Wear Model Research Articles

Improving Archard’s Wear Model: An Energy-Based Approach

Archard’s wear law encounters challenges in accurately predicting wear damage and volumes, particularly in complex situations like asperity–asperity collisions. A modified model is proposed and validated, showcasing its ability to predict wear in adhesive contacts with better accuracy than the original Archard’s wear law. The model introduces an improved wear coefficient linked to deformation energy, creating a spatially varying relationship between wear volume and load and imparting a non-linear characteristic to the problem. The improved wear model is coupled with the Boundary Element Method (BEM), assuming that the interacting surfaces are semi-infinite and flat. The deformation energy is calculated from the normal contact pressure and displacements, which are the common outputs of BEM. By relying solely on these outputs, the model can efficiently predict the correct shape and volume of the adhesive wear particle, without resorting to large and often slow models. An important observation is that the wear coefficient is expected to increase based on the accumulated deformation energy along the direction of frictional force. This approach enhances the model’s capability to capture complex wear mechanisms, providing a more accurate representation of real-world scenarios.

Wear mechanism study of rocket sled shoe material 30CrMnSiNi2A

The material used for the rocket sleds in this study was 30CrMnSiNi2A. The research focused on examining the wear patterns and elemental distribution of the 30CrMnSiNi2A alloy under high-speed (34.56 m/s, 69.12 m/s, 101 m/s) and heavy-load (150–600 N) conditions through both experimental and simulation methods. A conceptual wear model was developed by integrating experimental results with numerical outcomes. At speeds of 34.56 m/s and 69.12 m/s, the friction coefficient and wear rate decreased with increasing applied pressure. At 101 m/s, the friction coefficient was less influenced by pressure, whereas the wear rate increased with increasing pressure. Simulation results show that under a load of 600 N, the von Mises stress consistently increased with increasing speed.

Velocity-Incorporated Wear Model of Rolling Guide Shoe Material Selection

To ensure an accurate selection of rolling guide shoe materials, an analysis of the intricate relationship between linear speed and wear is imperative. Finite element simulations and experimental measurements are employed to evaluate four distinct types of materials: polyurethane, rubber, polytetrafluoroethylene (PTFE), and nylon. The speed-index of each material is measured, serving as a preparation for subsequent analysis. Furthermore, the velocity-wear factor is determined, providing insights into the resilience and durability of the material across varying speeds. Additionally, a wear model tailored specifically for viscoelastic bodies is explored, which is pivotal in understanding the wear mechanisms within the material. Leveraging this model, wear predictions are made under higher speed conditions, facilitating the choice of material for rolling guide shoes. To validate the accuracy of the model, the predicted degree of wear is compared with experimental data, ensuring its alignment with both theoretical principles and real-world performance. This comprehensive analysis has verified the effectiveness of the model in the selection of materials under high-speed conditions, thereby offering confidence in its reliability and ensuring optimal performance.

Effect of the Mineralogical Composition of Sandstones on the Wear of Mining Machinery Components

The paper provides and comments on the results of studies of the effect of sandstone-based abrasives and quartz sand alone on the wear of martensitic surfaces of wear-resistant steels. The wear process was examined on a ring-on-ring test rig seeking to determine the mass decrement parameter which characterised wear. In addition, SEM microscopy, optical profilometry and XRF analysis were used to analyse the abrasives used and damaged surfaces. The tests were conducted for three sandstone varieties, Carboniferous, Permian, and Cretaceous, and they made it possible to determine that the most intense process of deterioration of wear-resistant steels took place in the presence of quartz sand grain, while less intense wear was observed in the case of sandstone-based abrasives. The mass decrement values established in the presence of the sandstones in question did not differ significantly between individual sandstone varieties. Based on a surface damage analysis, the basic damage mechanism was found to be micro-scratching; however, with regard to the sandstones examined, it was also determined that individual grains could be pressed into surface irregularities and that films of soft hematite cement developed in the Permian sandstone and that inclusions of carbonaceous matter were formed in the Carboniferous sandstone. With reference to the wear process observations, a wear model was described for the surface of the steels examined in the presence of sandstone-based abrasives. This model presents the possibility of capturing wear products by unstable binder layers and changing the form of wear from three-body to two-body.

Erosion Characterization Of Gas-Solid Jets Impinging Onto Inclined Surfaces

Erosion caused by solid particles is an important phenomenon in many industrial applications. Wear modelling is a complex phenomenon due to the many relevant variables. In any event, the dynamics of the fluid flow and particles need to be characterized so that their interrelations are well understood and models can be advanced. Depending on their sizes, particles immersed in solid-gas flows may deviate from the fluid stream, meaning that any deployed measuring technique must take this into account. The work describes through PIV and PTV the flow and particle dynamics of a round air-jet loaded with carbon silicate particles (SiO2) impinging onto an inclined surface. Flow conditions are set for two different Reynolds numbers and four impinging angles. The experimental results are compared with numerical simulations furnished by a two-way coupling scheme. The results show that erosion wear is highly dependent on the kinetic energy of the particle at impact. The larger the size of the particle or the larger its velocity, the larger is the damage it causes. A correlation between the thickness of removed material with particle size distribution and flow rate is presented. For low flow rates, the distinction between the damage caused by particles of various sizes is small.

