3D Finite Element Modeling of High-Speed Sliding Wear

Abstract

Wear is defined as “the removal of material volume through some mechanical process between two surfaces”. There are many mechanical situations that can induce wear and each one can involve many wear mechanisms. This research focuses only on the wear due to dry sliding between two surfaces. Currently there is a need to identify and compare materials that would endure sliding wear under severe conditions such as high velocities. The high costs associated with the field experimentation of systems subject to high-speed sliding has prevented the collection of the data required to characterize this wear phenomenon. Simulating wear through finite elements would enable its prediction and would reduce experimentation costs. In the aerospace, automotive and weapon industries such a model can aid in material selection, design and/or testing of systems subject to wear such as: bearings, gears, brakes, gun barrels, slippers, locomotive wheels, or even rocket test tracks. This 3D wear model would allow us to reasonably predict high-speed sliding mechanical wear between two materials. The model predictions have shown reasonable results when compared against those measured on a sled slipper traveling over the Holloman High Speed Tests Track. This slipper traveled a distance of 5,816 meters in 8.14 seconds and reached a maximum velocity of 1,530 m/s.