Archard Wear Research Articles

Study on meshing and dynamic characteristics of herringbone gear pair considering tooth surface wear and modification

Due to errors and tooth surface wear of herringbone gear is inevitable. And tooth surface modification is the key technology to improve gear performance. Therefore, this paper studies the influence of tooth surface uneven wear and modification on herringbone gear pair's meshing and dynamic characteristics with errors. Firstly, herringbone gear pair meshing characteristic analysis model based on discrete tooth surface is established. Secondly, herringbone gear pair bending-torsion coupling dynamic characteristic analysis model considering friction is established, and the dynamic frictional force analysis process is given. Thirdly, combined with Archard's wear theory, the tooth surface uneven wear amount is obtained. The tooth surface uneven wear amount is substituted into meshing matrix as a tooth surface deviation. Finally, the meshing and dynamic characteristics of herringbone gear pair considering tooth surface wear and modification are studied by using the established analysis model of meshing characteristics and dynamic characteristics. The calculation results show that without tooth surface modification, tooth surface wear will deteriorate the meshing and dynamic characteristics rapidly. However, reasonable tooth surface modification can effectively improve meshing and dynamic characteristics of gear pair, so that the gear pair can still maintain stable transmission under wear condition.

The effects of load conditions and structural parameters on fretting wear of annular flat in heavy-duty gas turbine

Heavy-duty gas turbine is the core equipment in energy and electricity systems. In the compressor of a heavy-duty gas turbine, the forces and torques are usually transmitted by the friction force of the annular flat contact interfaces between two adjacent discs. Aimed at the annular flat connection structure of the combined rotor in heavy-duty gas turbine, the distribution of fretting characteristics on the annular flat is analyzed. The wear depth was calculated on the contact interface based on the modified Archard's wear theory and finite element method. On the annular flat, the time-varying distributions of fretting characteristics with the progress of wear are investigated. The increase of fretting cycles increases the wear depth of the annular flat. Moreover, the effects of load conditions and disc geometrical parameters on the fretting characteristics are studied. The increase of tie rod preload force and transmitted torque will intensify the fretting wear on the annular flat. In addition, the decrease of the distance between the tie rod and the annular flat and the decrease of the width of the annular flat will exacerbate the fretting wear on the annular flat. A fretting wear experiment is conducted to verify the finite element model. The experimental results show the fitting curve of wear depth decreases from the inner radius to the outer radius, which aligns with the results obtained from the finite element simulation. Ultimately, the research of this paper will provide a reference for the design and engineering application of the annular flat contact interfaces.

Analysis of the degradation in transmission accuracy of RV reducers considering the wear clearance between cycloidal wheels and pinwheels

To accurately determine the transmission accuracy degradation pattern of Rotate Vector (RV) reducers due to wear, a predictive method is proposed that simultaneously considers the initial clearance and wear clearance between the cycloid wheel and the pinwheel. The initial clearance is derived from a comprehensive gear system analysis, considering assembly errors, manufacturing errors and modifications. Building on this, the wear depth of the cycloid wheel tooth profile is numerically simulated using Archard's wear theory, revealing the wear distribution pattern under various operating conditions. A Gaussian regression model is used to predict the maximum wear amount for different operational durations. Based on the predicted wear amount, a multi-body dynamic simulation model incorporating wear clearance was established to analyze the transmission error under varying clearance conditions. Results indicate that the wear depth along the tooth profile initially increases and then decreases. The depth and region of wear along the tooth profile gradually increase with load and output speed, with the impact of load on the wear region being greater than that of output speed. Under the initial clearance condition, the maximum transmission error is 22.91″. As the wear clearance increases, transmission accuracy declines sharply. When the cumulative wear clearance reaches 0.2 mm, the transmission error exceeds the allowable backlash limit. This study provides a theoretical reference for predicting accuracy degradation and guides the manufacturing design of RV reducers.

A Contact Mechanics Model for Surface Wear Prediction of Parallel-Axis Polymer Gears.