The influences of normal load and displacement amplitude on fretting wear behavior of M50 bearing steel

This study aims to obtain key parameters such as the fretting wear coefficient and wear rate of M50 bearing steel through fretting wear experiments. By integrating the Umeshmotion subroutine, a validated 3D ball-plane energy dissipation fretting wear model was established. The research explores wear behavior and transition mechanisms under different normal loads and displacement amplitudes. Experimental and finite element analyses show that fretting wear rate is negatively correlated with normal load and positively correlated with displacement amplitude. These variables influence contact stress, shear stress, and slip distance, affecting wear morphology. Results indicate that increasing normal load transitions fretting wear from gross slip to partial slip, while increasing displacement amplitude shifts it from partial slip to gross slip.

Simulation of soil cutting blade wear

The results of a laboratory study of the wear patterns of blades of tillage parts are presented. To substantiate the model of soil-cutting blade wear in laboratory studies. Applied installation, providing rectilinear movement of the sample, one-time interaction of the blade with the particles of abrasive mass, and reproducing chip separation, inherent in most loamy soils. The dependence of the angle of inclination of the occipital chamfer to the bottom of the furrow, the width of the occipital chamfer and blade wear along the length of the sample from the cutting path, taken in studies for the main parameters of wear, were obtained. It was found that with increasing depth of cut, the intensity of wear increases, but when there are irregularities and undulations of the bottom of the furrow, it decreases due to the increase in the cutting path with lower loads due to the alternation of depressions and protrusions at the bottom of the furrow. With increasing hardness of the abrasive mass, the intensity of wear of the blade increases, at the same time the value of the stabilized angle of the occipital chamfer to the bottom of the furrow decreases, due to changes in the wear mechanism. With increasing cutting speed, the intensity of blade wear increases due to increased soil resistance forces and specifi c energy expended on its deformation and destruction. It was shown that the abrasive model of the soil corresponds to the real loamy soil for the study of wear of cutting elements. The expansion of the characteristics of the soil model peculiar to "nature" is due to the inclusion of additional components, in particular ceresin and vaseline, in the composition of the base "paraffin + quartz particles".

Analysis and prediction of uneven wear in metro pantograph-rigid catenary system

The non-elastic electrical contact between pantograph strip and wire, via a pantograph-rigid catenary system, results in much wear of metro strip. Every month, hundreds of thousands of strips are consumed in China due to the approximately 9900 kilometers of metro distance. Numerous instances of abnormal strip damage have been observed at the site, likely attributable to the uneven wear of strip. However, the cause of uneven wear on metro strip remains unclear to date. Hence, a wear model was developed based on the thermal equilibrium and wear mechanism, to investigate the uneven wear of strip in metro system. Various parameters, including contact force, electrical current, velocity, and copper content of the strip have been studied to explore their relationship with strip wear. Different laying structures, such as sine, half-wave, and folded line, exhibited varying degrees of uneven wear on the strip surface, with maximum depths observed at 4.20 mm per 104 km, 3.68 mm per 104 km and 1.02 mm per 104 km, respectively. The contact force holds the dominant position in metro wear, followed by current. Additionally, the wear rate also demonstrated sensitivity to the copper content of the strip.

Visco-elastohydrodynamic lubrication and wear model amended by deformation velocity

The deformation velocity caused by viscoelasticity is one of the drives of the Lubrication flow field and significantly influences the mixed lubrication and wear characteristics of journal bearings under dynamic loads. However, research considering the deformation velocity has yet to be reported. To address this research gap, we defined three-dimensional (3D) deformation velocities to amend the bearing surface velocity and proposed its calculation method based on the derivative function of the temporal association deformation equation and the finite element method. Therefore, a new mixed visco-elastohydrodynamic lubrication model amended by 3D deformation velocities was built and a nested solution method was proposed in which the sub-iterative process for deformation velocities was embedded into the oil film pressure iterative process. Furthermore, the lubrication model was coupled with the Archard model to predict wear. The viscoelastic parameter of the bearing was experimentally measured, and numerical simulations of lubrication and wear were performed for an ordinary bearing under a simple dynamic load and for the crankshaft main bearing of an internal combustion engine (ICE) under impact. The simulation results indicate that the deformation velocities reduce the extrusion effect and increase the contracting effect in the lubrication flow field. This enables the new model to identify the micro asperity contact, impact, and early wear features of bearings more accurately than the traditional mixed lubrication model. In addition, an increase in the ICE load intensifies the early wear of the bearing.

