Wear Rate Research Articles

Optimization of process parameters in fabricating AA6082/Nip surface composite using friction stir processing technique

Abstract In this present study, an attempt was made to improve the Ultimate Tensile Strength (UTS) and Microhardness (MH) of friction stir-processed AA 6082 with Nip surface composites without affecting the ductility of the Base Metal (BM). Nip micron particle with an average size of 149 μm (99.99 purity) was utilized as reinforcement and AA6082 as a matrix for fabricating the surface composites. Process parameters namely rotational speed, transverse speed, and volume fraction with three levels considered as input parameters for this study. Moreover, ultimate tensile strength, microhardness, and wear rate were determined as process output. For this study, experiments were conducted as per Taguchi’s L9 orthogonal array (OA) by repeating each trial three times and the average values were used for further analysis. ANOVA was performed to ensure the influential process parameter and the results exhibited that the volume fraction of Nip exhibited the most influential parameter among the three process parameters. Additionally, Grey relational analysis (GRA) was used to grade the rank of the experimental samples using the Grey Relation Coefficient (GRC). Based on this method, the optimal process parameters (Rotational Speed = 1250 rpm, Transverse Speed = 40 mm min−1, Volume Fraction = 18%) were chosen and the optimal sample (Rank 1) attained a UTS of 247 MPa and MH of 100 HV. The results revealed that the fabricated composite (AA6082/Nip) demonstrated an improvement in UTS (26.02%), MH (56.25%), and wear rate (57.38%) as compared to BM (AA6082). Eventually, the surfaces of the optimized samples were also analyzed by x-ray diffraction (XRD), energy dispersive x-ray analysis (EDAX), and field emission-scanning electron microscopy (FE-SEM) methods to confirm the composition of surface composite and the uniform distribution of particles.

Machine Learning and Taguchi Techniques for Predicting Wear Mechanisms of Ni-Cu Alloy Composites

Nickel-Copper alloys hybrid composite was formed in an induction furnace set up on a sand substrate. With different percentages of Al2O3 (3, 6, 9 and 12 wt.%) and TiO2 (constant 9wt.%) reinforcements, the goal is to examine the wear behavior and friction coefficient of Ni-TiO2-Al2O3. The factors considered for the wear analysis were sliding distance (1500, 1000, and 500 m), applied load (25, 50, and 75 N), and sliding velocity (1.46, 2.93, and 4.39 m/sec). The pin-on-disc equipment is utilized to perform different wear tests are carried out using in accordance with the Taguchi L27 orthogonal array. The machine learning used to correlate between actual and anticipated values for both metrics is strong, with a reasonable error margin. The Mean Squared Error (MSE) for the wear rate was 0.1025 (10.25%) in the Linear Regression model and 0.2390 (23.89%) in the Random Forest model. Regression analysis determined the impact of several parameters on wear rate, whilst machine learning approaches expanded the evaluation of wear rate and coefficient of friction beyond experimental data. The findings demonstrate the effectiveness of combining Taguchi methods with machine learning to accurately anticipate wear mechanisms in Ni-Cu alloy composites.

Enhancing wear resistance of aluminum 6061 composites with fly ash: A sustainable approach for industrial applications

This study investigated the benefits of adding fly ash as a reinforcement material. The benefits included cost-effectiveness, improved quality, isotropic behavior, and environmental advantages. To improve self-lubrication and wettability behavior, Al6061 alloy composites were fabricated with different amounts of fly ash (0%, 2%, 4%, 6%, and 8% by weight), along with a fixed amount of graphite (3wt.%) and magnesium (2wt.%). Wear tests were conducted using Taguchi’s Design of Experiment (DoE) approach on the composites. The optimized composition with 6% fly ash exhibited the least wear rate under the test conditions of load = 10 N, sliding velocity = 3 m/s, and sliding distance = 2 km. SEM images revealed a uniform distribution of fly ash and graphite reinforcement in the matrix, contributing to enhanced wear resistance. The composites exhibited fewer scratches and plastically deformed surfaces, indicating a decrease in wear rate and increased wear resistance with higher fly ash content. ANOVA were used, and four parameters were identified to be critical, Composition at 34%, Sliding Distance at 27%, load at 23%, and Sliding Velocity at 12% contribution with a statistical confidence of 95%. This research contributes to developing cost-effective and environmentally sustainable materials with improved mechanical properties. It makes them suitable for various industrial applications, such as the automotive industry, where wear resistance is essential.