As surface wear is one of the major failure mechanisms in many applications that include polymer gears, lifetime prediction of polymer gears often requires time-consuming and expensive experimental testing. This study introduces a contact mechanics model for the surface wear prediction of polymer gears. The developed model, which is based on an iterative numerical procedure, employs a boundary element method (BEM) in conjunction with Archard's wear equation to predict wear depth on contacting tooth surfaces. The wear coefficients, necessary for the model development, have been determined experimentally for Polyoxymethylene (POM) and Polyvinylidene fluoride (PVDF) polymer gear samples by employing an abrasive wear model by the VDI 2736 guidelines for polymer gear design. To fully describe the complex changes in contact topography as the gears wear, the prediction model employs Winkler's surface formulation used for the computation of the contact pressure distribution and Weber's model for the computation of wear-induced changes in stiffness components as well as the alterations in the load-sharing factors with corresponding effects on the normal load distribution. The developed contact mechanics model has been validated through experimental testing of steel/polymer engagements after an arbitrary number of load cycles. Based on the comparison of the simulated and experimental results, it can be concluded that the developed model can be used to predict the surface wear of polymer gears, therefore reducing the need to perform experimental testing. One of the major benefits of the developed model is the possibility of assessing and visualizing the numerous contact parameters that simultaneously affect the wear behavior, which can be used to determine the wear patterns of contacting tooth surfaces after a certain number of load cycles, i.e., different lifetime stages of polymer gears.

The Construction of a Small-Caliber Barrel Wear Model and a Study of the Barrel Wear Rule

The wear of small-caliber barrels is one of the key factors affecting barrel life. Based on the Archard wear model, a high-temperature pin plate wear experiment was carried out, and wear models of chrome-plated layers and gun barrel materials were established. In addition, a finite element model of the interaction between the bullet and the barrel was established. The movement of the projectile along the barrel was simulated and analyzed, and the force distribution of the spatial geometry structure of the rifling was mastered through simulation. The wear law of the gun barrel along the axial direction was obtained based on the wear model of the chrome-plated layer and gun barrel material. A position 100 mm away from the barrel breech wears very fast; this position is where the cone of the bullet is engraved in the barrel. At the position 150–350 mm away from the barrel breech, the barrel bore wears even faster. The barrel chrome layer is mainly affected by the gunpowder impact and projectile engraving, which is consistent with the actual failure of the coating. When the distance to the barrel breech is 350 m, the wear becomes stable. Through an analysis of the diameter of the barrel, it was found that, when the diameter of the barrel exceeded 12.85 mm, the barrel reached the end of its life.

On the use of vibrations and temperatures for the monitoring of plastic chain conveyor systems

In industrial automation, the transportation of unit loads plays a crucial role. This paper addresses the under-explored area of plastic chain conveyors, a versatile and efficient means of transport within production processes. Despite their widespread use, these conveyors suffer from wear and tear due to continuous contact between the chain and guide rails, often leading to unscheduled shutdowns and increased costs. The literature on monitoring solutions for such systems is sparse, particularly for plastic chains. This paper aims to bridge this gap by surveying the most common wear mechanisms for these systems and presenting a physical model that describes the interaction between the chain links and guide rails, based on chain of masses, springs and dampers and the Archard wear model. This model allows to relate the variations due to wear with other physical quantities, such as passage frequencies of the links and heat generated due to friction. The comprehensive model provides analytical formulas to understand the vibrations induced by the chain on the platform and the guide-rail temperatures. To validate the model and evaluate how the measurements are affected by the degradation of the system, an extensive experimental campaign was conducted on a conveyor test rig, acquiring vibration and temperature data. The end goal is to identify and discuss methodologies suitable for estimating the wear mechanisms of conveyor systems, with a focus on the constraints of industrial environments. Hence, this study aims to lay the groundwork for defining monitoring solutions that enhance the maintenance efficiency of plastic chain conveyor systems. The results suggest that the power Spectral Densities (PSD) of the platform’s accelerations are sufficient to estimate the average links pitch, which in turn could be used to assess the chain elongation. Besides, the local temperatures confirmed the model observations, making them suitable for estimating the slide-rail thinning.

