Simulation of textured surface topography during a low wear process

Abstract

Wear experiments were conducted on a block-on ring tester. The stationary block made from cast iron of 50 HRC hardness was ground. The rotated ground ring was made from 42CrMo4 steel of 32 HRC hardness. The rings were modified by a burnishing technique in order to obtain surfaces with oil pockets. Oil pockets of spherical and of drop shape were tested. The correlation and regression analysis of parameters of textured surface topography was carried out. Two sets of surfaces were analysed: after machining and after “zero-wear”. As the result of analysis, minimum number of parameters describing this surface kind was obtained. A simple truncation model of the ring surface change was used. Worn surface topographies, after a low wear, were also modeled in a different way. An idea of the proposed method of surface topography modeling is imposition of random surface of Gaussian ordinate distribution on the base surface (after burnishing). The modeled surfaces were correctly matched to the measured surfaces in 90% of all analysed cases. Basing on the simulation, the local wear values during a low wear process were calculated and compared with experimental ones.