Analysis and prediction of surface wear resistance of ball-end milling topography

Abstract

Surface topography has an important effect on the wear resistance of contact surfaces. Non-smooth surfaces have stronger wear resistance than smooth surfaces. In this paper, the sliding wear characteristics of the surface of a quadrangular pit formed by ball-end milling were studied. Using the Archard wear model and the UMESHMOTION subroutine in ABAQUS software, the finite element simulation analysis of the sliding wear process was performed under dry friction conditions. Combined with finite element simulation data, the contact area, contact pressure, wear zones and the relative wear rate of the quadrangular pit topography with different sizes were analyzed, and the relationship between the quadrangular pit size and wear resistance was obtained. Based on Grey System Theory, the grey incidence between the relative wear rate of the topography surface and the areal surface roughness was obtained. Based on this, a zeroth order four variable grey model, GM(0, 4), for determining the wear resistance of the topography surface was established, and the model was verified experimentally. This research provides a new method for the judgment of the surface wear resistance of ball-end milling topography with the different sizes of quadrangular pits.