Simulation on the Effect of Braking Force and Brake Shoe Material Type on The Wear Rate of Railway Bogie Brake Block

The brake block in the railway bogie system is an important component in supporting the operational safety of trains, so it needs to be inspected to determine its performance and service life. A simulation-based study was conducted to predict the wear rate of railway brake block with oriented braking force (F = 25.66 kN - 29.54 kN) and different material types, namely grey cast iron with hardness 170 HBN and metallic composite with hardness 90 HRR. The method of the study was carried out by Finite Element Analysis (FEA) simulation and calculating the wear rate with the Archard wear equation to measure the comparison of the amount of wear volume that occurs on the two materials. The results of the braking ability calculation can be concluded that the different types of brake block materials can affect the ability to decelerate during the deceleration process, causing differences in stopping mileage according to the type of material, such as gray cast iron (μ = 0.30) which has an average mileage of 15 metres and metallic composite (μ = 0.21) has an average mileage of 66 metres. The wear simulation results obtained are that the grey cast iron brake block has an average wear rate of 2,8285e-08 /s which is greater than the metallic composite which is only 1,5391e-08 /s. With this data, it can be concluded that oriented to the braking force load, the metallic composite brake block material has the advantage of a longer service life than grey cast iron.

Numerical investigation of bucket wear and excavation performance with non-spherical materials

Wear significantly affects equipment performance at mining sites, especially when excavating materials with diverse shapes, leading to increased bucket wear and reduced service life. This work combines the co-simulation of multibody dynamics and discrete element method with the Archard wear model to investigate the dynamic interactions between the bucket and non-spherical materials, and the impact of bucket wear on excavation performance. The results indicate that wear is evident on the bottom surface, side surface, and teeth of the bucket throughout the working cycle. The wear patterns observed for different teeth vary, highlighting the importance of maintenance for the middle and side teeth. Compared to spherical particles, ellipsoidal ones cause greater excavating resistance, bucket wear, and hydraulic fluctuations. As wear intensifies, the teeth become blunt, and the bottom surface exhibits unevenness, resulting in reduced payload and increased resistance and hydraulic power. Proposed wear mitigation strategies can help uphold satisfactory operating performance.

Prediction of wear of short glass fiber reinforced polyamide 66 composite sprocket

The wear of a polymer composite sprocket primarily depends on contact pressure and sliding velocity that vary significantly during service. The sliding distance and contact pressure at the sprocket/roller interface were estimated for a pristine polymer composite sprocket engaged with a standard and a 3% extended steel chain by employing the explicit finite element method. A set of experiments was executed to find the friction and wear coefficients of sprocket material using polyamide 66 composite pins and standard steel disc at sliding speeds of 1, 2, and 3 m/s and normal loads of 10, 20, 30, and 40 N. The wear depth is estimated after getting friction and wear coefficients experimentally, and contact pressure and sliding distance numerically. Archard wear model was executed using the UMESHMOTION subroutine with the Arbitrary Lagrangian-Eulerian technique in ABAQUS. The peak contact pressure on the sprocket is increased approximately by 1.5 times as the chain elongates from 0% to 3%. A pristine sprocket engaging a 3% extended chain after one lakh cycles experienced an approximate wear depth of 90 µm.

Peridynamic study on thermomechanical damage of the rail during wheel idling

Wheel idling is an extreme sliding contact scenario that accelerates rail failure. Using temperature-dependent elastoplastic materials, a peridynamic (PD) model for wheel-rail contact was developed to investigate the thermomechanical damage behavior of rails during wheel idling. Numerical simulations of loading and unloading during wheel idling under different loads were performed, and the results of contact stress, temperature, plastic deformation, and material damage were obtained and analyzed. During loading, the temperature of the rail surface increases rapidly to over 1200 °C, which is well above the austenitization temperature. The intense thermal softening caused by high temperatures deteriorates the wheel-rail contact relationship and leads to a surge in plastic deformation. The softened surface material was continuously removed by the contact load, leading to severe wear damage, and the wear depth increased significantly with the load and idling time. The wear coefficients for the Archard wear model were derived using the wear results from the PD model. During unloading, the surface material cools rapidly at a rate of 1400°C/s through heat transfer into the rail, undergoing martensitic transformation and forming a brittle and hard white etching layer. The thickness of the WEL decreases as the wear depth increases.

