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Research Article | Open Access

Numerical analysis of time-varying wear with elastic deformation in line contact

Wanglong ZHAN, Ping HUANG()

School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, China

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Abstract

Wear is an important factor for failures of mechanical components. Current research on wear is mainly focused on experiments while the numerical simulation of wear is hardly used owing to the complexities of the wear process. Explaining the effect of friction on the wear process is important, as it will lead to a deeper understanding of the evolution of wear. This study proposed a numerical method to expound the wear process in the contact between an elastic cylinder and a half-space simulating the ring-block tester. There are two difficulties during the calculation; one is that the contact shapes vary with time, causing the pressure distribution to change simultaneously and the other is the integral equation for calculating the contact pressure under different worn shapes. In the present study, the wear rate was computed using Archard's law and the wear process was calculated step by step until the specified total sliding distance was achieved. During each step of the calculation, the contact topography was updated. The simulation intuitively reproduced the contact state of change from line to surface contact throughout the wear process. Reasonable agreements on the changes of the wear scar, achieved from experiments and numerical simulations, were obtained.

Keywords

time varying wear singular integral equation elastic deformation wear scars contact pressure

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Volume 7 Issue 2,
April 2019

Pages 143-152

DOI: 10.1007/s40544-017-0195-1

Cite this article:

ZHAN W, HUANG P. Numerical analysis of time-varying wear with elastic deformation in line contact. Friction, 2019, 7(2): 143-152. https://doi.org/10.1007/s40544-017-0195-1

10.1007/s40544-017-0195-1.F001 Fig. 1Friction and wear experimental model of the ring-block tester.
10.1007/s40544-017-0195-1.F002 Fig. 2Diagram of a contact between two elastic bodies.
10.1007/s40544-017-0195-1.F003 Fig. 3Scheme of the contact between a cylinder and an elastic half-space.
10.1007/s40544-017-0195-1.F004 Fig. 4Comparison of Hertzian problem from analytical solution and numerical results under different friction coefficients: (a) distribution of contact pressure; (b) numerical (symbol) and theoretical (line) results of contact width and ratio of right to left contact width. Other parameters, object 1: $E_{1} = 200 GPa$ , $ν_{1} = 0.3$ ; object 2: rigid body. $L = 300 kN / m$ , $R = 24.61 mm$ .
10.1007/s40544-017-0195-1.F005 Fig. 5Diagram of wear width mapping.
10.1007/s40544-017-0195-1.F006 Fig. 6Variations of the friction coefficients with time.
10.1007/s40544-017-0195-1.F007 Fig. 7Predicted evolution of contact pressure with increasing sliding distance s.
10.1007/s40544-017-0195-1.F008 Fig. 8Evolutions of contact width and peak pressure with increasing sliding distance.
10.1007/s40544-017-0195-1.F009 Fig. 9Predicted wear profiles for block under different sliding distance.
10.1007/s40544-017-0195-1.F010 Fig. 10Comparison of numerical prediction and experimental results for worn surface profiles of the flat specimen after sliding: (a) 75 m; (b) 150 m; (c) 225 m; (d) 300 m.
10.1007/s40544-017-0195-1.F011 Fig. 11Variation of ratio of right to left contact width with increasing sliding distance for $μ = 0$ and $μ = 0.5$ . The ring is assumed as a rigid body and the other simulation parameters are the same as in Section 5.1.

Return

10.1007/s40544-017-0195-1.T001Table 1Experimental condition.

Speed (rpm)	100
Load (N)	246
Temperature (℃)	25 ± 1
Young\'s modulus (GPa)	209, 204
Poisson\'s ratio	0.269, 0.285
Sliding distance (m)	75, 150, 225, 300

10.1007/s40544-017-0195-1.T002Table 2Comparison of numerical prediction and experimental results for wear scars on the flat specimen.

Sliding distance (m)	Scar width (μm)		Maximum wear depth (μm)
Sliding distance (m)	Experimental	Predicted	Experimental	Predicted
75	980	822.97	3.34	3.35
150	1,090	1,034.78	3.84	5.35
225	1,230	1,183.72	5.95	7.03
300	1,370	1,302.41	8.04	8.53

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