Total wear in transient regime consists of transient wear and linear wear components. Within the transient regime metal possess higher wear rates than the steady state. FEM computational based wear models ignore transient regime which leads to higher error. This paper emphases on predicting the total wear in transient regime of 316 stainless steel pin against AISI 52100 bearing steel disc for 20 N and 30 N.Novel methodology is proposed to calculate individual wear components. Linear component by FEM based Abaqus software using an extrapolation technique to reduce computational time without compromising the accuracy. Transient component is calculated using Gauss Newton regression method. Further, total wear is modelled by addition of linear and transient wear components. Simulated total wear has good agreement with experimental wear error within 11% for both the loads. Corresponding transient wear rate was found to be approximately 2.5 times higher than steady state wear. This establishes the robustness of proposed methodology. 

Transient Wear FEA Modelling Using Extrapolation Technique for Steel-on-Steel Dry Sliding Contact

The present study proposes the further validation of a simple mathematical procedure recently proposed by the authors to describe contact and wear evolution in line and point contacts. The procedure assumed that the maximum contact pressure could be determined using Hertz equations and a parabolic pressure profile. The contact half-width was obtained using the equilibrium equation and the Archard wear law. Several cases were selected from the literature, reporting experimental data or Finite Element simulations, and the results were compared to those obtained with the proposed approach. This paper confirms the reliability and potentialities of the proposed analytical procedure, which is capable of providing accurate solutions in case of frictional contacts and at the borders of the contact area, where the main discrepancies were found in the previous study.

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Further Validation of a Simple Mathematical Description of Wear and Contact Pressure Evolution in Sliding Contacts

For predicting the sliding wear in Pin-on-Disc (PoD) tribometer contact, a numerical wear simulation technique is presented in this paper. It is based on the Finite element method (FEM) which incorporates the Archard's wear law and the UMESHMOTION subroutine for calculating the wear depth for a 3-D PoD tribometer contact. FEM is utilized in solving the 3-D contact problem. The geometry is updated using the UMESHMOTION subroutine coupled with the Augmented Lagrangian-Eulerian (ALE) remeshing technique of ABAQUS. But, a significant disadvantage of FEM wear prediction is the enormous computational time required for performing 3-D analysis. Hence, to minimize the computational time, an approximation technique is introduced which accounts for the contact pressure evolution at the contact region. It decreased the simulation time and also preserved the accuracy of 3-D wear prediction. Finally, the results obtained from the simulations are compared with the experiments for brass-on-bearing steel PoD contact. An accuracy of 98.81% was obtained for the 10N and 83.10% for the 30N load.

Bose Kunal Kumar

Papers

3-D FEM Wear Prediction of Brass Sliding against Bearing Steel Using Constant Contact Pressure Approximation Technique