Finite element analysis wear simulation of a conical spinning contact considering surface topography

Abstract

A wear model considering surface topography is developed and used to calculate wear in conical spinning contacts both analytically and with FEM, using the commercial software ANSYS 5.0A. The model is based on the linear wear law and the Abbott curve linearisation. In finite element analysis (FEA) wear simulations, the wear law is discretised and Euler integration scheme is used. In the analytical approach the elastic deformations of the bodies are neglected. The analytical results are in good agreement with the FEA results, if the conical contact is conforming. The agreement of analytical and FEA wear results is poor, if the contact is non-conforming. The elastic behaviour of bodies thus has a major influence on the contact conditions. Higher surface topography causes bigger wear depths and rates. The wear rate of a conical contact in general approaches during the wear procedure that of the smooth conforming one. Higher surface topography causes faster running-in procedure, if the contact is non-conforming, since the increase rate of the contact area size is a function of both the cone and socket angle difference and the surface topography height. The FE model and procedure are also described.