A new model for predicting thickness loss due to both corrosion wear and mechanical wear

Thickness loss due to corrosion wear generally occurs on ship structural members in corrosive environments. For corrosion wear, a probabilistic model can be successfully identified from the thickness measurements data to evaluate and estimate wear conditions. On the other hand, thickness loss due to mechanical wear may occur in some ship structural members in addition to thickness loss due to corrosion wear. In this study, a new probabilistic model for the case where mechanical wear is superimposed to corrosion wear is proposed. The condition observed in the actual structure is a mixture of corrosion wear condition and condition of corrosion wear with mechanical wear. When identifying a probabilistic model based on the plate thickness measurements data, it is impossible to distinguish whether the measurements data represent a corrosion condition due to corrosion wear or corrosion wear with mechanical wear. Therefore, a method is examined to obtain a model that would be the maximum likelihood by classifying the data using latent variables. By classifying the data and identifying both of a probability model of corrosion wear and a probability model of corrosion wear with mechanical wear, respectively, the posterior distribution of the latent variables is updated. These processes are repeated until the likelihood of the mixed probability models is maximized. For verification, a set of corrosion data consisting of mixed wear conditions were simulated and analyzed. It shows that both probability models could be properly identified with the proposed method, and in particular, the amount of diminution corresponding to high cumulative probability could also be properly estimated. Furthermore, this method was applied to thickness measurements data of ship structural members in the lower cargo holds of bulk carriers, where mechanical wear is also a concern, and it was confirmed that there was no difference in the corrosion wear condition of the members in the lower part of cargo holds of bulk carriers, however, significant differences were observed in the degree and extent of mechanical wear, indicating that the influence of mechanical damage is very significant in the wear condition of these members.

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.

Multiphase flow and nozzle wear with CFD-DEM in high-pressure abrasive water jet

The issue of wear failure in High-Pressure Abrasive Water Jet (HP-AWJ) nozzles is an unavoidable challenge, and studying methods to enhance and predict the effective lifetime of nozzles is worth deep exploration. This paper employs a CFD-DEM coupling numerical approach to investigate wear phenomena inside the HP-AWJ nozzle, aiming to capture the realistic particle wear and erosion failure issues at the focusing tube region, which is a high-wear area of the HP-AWJ nozzle. Furthermore, the study considers realistic particles and nozzle wall constitutive models, incorporating material properties into the physical model, and employs computer-aided design methods to reflect wear failure conditions at different time intervals in the inner wall of the focusing tube at the nozzle. The results demonstrate that the number of realistic particles and initial inlet velocity has no impact on the particle exit kinetic energy. However, the particle-wall restitution coefficient affects the average particle kinetic energy at the outlet in the AWJ nozzle. The equivalent model of the realistic particles reflects the influence of the particle roundness on particle kinetic energy, acceleration, and stress concentration variations in the nozzle. These variations further affect the particle erosion rate on the nozzle wall and the actual wear failure problems on the wall surface. Finally, by combining the proposed erosion and wear model, a representative erosion profile at the AWJ focusing tube location comparable to experimental results is obtained, and the wear depth of the focusing tube changing with time is also studied. The results and methodologies presented in this paper provide valuable guidance for controlling the effective service lifetime of the AWJ nozzle, improving machining efficiency, and extending the lifespan of the AWJ nozzle.

Scouring erosion resistance of metallic materials with composite microstructures

Slurry erosion can cause severe damage and often constitutes a significant portion of the total production cost in many industries such as oil sands and mining. The most commonly used materials for such applications are metallic materials having a composite microstructure consisting of hard reinforcement phases in a more ductile metal matrix. Typical examples are high chromium white irons and tungsten carbide welding overlays. The main purpose of this work is to evaluate the scouring erosion resistance of such materials for applications in handling fine sand slurries and to introduce a wear model to help understand the correlation between erosion resistance and the characteristics of microstructures.Five high chromium white cast irons and four spray and fusion coatings composed of cast tungsten carbide particles and Ni–Cr–B–Si–Fe matrix have been studied using a Coriolis scouring erosion tester in a fine sand slurry. The relationship between the erosion resistance and different microstructure parameters was explored. For the chromium white cast irons, the erosion resistance increased with increase in carbide volume fraction but the spray and fusion coatings showed the opposite trend, i.e., their erosion resistance decreased with increase in the carbide volume fraction. No clear correlation was found between erosion resistance and free path for the spray and fusion coatings while for the chromium white cast irons, the erosion resistance was found to increase rather than decrease with increase in free path.To help explain the experimental results, a wear model has been proposed for the wear resistance of composite microstructures composed of a reinforcement phase (RP) and a metal matrix. In the model, the wear surface of the material is distinguished by four different features/regions, each having unique wear resistance. The rule of mixtures (ROM) for wear resistance is applied to formulate the wear resistance of the material with the above four wear surface features. It is shown that the results can be reasonably well explained based on the proposed model by using the total edge length, L, of the RP particles exposed on a unit area of the wear surface.

