatigue and fretting fatigue lives of Al7075-T6 alloy
using RBFF machine Fig. 11 Comparison between fretting fatigue lives of Al7075-T6 alloy
using Shimadzu and RBFF machines accompany with error percentage

S f ¼ S e ¼ C load C size C surface C temp C reliable S e0 ð4Þ holder are 9,500 and 22,000 rpm, respectively, which are
higher than the operating speed of 2,800 rpm.

S e0 ¼ 0:5S ut ð5Þ
4 Experimental details to investigate the RBFF machine
performance
3.2 Design of the bearings
Aluminum alloy 7075-T6 was used in this investigation. The
There are three bearings in RBFF machine, two bearings for material's composition obtained using EDX apparatus is illus-
supporting the main shaft and one bearing to support the trated in Table 1. From a number of tensile tests, the yield
specimen. The aim of selecting the appropriate bearings is to stress and ultimate strength of Al7075-T6 were obtained as
find the bearings fatigue live at main shaft and specimen follows: σy =520 MPa and σut =590 MPa, respectively. The
holder. The maximum moment is applied on point B, as it round shape specimens used in this work were prepared in
can be seen in Fig. 8; it means that the support at point B accordance with ISO standard. Fretting fatigue pads were
suffers more force than other support at point A. From the fabricated from stainless steel 410 plate. The specimens were
calculation of the proper diameter for the shaft from previous gripped and loaded rotationally in a rotating bending fretting
section, the inner diameter of bearings is known. Using Eq. 6, fatigue test apparatus. When a fatigue specimen is subjected to
the fatigue lives of bearings are found [18]. cyclic stresses, fretting between the contact pads and specimen
is generated.

3 Plain and fretting fatigue testing were carried out at room
C
L¼ ð6Þ temperature in a two-point loading rotating bending machine
R
(R =−1) under constant stress amplitude at a rotational speed
of 3,000 rpm. The relationship between the stress amplitude
Whereas L is fatigue life, C is dynamic load rating, and R is and the number of cycles to failure for the all the condition
applied load on bearing A. The fatigue lives of bearings are analyzed is defined by Eq. 1 [19, 20].
around 9E10 for bearing A, 3E11 for bearing B, and 5.5E9 for
bearing at point D, which support the specimens, respectively. S ¼ ANbf ð7Þ
Bearings limiting speed for shaft supports and specimen
Where S is stress amplitude, A is fatigue strength coeffi-
0.59 250 MPa
0.58 cient, b is fatigue strength exponent, and N f is number of
Coefficient of friction

0.57
0.56
cycles to failure.
0.55
0.54
0.53
0.52
0.51 5 Fretting fatigue test results
0.5
0.49
0.48 In order to examine the performance of the fretting fatigue
0.47 ×1000
0 50 100 150 200 250 300 350 400 450 500 550 testing apparatus, RBFF, a number of specimens were tested
Number of cycles in this investigation. The experiments were conducted for
Fig. 10 Friction coefficient versus fretting fatigue life stress ratio of R =−1, 50 Hz (for RBFF) at a constant contact
 Author's personal copy
Int J Adv Manuf Technol

Fig. 12 Cross-section view of

fracture specimens under fretting (a) (b)
fatigue a at bending stress Fretting zone Fretting zone
200 MPa and 1.5E106 cycles and
b at bending stress 300 MPa and
1.2E105 cycles
Tensile zone Tensile zone

Fretting zone Fretting zone

1mm 1mm

force of 1,200 N, and working stress amplitudes of 150– large-amplitude stress cycles show up as larger striations than
300 MPa. A number of tests were also performed using the more frequent small amplitude once, indicating that higher
rotating bending fatigue (Shimadzu, Japan) under the same stress amplitudes cause larger crack growth per cycle [18, 21].
conditions as stated above for comparison purposes. The plain
fatigue and fretting fatigue results are given in Table 2. As the
results indicate, the fatigue lives obtained from the Shimadzu 6 Conclusions
testing machine and RBFF are very close. Figure 9 shows S/N
curve of plain fatigue and fretting fatigue lives of Al7075-T6 A newly fretting fatigue testing machine design under rotat-
alloy using RBFF machine. As it can be seen from the figure, ing–bending approach is presented by the authors in this
fretting decreases the fatigue life of Al7075-T6 alloy drasti- work. The machine is capable of exerting adjustable bending
cally. The friction coefficient is calculated from the relation and contact loads. The frequency of the apparatus can be
μ =F /P, in which P is the normal force applied by the varied up to 50 Hz. The performance of the machine is
adjusting bolts to the pads and is kept constant throughout validated by fatigue tests which carried out using the
the experiments (P =1,200 N). F is also measured from the Shimadzu fatigue testing machine. The result shows a close
experiments using the calibration curve shown in Fig. 7b. A agreement between RBFF and Shimadzu fatigue testing ma-
typical curve of friction coefficient versus fretting fatigue life chine. The device has a simple variable eccentric system for
is shown in Fig. 10. Figure 11 presents comparison between fluctuating loading. The system is pure mechanical with no
fatigue lives of Al7075-T6 alloy using Shimadzu and RBFF need for hydraulic systems which are sophisticated, expen-
machines accompanied with error percentage. As it can be sive, and slow. The machine is cheap, light, small, and man-
seen from the figure, the results are in close agreement and the ageable. The device is well instrumented for varying and
maximum and minimum errors obtained are 8.22 and 2.78 %, measuring axial loads, fatigue cycles, and test frequency.
respectively. Furthermore, RBFF machine has the capability to measure
Fracture surface of tested specimens were examined using the friction coefficient between specimen and fretting pads,
optical microscopy. A typical fractured specimen and cross- while the specimen is rotating by using an electrical rotating
sectional views are illustrated in Fig. 12. The figures clearly connector.
indicates that the fracture surface consists of two quite distinct
regions; a fatigue zone created by crack propagation and a Acknowledgments The authors acknowledge the financial support
tensile region which gives rise to fracture of specimen when it under the research grant with no. UM. TNC2/IPPP/UPGP/261/15
is sufficiently weakened by the crack zone development. (BK030-2013) from the University of Malaya, Malaysia.
Crack-propagation growth rate is very small, on the order of
10−8 to 10−4 in per cycle, but this adds up over a large number
of cycles. If the failed surface is viewed at high magnification, References
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