Tribo-Dynamic-Wear coupling analysis for Water-lubricated Bearings with journal surface imperfection under repeated start-stop cycles

Water-lubricated Bearings (WLBs) are the core transmission components of a ship propulsion system, and their wear behavior primarily occurs during the starting and stopping states. To characterize the wear behavior of WLBs, an equivalent experiment is conducted on bush material to obtain the relationship between dimensionless wear coefficient and sliding distance based on the Archard wear model. Then, an experimentally determined transient wear model is incorporated into a tribo-dynamic model to develop a fully coupled Tribo-Dynamic-Wear (TDW) model for the WLBs during repeated start-stop cycles. In this model, the 3D thermal effect, the transient bush worn surface and the geometric imperfection of the journal surface are considered. Numerical results show that the wear rate is more significant at the beginning of the start-up state and the end of the stopping state of the WLB. Meanwhile, it is found that compared to a perfect journal, a reasonable undulation number and undulated amplitude of the journal surface can improve the wear resistance performance of WLBs during repeated start-stop cycles. More specifically, a relatively lower undulation number leads to a smaller wear volume than the perfect journal, and the undulated journal surface has an optimal undulated amplitude that minimizes the wear volume.

Response surface test simulation of locking system reliability considering kinematic pair wear evolution

The concentrated load endured by the locking system during the weapon mounting and release procedures may lead to mechanical wear in hinges and kinematic pairs, thereby influencing the functional reliability of the weapon rack mechanism system. This study aims to investigate the impact of kinematic pair wear evolution on the reliability of the locking system. Firstly, a rigid-flexible coupling multi-body dynamics model of the locking system was established to simulate the dynamic behaviors of the rack under different loading conditions. Moreover, the wear amounts of the main kinematic pairs were precisely calculated by the Archard wear model to provide data support for the subsequent reliability analysis. Subsequently, the response surface method was employed to design the orthogonal experiments for the reliability analysis of the locking system, and the reliability degradation law of the locking system within the design lifespan was obtained through the Monte Carlo method simulation. The research findings indicate that the wear of kinematic pairs has a significant effect on the motion function and accuracy of the mechanism. The motion reliability of the mechanism can be maintained above 99% within the design lifespan. Nevertheless, when the usage time exceeds twice the design lifespan, the reliability drops significantly to approximately 85%, and the influence degrees of different wear positions on the reliability were obtained through the sensitivity analysis. The research results not only provide a scientific basis for the optimal design of the locking system but also offer a novel perspective and method for the reliability assessment and maintenance strategy of the weapon rack locking system.

Study on the tribological performance at the interface between a steel wire rope and groove during a twisting process

In actual use, a steel wire rope is often stretched and twisted around a groove, increasing the risks of contact fatigue, friction and wear at the rope-groove interface under a long-term service condition. With the consideration of influence factors such as the nonlinear contact and wear between the rope and groove, the tribological performance at the rope-groove interface during a twisting process is analyzed in this study. A winding rope-groove model is first established in order to obtain the contact and sliding solutions at the interface between the rope and groove, which are then used as the load conditions of a simplified local model that is built for wear solution using a modified Archard's wear theory. Based on the finite element simulation software ABAQUS, the ALE adaptive mesh technology and UMESHMOTION subroutine secondary development are adopted to analyze the evolutions of wear topography and contact behavior between the rope and the groove. The results show that the twisting movement of the steel wire rope around the groove causes an interfacial wear between them. The wear scars occur on the outside wire of the steel wire rope and the bottom area of the groove, and the wear scar on the groove is smaller but deeper. A ring-shaped region of stress concentration happens near the edge of wear region. As the wear process proceeds, the depths and dimensions of the wear scars increase, while the contact pressure decreases. The contact performance and wear change dramatically at the beginning of wear process and tend to be stable subsequently. An increment of lay angle of the outside wire aggravates the wear and contact between the steel wire rope and the groove.

