Three-dimensional finite element simulations of fretting wear in steel wires used in coal mine hoisting system

Abstract

Fretting wear is a surface damage phenomenon that occurs at contacting surfaces due to the micro relative movements of contacting surfaces. It is not easy to consider the parametric study of this phenomenon by experimental methods. For example, it is not straightforward to measure the contact stresses and wear scars under different loading conditions during the experimental process. Furthermore, the experimental process is economically expensive and time-consuming. In this paper, the fretting wear behavior of steel wire ropes used in coal mine technology is numerically investigated and the results are compared with experimental data. The numerical results of the effect of contact parameters on the fretting wear process during the fretting cycles are also analyzed. For this purpose, a three-dimensional Finite Element (FE) model is created and validated with an analytical solution. The simulations of the FE model are performed using the commercially available FE tool ABAQUS combined with subroutine UMESHMOTION. The available experimental data of fretted wires in the form of coefficient of friction is used to define the interaction between the contacting surfaces of FE model and the maximum wear depth is used to validate the wear depth obtained through the numerical model. A convergence study is also carried out to select the most suitable parameters for the simulation of contacting surfaces. After the validation of the FE model, the effect of fretting amplitude, contact load and different contacting angles of fretted wires on wear characteristics is considered. The results show that higher fretting amplitude and contact load have a significant effect on wear profile, wear depth, and wear scar. The maximum wear depth, wear depth increasing rate and contact stress decreasing rate is high for higher contact angles compared to smaller contact angles.