Improving the tribological and corrosion behavior of Ni[sbnd]B coating with low boron content from optimized lead-free bath on aluminum alloys

This study focuses on producing environmentally friendly, lead-free nickel‑boron (NiB) coatings as an alternative to hard chromium coatings. Using the electroless method, the NiB coatings were fabricated from a lead-free bath, and the effects of varying B and Ni concentrations on the coatings' chemical composition, surface morphology, hardness, corrosion resistance, and wear performance were investigated. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) were used to analyze surface morphology and phase composition. Corrosion performance was evaluated using potentiodynamic polarization (PP) and electrochemical impedance spectroscopy (EIS), while wear behavior was tested at sliding speeds of 20, 30, and 40 cm/s. The study highlights the critical role of sliding speed on wear mechanisms, friction coefficient, wear rate, and surface morphology. The analyses revealed that the optimal NiB coating, containing 34 g/L Ni and 3 g/L B, exhibited the highest hardness, the lowest corrosion rate, and the highest wear rate performance. The values obtained from these analyses were 891 HV for hardness, 8.87 × 10−6 mpy for corrosion rate, and 2.21 × 10−4 mm3/N·m for wear rate. The use of analysis of variance (ANOVA) identified key factors influencing these properties. The findings suggest that optimizing boron and nickel concentrations significantly enhances NiB coatings' corrosion resistance and wear performance, making them suitable for industrial applications.

Effect of Gasket Wear Rate on Hydraulic Performance and Internal Flow of Multistage Centrifugal Pump with Floating Impellers

Abstract The sealing gaskets of multistage centrifugal pumps are prone to wear during operation. This study investigates the influence of gasket wear rate on hydraulic performance and internal flow field through numerical simulations. As the wear rate of the gasket increases, both the efficiency and head coefficient of the pump gradually decrease. When the gasket is completely worn out, the efficiency decreases by 5.6% and the head coefficient decreases by 9.5% compared to the unworn gasket condition. Analysis of the internal flow field reveals that the front side chamber is most significantly affected by gasket wear. As the gasket wears, the flow velocity within the front side chamber increases gradually, and the high-entropy production zone expands, thereby affecting the hydraulic performance of the pump. The findings of this study provide practical engineering insights for enhancing the operational performance of multistage centrifugal pumps.

High-temperature tribological evaluation of cobalt-based laser cladded disc for automotive brake systems

This study investigates the high-temperature wear behavior of laser-cladded (LC) cobalt-based Stellite 6 alloy coatings and compares the wear resistance of the cladding layer to the grey cast iron (GCI) substrate material at three different elevated temperatures: 150 °C, 250 °C, and 350 °C. Wear mechanisms at elevated temperatures were analyzed using SEM-EDS and Raman Spectroscopy to understand the material removal processes and degradation for the discs and counterpart composite friction material pins, respectively.The results indicated a significant improvement in wear resistance for cobalt-based alloy cladding at high temperatures. Wear rates were reduced by 5.0 %, 43.0 %, and 16.0 % at 150 °C, 250 °C, and 350 °C, respectively. The LC - brake pin tribo-pair exhibited a continuous increase in friction coefficients (CoF) with an increase in testing temperatures. The wear mechanism for laser-cladded discs exhibited a combination of abrasive and adhesive wear, with abrasive wear prevailing at 150 °C and increased adhesive wear at 250 °C and 350 °C. However, at 350 °C, decomposition of phenolic resin and the adhesive wear mechanism, led to brake pin failure. For GCI discs oxidative wear was identified as the predominant wear mechanism. The improved knowledge of wear mechanisms on LC Stellite 6 against composite brake pins, is set to enhance surface modification of GCI for brake disc applications.

