Numerical simulation and experimental verification of fatigue crack propagation in high-strength bolts based on fracture mechanics

To investigate the fatigue crack propagation behavior of high-strength bolts for high-speed train brake discs, the fatigue crack propagation of high-strength bolts with initial defects under various load ratios was numerically simulated and experimentally verified based on fracture mechanics in this paper. Firstly, the fracture mechanics model of a three-dimensional hexahedral mesh with initial root defects was established using ABAQUS-FRANC3D interactive technology. Then the stress intensity factor (SIF) of the crack front was calculated by the stress superposition of the crack surface to simulate the coupling effect of preload and axial cyclic load. Based on it, fatigue crack propagation was simulated. Finally, the corresponding fatigue experiments on prefabricated crack bolts were carried out. The results show that mode I cracks dominate in the process of crack propagation. The stable crack propagation zones of the fractured high-strength bolts all show a semi-elliptical cross-section. The SIF of the crack front decreases with the increase of the load ratio, thus making the crack propagation life increase with the increase of the load ratio. The experimental outcomes are in great agreement with the simulation results, which verify that the numerical simulation method can effectively and accurately evaluate the fatigue life of high-strength bolts with initial defects and provides an effective means for predicting the fatigue crack propagation life of the same type high-strength bolts in engineering applications.