3-D FEM Wear Prediction of Brass Sliding against Bearing Steel Using Constant Contact Pressure Approximation Technique
TL;DR: In this paper, a numerical wear simulation technique is presented for predicting the sliding wear in Pin-on-Disc (PoD) contact, which 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 3D PoD tribometer contact.
Abstract: 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.
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TL;DR: In this paper , the total wear in transient regime of 316 stainless steel pin against AISI 52100 bearing steel disc for 20 N and 30 N was predicted using Gauss Newton regression method.
Abstract: 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.
TL;DR: In this paper , the authors further validated 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.
Abstract: 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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TL;DR: In this article, the authors compared the deduced dependence of the experimental observables on the load with the experimental evidence and concluded that the most realistic model is one in which increasing the load increases both the number and size of the contact areas.
Abstract: The interpretation of certain phenomena occuring at nominally flat surfaces in stationary or sliding contact is dependent on the assumed distribution of the real area of contact between the surfaces. Since there is little direct evidence on which to base an estimate of this distribution, the approach used is to set up a simple model and compare the deduced theory (e.g., the deduced dependence of the experimental observables on the load) with the experimental evidence. The main conclusions are as follows. (a) The electrical contact resistance depends on the model used to represent the surfaces; the most realistic model is one in which increasing the load increases both the number and size of the contact areas. (b) In general, mechanical wear should also depend on the model. However, in wear experiments showing the simplest behavior, the wear rate is proportional to the load, and these results can be explained by assuming removal of lumps at contact areas formed by plastic deformation; moreover, this particular deduction is independent of the assumed model. This suggests that a basic assumption of previous theories, that increasing the load increases the number of contacts without affecting their average size, is redundant.
5,771 citations
"3-D FEM Wear Prediction of Brass Sl..." refers background or methods in this paper
...Finally, the wear volume was used to obtain the dimensional wear coefficient with the help of Archard's wear law [3], given by...
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...The wear model which takes into consideration these parameters for wear rate calculations is the Archard's model [3]....
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...Among them, one of the most commonly used sliding wear prediction equation is the Archard's wear law [3]....
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TL;DR: Most wear models and equations in the literature were analyzed as to origin, content and applicability as discussed by the authors, and no single predictive equation or group of limited equations could be found for general and practical use.
820 citations
"3-D FEM Wear Prediction of Brass Sl..." refers background in this paper
...There are about 300 equations for friction and wear which are found in the literature [2]....
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TL;DR: In this paper, the authors presented a wear simulation approach with commercial finite element software ANSYS, which is well suited for the solving of contact problems as well as the wear simulation.
368 citations
"3-D FEM Wear Prediction of Brass Sl..." refers methods in this paper
...[5] used a maximum allowable time increment approach, to minimize the computational time....
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...Many techniques have been used in solving contact problems like the Green’s function molecular dynamics (GFMD) [4], the Winkler model [5], Boundary element method (BEM) [6, 7], Archard-Based Models [8], Global Incremental Wear Model (GIWM) [9], Finite Element Method (FEM) [10-12] etc....
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...[5] used FEM to predict the wear of 2-D spherical pin-on-disc unlubricated steel sliding contacts....
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TL;DR: In this paper, a methodology to compute the (renormalized) elastic interactions of surface atoms is presented, based on the fluctuation-dissipation theorem, with the help of which thermal fluctuations of atomic displacements can be related to the elastic Green's functions and thus to the effective coupling between surface atoms.
Abstract: This paper is concerned with the principles of Green's function-based molecular dynamics (GFMD) simulations of semi-infinite elastic solids and their application to various contact mechanical problems. A methodology to compute the (renormalized) elastic interactions of surface atoms is presented first. It is based on the fluctuation-dissipation theorem, with the help of which thermal fluctuations of atomic displacements can be related to the elastic Green's functions and thus to the effective coupling between surface atoms. We suggest a sparse representation of these renormalized spring constants and present numerical results for some simple two- and three-dimensional lattices. The renormalized elastic interactions can be obtained for relatively small systems and then be extrapolated to large systems. They incorporate the full elastic response of semi-infinite solids in a way that only surface atoms have to be considered in molecular dynamics simulations. The usefulness of GFMD is demonstrated by applying it to various idealized contact models, such as nonadhesive Hertzian contacts as well as nonadhesive contacts between flat, semi-infinite elastic solids and a self-affine, rigid substrate. In all cases, a zero probability density $P(p)$ for infinitesimally small contact pressures $p$ is found, as predicted theoretically. If the self-affine, nonadhesive surfaces are under such high loads that the contact is complete, the pressure histogram can be represented by a Gaussian also in accordance with theoretical predictions. However, if the topography of the substrate resembles that of industrial steel surfaces and the loads are moderate, $P(p)$ decays exponentially for medium and large $p$ in contradiction to theoretical predictions for randomly rough surfaces.
168 citations
"3-D FEM Wear Prediction of Brass Sl..." refers methods in this paper
...Many techniques have been used in solving contact problems like the Green’s function molecular dynamics (GFMD) [4], the Winkler model [5], Boundary element method (BEM) [6, 7], Archard-Based Models [8], Global Incremental Wear Model (GIWM) [9], Finite Element Method (FEM) [10-12] etc....
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TL;DR: In this article, a wear simulation approach based on Archard's wear law is implemented in an FE post-processor that works in association with a commercial FE package, ABAQUS, for solving the general deformable-deformable contact problem.
Abstract: In order to predict wear and eventually the life-span of complex mechanical systems, several hundred thousand operating cycles have to be simulated. Therefore, a finite element (FE) post-processor is the optimum choice, considering the computational expense. A wear simulation approach based on Archard's wear law is implemented in an FE post-processor that works in association with a commercial FE package, ABAQUS, for solving the general deformable–deformable contact problem. Local wear is computed and then integrated over the sliding distance using the Euler integration scheme. The wear simulation tool works in a loop and performs a series of static FE-simulations with updated surface geometries to get a realistic contact pressure distribution on the contacting surfaces. It will be demonstrated that this efficient approach can simulate wear on both two-dimensional and three-dimensional surface topologies. The wear on both the interacting surfaces is computed using the contact pressure distribution from a two-dimensional or three-dimensional simulation, depending on the case. After every wear step the geometry is re-meshed to correct the deformed mesh due to wear, thus ensuring a fairly uniform mesh for further processing. The importance and suitability of such a wear simulation tool will be enunciated in this paper.
142 citations
"3-D FEM Wear Prediction of Brass Sl..." refers methods in this paper
...[13] used FEM to predict the dry sliding wear of both 2-D and 3-D deformable contact surfaces....
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