Stiffness reliability analysis of harmonic drive considering contact pairs wear

PurposeThe purpose of this paper is to analyze the stiffness reliability of harmonic drive (HD) considering contact pairs wear.Design/methodology/approachIn terms of theoretical calculation, the contact pairs wear of HD are calculated based on Archard wear formula and the relative motion characteristics of contact pairs. According to the motion trajectory of flexspline teeth, the teeth backlash and the number of meshing teeth, the meshing stiffness and overall stiffness of HD are analyzed considering the wear and its randomness of contact pairs. Combined with Monte Carlo Simulation, the stiffness reliability evaluation method considering contact pairs wear is proposed, and the result of this method is verified by the stiffness reliability result deduced from the stiffness degradation measurement data.FindingsConsidering contact pairs wear, during operation, the teeth backlash increases, the number of meshing teeth decreases, the meshing stiffness decreases, ultimately leading to a gradual decrease in the overall stiffness of HD. When only one type of contact pair wear is considered, the influence of flexspline and circular spline contact pair wear on HD stiffness reliability is greater. Compared with the stiffness reliability evaluation results obtained from the stiffness degradation data in the literature, the mathematic expectation of stiffness degradation failure life distribution obtained from the proposed method is relatively bigger.Originality/valueThe stiffness reliability evaluation method of HD considering contact pairs wear is firstly proposed. The stiffness reliability evaluation result from theoretical calculation is verified by the stiffness reliability results deduced from HD stiffness degradation measurement.

Numerical Analysis of Tooth Contact and Wear Characteristics of Internal Cylindrical Gears with Curved Meshing Line

In order to improve the contact strength and reduce the sliding friction of the gear pair, an internal cylindrical gear pair with a curved meshing line is studied in this paper. Firstly, a curved meshing line is designed. The tooth profiles of the internal gear pair with the designed meshing line are calculated by using differential geometry and the gear meshing principle. Secondly, a wear model is established by combining the finite element method and the Archard wear formula. Then, a numerical simulation is conducted; the relative curvature, sliding coefficient, sliding distance, maximum contact pressure, transmission error, and wear depth are calculated. Ultimately, the variation law of tooth surface wear of new gear with and without installation errors is observed under different stress cycles. On this basis, the influence of tooth modification on tooth surface wear is further researched. Through the results, the advantages of the introduced novel internal cylindrical gears in wear resistance are further demonstrated. The study in this paper provides new research ideas and methods for gear wear research and gear design.

Research on Wear Behavior Between Crossed Parabolic Cylinders in the Early Stage of Cyclic Fretting

Abstract In practice, even the tiny relative reciprocating motion generated by external load or environmental vibration can cause interface wear. In this work, three-dimensional (3D) finite element analysis (FEA) is used to investigate the fretting wear between deformable crossed parabolic cylinders. Fretting is achieved by the application of a periodic displacement-controlled load, while the contact pair is defined as the same material, i.e., Carbon Steel/Carbon Steel, Copper Alloy/Copper Alloy, and Aluminum Alloy/Aluminum Alloy. Meanwhile, three different axis crossing angles are also studied, i.e., 45°, 60°, and 90°. Originally, a wide range of coefficients of friction (COFs) are applied to the interface without considering the damage. The results show that, when the COF is sufficiently large (µ = 1), the junction growth and the tangential load increase significantly in the first loading cycle, but then become gradually stable. Subsequently, the Archard wear model is applied to the frictional interface. Empirical equations for the initial gross slip distance and the wear volume at the end of the partial slip are established in turn. Furthermore, an empirical equation for the wear volume of a single fretting cycle is established, which is in good agreement with the FEA results. Lastly, the effect of relevant parameters on the wear volume for a single fretting cycle under elastic condition is discussed, but also the evolution of wear volume in the early stage of cyclic fretting. All the results are normalized, enabling their application to the 3D fretting wear of other material pairs.