Precision evolution model for the grinding-wheel wear in ELID grinding of nonstandard ultra-precision bearing raceways

Precision evolution model for the grinding-wheel wear in ELID grinding of nonstandard ultra-precision bearing raceways

Investigation on the causes of rail corrugation in high-speed railways based on the wheel–rail transient rolling contact model and wear model

This work investigated the causes of rail corrugation in a high-speed railway. A three-dimensional (3D) finite element (FE) model of the vehicle-track system (VTS) and a rail wear prediction model were developed. The 3D FE model was employed to study the dynamic interactions of the VTS excited by rail welds with varying wavelengths. The wear model calculates the wear depth on rail surface based on the Archard’s theory. The frequency response analysis and modal analysis were implemented to identify the vibration modes relevant to the corrugation. The phase relationship between the initial corrugation and the resulting dynamic wear was discussed. The vertical vibration at 543 Hz of the track was found to be responsible for the initiation of the studied corrugation. The excitation from the rail welds is one of the necessary conditions for the formation of this type of corrugation. The evolution of the phase shift of the dynamic wear with respect to the existing corrugation indicates that the corrugation caused by the rail welds is self-limited and the corrugation will stabilize at a certain value. The corrugation will translate on the rail surface due to a leading phase angle of the dynamic wear relative to the corrugation geometry.

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.

Fracture Mechanics-Based Modelling of Tool Wear in Machining Ti6Al4V Considering the Microstructure of Cemented Carbide Tools

Fracture Mechanics-Based Modelling of Tool Wear in Machining Ti6Al4V Considering the Microstructure of Cemented Carbide Tools

Numerical prediction of erosion of Francis turbine in sediment laden flow

Abstract Francis turbine is adopted in many hydropower stations widely. Usually, the operating environment is sandy water flow, and the unit will suffer from sediment wear, affecting the operating life of the unit. This article focuses on the wear problem of hydraulic turbines and uses numerical simulation to conduct research on sediment wear. Lagrange model is adopted to predict the sediment concentration in the flowpassageof the unit, and Tabakoff model is used as the wear model. The results indicate that the guide vane blades, seat rings, end clearance, and runner blades and lower rings of hydraulic turbines are prone to sediment erosion. According to friction mechanics, these areas are mainly subjected to impact wear caused by particle impact at the inlet of the guide vane and the runner. The wear on the surface of the blade passage is mainly caused by frictional wear caused by particle sliding motion. The research results provide a certain help for the optimization of hydraulic turbine wear resistance in engineering.

Evaluation of Wear Model Equations Through Analysis of Experimental Wear Data of Materials from Literature

Understanding the correlation between material characteristics and wear behavior helps in the development and manufacturing of high-quality materials for components subjected to wear, like brake pads, bearings etc. The majority of published research papers present experimental data from pin-on-disc experiments in which wear volume loss is measured using wear rate and sliding distance. However, in many publications pin on disc experimental data is interpreted by statistical methods like Taguchi method to understand the effect of material characteristics on wear behavior. This method indirectly correlates wear behavior to material parameters like hardness, modulus of elasticity and toughness of the material. However, many mathematical models are proposed in literature to directly relate material characteristics to wear behavior. However, there are gaps in published literature in interpretation of experimental data with mathematical model equations. The mathematical models like Archard model, Evans and Wilshaw model, Kato model etc proposed in literature are defined to link material characteristics like modulus of elasticity, hardness, toughness etc to wear behavior. In this study, it is proposed a methodology to interpret the pin on disc experimental wear data by fitting an analytical model to understand effect of material characteristics on wear behavior of materials.

Synergistic approach to tribological characterization of hybrid aluminum metal matrix composites with ZrB2 and fly ash: Experimental and predictive insights

This research delves into the tribological performance of hybrid aluminum metal matrix composites (HAMMCs) incorporating zirconium diboride (ZrB2) particles and fly ash as reinforcing agents. The study employs a linear reciprocating wear test to investigate the impact of dry sliding wear on these HAMMCs under ambient and elevated temperatures. Wear mechanisms are discerned through field emission scanning electron microscopy. Optimization of wear test parameters, coefficient of friction (COF), and wear rate is achieved using the genetic algorithm. Additionally, artificial neural network (ANN) and multiple linear regression analysis are employed to formulate a predictive model for wear, estimating specific wear rate and COF under various testing conditions. The ANN predictions exhibit a deviation ranging from 0% to 1.39% from the experimental values, indicating the model's effectiveness in understanding and predicting wear behavior in the study of HAMMC.