Preparation and performances of conductive, wear-resistant, and anti-corrosion coatings based on low content monodisperse SWCNTs

Single-walled carbon nanotubes (SWCNTs) are considered an ideal candidate material for multifunctional coatings because of their excellent electrical, thermal and mechanical properties. However, achieving uniform dispersion of SWCNTs while maintaining their structure and performance remains a significant challenge. The monodisperse SWCNTs (m-SWCNTs) can be obtained using a non-covalent PVP dispersant under the graded homogenization method. PVP acted as steric hindrance due to the π-π conjugate, thereby hindering the agglomeration and preventing the damage of SWCNTs. We incorporate low amounts of m-SWCNTs into fluorocarbon (FC) coatings to fabricate m-SWCNTs/FC composite coatings. We also investigate the effect of m-SWCNTs content on the electrical conductivity, corrosion resistance and wear resistance of the composite coating. Our results indicate that when the content of m-SWCNTs reaches at 0.25 wt%, the electrical resistivity of the m-SWCNTs/FC composite coating is 1.67 × 10−2 Ωm, significantly decreased by 9 orders of magnitude compared to FC coating. The conductive network would be formed by the high aspect ratio and non-damaged of m-SWCNTs to improve the conductivity. Additionally, the wear rate containing 0.15 wt% m-SWCNTs decreased by 50.1 % due to the improved strength and heat conduction to inhibit the adhesive wear. Furthermore, in comparison to bare steel, the corrosion current density of 0.15 wt% m-SWCNTs/FC composite coating is reduced by two orders of magnitude due to zigzag the corrosive path. Our studies suggest that the m-SWCNTs/FC composite coatings have a broad prospect in preparing large-scale, high-performance, and low-cost functional coatings.

Improving microstructure and frictional wear behavior of plasma cladding FeCoCrNiMo high-entropy alloy layers by annealing treatment

The application of high-strength, wear-resistant materials for the restoration of large-scale coal development equipment is pivotal in ensuring efficient production and energy conservation within the industry. In this study, FeCoCrNiMo high-entropy alloy (HEA) cladding layers were fabricated on Q235 steel using plasma cladding techniques and subsequently subjected to annealing at 700°C, 800°C, 900°C, and 1000°C, respectively. The microstructural evolution, hardness, and wear resistance of the annealed cladding layers were thoroughly investigated. The results indicated that the microstructure of FeCoCrNiMo HEAs predominantly consisted of alternating eutectic formations of FCC, σ, and μ phases. The content of σ phase initially increased and then decreased with the increase of the annealing temperature. As the σ phase increased, both the microhardness and wear resistance were enhanced. Compared to HEA layers annealed at other temperatures, the HEA layer annealed at 900°C exhibited the highest hardness (700 HV). The wear mechanisms of the cladding layers were predominantly characterized by oxidative wear and adhesive wear. Notably, a stable oxide film was observed on the surface of the cladding layer treated at 900°C, with a wear rate as low as 1.27×10-7mm3N-1mm-1. This study provided a technological basis and theoretical support for the repair of coal equipment.

Improving the mechanical and tribological properties of Cu matrix composites by doping a Mo2BC ceramic

Cu matrix composites (CMCs) are widely employed for tribological applications such as in sliding bearings and electrical contact fields. However, the Cu matrix needs to be modified to improve its mechanical and tribological properties. In this study, CMCs reinforced with Mo2BC ceramic particles (10–30wt.%) are prepared via the spark plasma sintering (SPS) route method. In comparison with the plain Cu sample, when the content of the Mo2BC particles increased to 30wt.%, the Vickers hardness, yield strength, and tensile strength of CMCs increased by 196%, 157%, and 588%, respectively. Fine grain and load transfer strengthening mechanism are considered the main strengthening mechanism. Introducing the Mo2BC ceramic effectively reduces friction and wear as well as the frictional noise vibration of CMCs. Incorporating Mo2BC ceramic into the Cu matrix can elevate the load-bearing ability, inhibiting mechanical and adhesive wear. In addition, the composite exhibits superior friction and wear properties as the content of Mo2BC ceramic increases gradually up to 30wt. %, where the friction coefficient and wear rate are as low as 0.35 and 3.25 × 10−6 mm3/Nm, respectively. A layer of tribo-film containing Fe2O3 derived from the counterparts and induced by the tribo-oxidation reaction can provide a lubricating effect. Considering the superior mechanical and tribological properties, the as-prepared CMCs could be an attractive alternative material for sliding bearing fields.

