Fretting Wear, Fretting Fatigue and Damping of Structures: Design Engineering Hand Book Learned from Failure Cases (Solid Mechanics and Its Applications, 276)

Preface
Contents
1 Case Studies of Fretting Failures
	1.1 Fretting Fatigue Damage on Turbine Generator Rotors [1]
		1.1.1 Accident Situation
		1.1.2 Investigation of the Cause
	1.2 Fretting Fatigue Failure of Fan Blades
		1.2.1 2016/08/27, Southwest Airlines Flight Number 3472, CFM56-7B24 Turbofan Engine Trouble [7]
		1.2.2 2018/02/13, United Airlines Flight Number UA1175, Boeing 777–200, PW4077 Turbofan Engine Trouble [11–13]
	1.3 Fretting Fatigue Failure of Steam Turbine Rotor Blades [14–16]
		1.3.1 Accident Situation [14]
		1.3.2 Investigation of the Cause
	1.4 Fretting Fatigue Failure of Wheel/Axle-Hub Fastening Part
		1.4.1 Accident Situation [16–20]
		1.4.2 Investigation of the Cause
	1.5 Fretting Fatigue Failure of the Fastening Part of the Roller Coaster
		1.5.1 Accident Situation
		1.5.2 Investigation of Cause (See Chap. 6)
		1.5.3 Countermeasure Technology (See 6.2.1)
	1.6 Fretting Fatigue Failure of a Nuclear Power Plant Steam Generator [23]
		1.6.1 Accident Situation
		1.6.2 Investigation of the Cause
		1.6.3 Countermeasures
	1.7 Nuclear Cooling Fan Keyway Fretting Fatigue Damage [27]
		1.7.1 Accident Situation
		1.7.2 Investigation of the Cause
		1.7.3 Maker’s Final Measures
		1.7.4 Author’s Recommended Measures
	References
2 Overview of Fretting Damages
	2.1 What is Fretting Damage?
		2.1.1 The Features of Fretting Damage
		2.1.2 Mechanical Conditions on Fretting Damage
	2.2 Fretting Damage Evaluation and Strength Design
		2.2.1 Combined Evaluation Method Considering Both Wear and Fatigue Damage
		2.2.2 Combined Evaluation Process of Fretting Fatigue Strength/life Considering Both Wear and Crack Propagation
	References
3 The Mechanisms and Mechanics Analyses of Fretting Wear and Fretting Fatigue
	3.1 Mechanics Analyses and Experimental Observations of Fretting Wear
		3.1.1 Contact Pressure Under Normal Force Load
		3.1.2 Contact Stress Under Normal and Tangential Loadings
		3.1.3 Slip Amount and Wear Amount
		3.1.4 Experimental Observation
	3.2 Example of Mechanical Analysis of Fretting Wear
		3.2.1 Basic Formula for Loosening Due to Microslip
		3.2.2 Loosening Behavior Under Cyclic Rotational Loadings
		3.2.3 Loosening Behavior Under Cyclic Axial Loadings
		3.2.4 Analysis of Loosening Rate of Bolted Joints Under Cyclic Axial Loading and Comparison with Experimental Results [19, 20]
		3.2.5 Material Factors and Environmental Factors for Fretting Wear
		3.2.6 Mechanical Analysis of Fretting Fatigue
	References
4 Example of Strength Design Considering Fretting
	4.1 Strength and Life Evaluation Using Macroscopic Stress
		4.1.1 Fretting Fatigue Problem of the Fastened Body in a Bolted Joint that Receives a Bending Load [1]
		4.1.2 Fretting Fatigue in the Connecting Rod Bolt
		4.1.3 Failure of Axle Bolts in Roller Coasters [1, 4, 5, 6]
	4.2 Strength and Life Evaluation Using Microscopic Stress
		4.2.1 Fretting Fatigue of SUS304 Steel Balls and Steel Plates [11, 12]
		4.2.2 Fretting Fatigue of SUJ2 Steel Ball and Glass Plate [21, 22]
	References
5 Prevention Technology for Fretting Damage
	5.1 Anti-Fretting Design Method From the Viewpoint of Mechanics [1, 2]
		5.1.1 Influence of Contact Pressure
		5.1.2 Influence of the Shape of the Contact Edge
	5.2 Stress Release Groove
		5.2.1 Stress Release Grooves in Round Bars with Local Contact [9]
		5.2.2 Stress Release Grooves in Plane Contact Fretting [10]
	5.3 Improvements of the Contact Surface
		5.3.1 Reducing the Rigidity of the Contact Surface
		5.3.2 Application of Surface Compressive Residual Stress
	References
6 Maintenance Management of Fretting Damage and Health Monitoring Technology
	6.1 Maintenance Management Technologies of Railway Axle Shafts [1, 2]
		6.1.1 Ultrasonic Flaw Detection of Shinkansen Axle Shafts
		6.1.2 Continuous Monitoring System on Axle Crack Applying the Leak-Before-Break (LBB) Concept
		6.1.3 Evaluation of the Applicability of the Leak-Before-Break (LBB) Method on the Crack Monitoring System on the Train Bogie Frame [8, 10]
	6.2 Maintenance Management of Jet Engine Fan Blades
		6.2.1 Thermal Acoustic Imaging Inspection (TAI) Process
		6.2.2 Applicability of the Leak-Before-Break (LBB) Crack Continuous Monitoring System to Fan Blades
	6.3 Maintenance Management of Screw Joints [11]
		6.3.1 Sensor and Experimental Preparation
		6.3.2 Measurement Results
		6.3.3 Development of Online Health Monitoring
	References
7 Fretting Fatigue Under Torsional Loads [1]
	7.1 Experimental Study [1]
	7.2 Analytical Studies
		7.2.1 Overview of Analysis
		7.2.2 Friction Coefficient of the Contact Surface
		7.2.3 Contact Pressure Distribution on the Mating Surface
		7.2.4 Stress Distribution
	7.3 Fatigue Strength Evaluation of Various Interference Fit Joints
	References
8 Fretting Fatigue of Materials Other Than Steel
	8.1 Fretting Fatigue of Titanium Alloy
		8.1.1 Fretting Fatigue of Ti–6Al–4V Alloy [1, 4]
		8.1.2 Fretting Fatigue of Ti-6242 Alloy [7]
	8.2 Fretting Fatigue of Aluminum Alloy
		8.2.1 2024-T351 Aluminum Alloy [8–10]
		8.2.2 Aluminum Alloy for Welded Structure (A7N01-T6) [13]
	References
9 Fretting Damage and Structural Damping
	9.1 Mechanical Model and Analysis Evaluation Target
	9.2 Evaluation of Fretting Fatigue with the Friction Transfer-Type Mechanical Model (Low Contact Pressure and Large Slip)
		9.2.1 Test Method
		9.2.2 Test Results and Discussion
		9.2.3 Analytical Evaluation of Fretting Fatigue Strength
	9.3 Evaluation of Fretting Wear with the Friction Transfer-Type Model (Low Contact Pressure, Large Slip)
		9.3.1 Basic Formula of Fretting Wear
		9.3.2 Wear Test Method
		9.3.3 Wear Test Results and Quantitative Evaluation of Fretting Wear
	9.4 Friction Model of the Contact Surface and Examination of the Natural Frequency and Structural Damping by Vibration Test
		9.4.1 Vibration Test of the Dovetail Model
		9.4.2 Consideration of the Contact Surface Friction Model and Vibration Test Results
	References