Micro-mechanical modelling of fretting fatigue crack initiation and wear in Ti–6Al–4V

A micro-mechanical modelling methodology is presented for predicting fretting fatigue crack nucleation in Ti–6Al–4V. The methodology is based on a combination of (i) a unit cell crystal plasticity model of Ti–6Al–4V, (ii) a frictional contact model of an experimental fretting wear configuration, and (iii) implementation of a microstructure-sensitive fatigue indication parameter for prediction of crack nucleation. A novel micro-mechanical method for wear prediction is presented. A key finding is the important role of cyclic micro-plasticity in ostensibly elastic loading regimes in fretting wear, resulting in significant effects on distributions of salient fretting contact variables such as contact pressure.