Numerical study of the effects of residual stress on fretting fatigue using XFEM

Residual compressive stress can improve fretting fatigue strength. In this paper, the effects of residual stress on fretting fatigue of Al 2024-T351 alloy specimens are studied using a numerical approach. The extended finite element method combined with the cyclic cohesive zone model is adopted to model fretting fatigue crack growth behavior. It is shown that residual stress changes the fretting fatigue crack growth path and enhances fretting fatigue life. Crack initiation angle, depth of knee point, crack initiation life, crack propagation life and total life are greater for specimens with residual stress compared to specimens without residual stress. The effects of residual stress are more remarkable for specimens with a high intensity of residual stress. However, the effects of residual stress reduce at a high bulk load level.