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Comparative Analysis of Multi-Axial Fretting Fatigue Crack Initiation Life Prediction Models Modified by Fretting Damage Parameters

Xiaoling Shi, Ning Wang, Debao Hu
Vol.8, No.6, pp.23-32, 2026 DOI: 10.62051/ijmee.v8n6.03 September 2, 2026
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Abstract: Fretting fatigue is a special fatigue failure mode induced by the coupling of micro-amplitude relative slip and multi-axial cyclic loads on contact pairs of mechanical structures. Its crack initiation is characterized by concealment, randomness and severe damage, serving as a core trigger for the failure of key structures in aerospace, rail transit, energy equipment and other fields. Traditional uniaxial fretting fatigue life prediction models fail to account for the coupling effect of multi-axial stress and strain as well as the synergistic damage mechanism of fretting wear and contact slip, suffering from low prediction accuracy and limited applicable scenarios. Based on the critical plane fatigue theory and combined with the damage characteristics of fretting contact, this paper introduces three correction parameters, namely relative slip amplitude, contact stress gradient and surface wear damage, to establish a multi-axial fretting fatigue crack initiation life prediction model. The model is verified via finite element simulation and classical fretting fatigue test data. The results show that the modified model can effectively characterize the evolution law of composite damage in fretting contact zones under multi-axial loads. Compared with the traditional FS critical plane model and Ruiz damage model, the life prediction error is controlled within 15%, which greatly improves the prediction accuracy of fretting fatigue crack initiation life under complex working conditions. The proposed model can provide theoretical support for fatigue life evaluation and structural optimization design of precision mechanical contact structures.
Keywords: Fretting Fatigue, Multi-axial Load, Damage Parameter Correction, Critical Plane Method, Crack Initiation, Life Prediction
APA Citation: Xiaoling Shi, Ning Wang, Debao Hu (2026). Comparative Analysis of Multi-Axial Fretting Fatigue Crack Initiation Life Prediction Models Modified by Fretting Damage Parameters. International Journal of Mechanical and Electrical Engineering, 8(6), 23-32. https://doi.org/10.62051/ijmee.v8n6.03

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