A multiaxial stress-based critical distance methodology to estimate fretting fatigue life

Abstract This work presents a methodology for fretting fatigue life estimation based on the evaluation of a multiaxial fatigue parameter at a critical distance below the contact surface. The fatigue parameter is defined using the Modified Wohler Curve Method together with a measure of shear stress amplitude based on the Maximum Rectangular Hull concept. To apply the approach in the medium-cycle fatigue regime, the critical distance is assumed to depend on the fatigue life. Available fretting fatigue experiments conducted on a cylinder-on-flat contact configuration made of Al–4%Cu alloy were used to evaluate the methodology. Most of the fatigue life estimates were within factor-of-two boundaries.