Parametric analysis of the relationship between squeal and friction wear in motorcycle disc brakes

Squeal is a noise problem that affects all types of automotive brake systems and may affect the health of the population living in heavy traffic areas. Parameters such as pressure, friction, and Young’s Modulus are crucial in determining brake noise generation. Notably, wear on rubbing surfaces emerges as a key contributor to squeal, affecting the overall brake system functionality and necessitating frequent maintenance and parts replacement. This study conducted a detailed analysis of the influence of material and operational factors on squeal generation, specifically examining their relationship with friction wear in motorcycle disc brakes. To achieve this goal, a parametric study was conducted using finite element analysis software ANSYS. Thus, the study involved subjecting the geometry to static and modal analyses to verify the generation of unstable modes. Additionally, two models were built to analyze the influence of wear on noise: one with Archard wear activated, which calculated the worn volume, and another with this option disabled. The results of the study suggest that wear is a crucial parameter that must be considered in numerical models, given its significant impact on stability attributes. Moreover, since material and operational parameters play a substantial role in generating squeal noise, this study provides valuable insights into the causes and effects of brake noise, offering practical recommendations for mitigating this common problem in motorcycle disc brakes. The model developed also serves as foundational framework for configuring simulations for similar systems, automotive or train disc brake, to study the noise and lifespan of pads.

Numerical and experimental validation of tribological phenomenon in wind turbine brake pads using novel Archard's wear coefficient

Designing effective mechanical brakes for wind turbines has been hindered by the historical reliance on simplistic criteria such as wear rate and friction coefficient for material selection. In this study, a novel approach to predicting wear rate was proposed, utilizing Archard's wear coefficient and considering factors such as material composition, hardness, sliding distance, and axial load. Furthermore, we developed a numerical model to simulate the tribological behavior of wind turbine brake pads, integrating the novel wear coefficient derived from a hybrid mathematical model with cubic and radial basis functions. This comprehensive approach bridges the gap between experimental data and theoretical insights, offering a robust framework for optimizing brake pad design and performance.

Nonlinear dynamic characteristics of mechatronics integrated planetary gears considering wear and temperature effects

The electromechanical planetary gear system has high work efficiency and long service life, but factors such as heat, wear, and electrical signals can affect the transmission performance of electromechanical planetary gears. This article comprehensively considers factors such as temperature, tooth surface wear, lubrication, current and voltage, damping ratio, etc. Based on the principle of thermal deformation, Archard wear model, and equivalent circuit principle, a dynamic model of electromechanical planetary gears is established. The existing literature has not comprehensively analyzed the effects of temperature, wear, and electrical signal changes on the nonlinear characteristics of electromechanical planetary gear systems. The results show that when the motor current is between 7 A and 18 A and the voltage is lower than the rated voltage, the system is in a stable state; as the temperature rises, the system tends to stabilize; the gear wear exceeds 30 μm, and the bifurcation characteristics of the system are more pronounced.

A novel wear prediction method and wear characteristic analysis of piston/cylinder pair in axial piston pump

The wear of the piston/cylinder pair in the axial piston pump is a significant factor that adversely affects pump performance. To conduct a thorough investigation into the wear characteristics of the piston/cylinder pair, a dynamic model based on the equivalent load method is established. Then, a novel wear prediction method for the piston/cylinder pair is proposed by integrating the Archard wear model. The validity of the proposed method is confirmed through experimental verification. The results demonstrate that specific circumferential areas of the cylinder bore exhibit severe wear, and the distribution of these areas remains relatively stable over time. At the swash plate side, the most severe wear area along the circumference direction is concentrated in the range of approximately 200°–320°, which means the area that deviates from the extreme position in the radial direction of the pitch circle by a specific angle, with the deviation direction being opposite to the rotational speed. Conversely, at the valve plate side, the most severely worn circumferential area is situated in the range of about 0°–120°, which is opposite to the area at the swash plate side. The proposed wear prediction method offers improved computational efficiency, providing valuable support for analyzing the wear characteristics and failure mechanisms of piston pumps.