Effect of heat treatment on wear resistance of cold-sprayed Ti-diamond composite coating

In order to enhance the wear resistance of cold-sprayed Ti coatings, Ti-diamond (Ti-MD) composite coatings were fabricated, followed by heat treatment at different temperatures. The effects of heat treatment temperature on the wear resistance of the composite coatings were assessed using X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), microhardness testing, and wear resistance experiments. The results show that the composite coating undergo no phase transformation after heat treatment, and exhibits higher microhardness and improved wear resistance. The porosity results showed that the porosity of the coating decreased as the heat treatment temperature increases. TEM results showed that stable TiC (about 10 nm) was formed at the interface between the titanium and diamond particles after heat treatment at 800 °C, and nanoindentation results showed that the heat-treated coating had higher deformation resistance. Specifically, when the heat-treated temperature rose to 800 °C, the composite coating exhibits an 80 % reduction in wear rate, primarily attributable to the decreased porosity of the coating and the enhanced adhesion between Ti and diamond particles. The wear mechanisms of the heat-treated coatings are predominantly reduced oxidative and abrasive wear.

The investigation of support effect from hard substrate to soft coating of PI/EP-PTFE under different coating thicknesses and frictional contacts

Engine bearings on ships can experience rapid failure under extreme conditions, such as when seawater infiltrates the engine compartment due to collisions with reefs or missile attacks. To enhance the self-lubrication and wear resistance of these bearings, a composite coating consisting of ZrO2-PI/EP-PTFE has been designed. This coating was applied using liquid spraying technology onto the surfaces of A370 aluminum alloy, CuPb22Sn2.5 copper alloy, and 15# carbon steel. Three different coating thicknesses—20 μm, 30 μm, and 40 μm—were applied to each substrate. The tribological properties of these coatings on the three substrates were investigated under both dry sliding wear and seawater corrosion conditions. The results indicated that the tribological performance of the coatings is influenced by factors such as the coating hardness, frictional contacts, and the supporting effect of the substrate. The hardness and elastic modulus of the coatings decreased as the coating thickness increased. A thicker coating results in reduced support from the substrate. The adhesive wear of these coatings under dry sliding wear conditions on the different substrates is also presented. The coefficients of friction (CoFs) of these coatings increased with coating thickness on all three substrates. In contrast, the wear rates decreased as the coating thickness increased. The hardness of the coating was influenced by the support effect of the substrate. The primary factors governing the tribological performance of the coating under dry sliding conditions are the pinch action of the hard grinding ball against the soft coating on the hard substrate and the contact pressure. Abrasive wear, spalling wear, plough grooves, and spalling pits were observed under seawater corrosion conditions. These findings suggest that increased coating thickness is associated with lower coefficients of friction (CoFs) and wear rates. The main contributing factors are seawater corrosion and the scouring effect of high-frequency reciprocating friction.

Wear behavior of CoCrFeNi high-entropy alloy prepared by mechanical alloying

Equiatomic quaternary CoCrFeNi powder was prepared from the individual metals by mechanical alloying of the mixed powders at room temperature. The as-milled powder contained particles of irregular shape with an average particle size of 0.62 μm, and exhibited a dual-phase composition of the face-centered cubic and the body-centered cubic structures. The as-milled powder was consolidated by hydraulic pressing at room temperature and sintered at 950 °C in argon and vacuum. The compacted material exhibited a single-phase composition of the face-centered cubic structure alone and a chemical composition close to equiatomic with uniform distribution of all constituents, indicating that the desired CoCrFeNi high-entropy alloy (HEA) had been formed. The microhardness of the vacuum-sintered CoCrFeNi HEA was measured to be 118±7 HV, exceeding that calculated by the rule of mixture. The coefficient of friction was determined by pin-on-disk dry sliding studies at room temperature and found to be 0.65 and 0.44 for the applied loads of 25 for 35N, respectively, and the corresponding wear rates were 4.6×10-4 and 9.1×10-4 mm3/N·m. XPS studies on the worn alloy surfaces showed the formation of oxidized tribo-layers, composed of predominantly Cr2O3. Overall, this study has demonstrated that mechanical alloying followed by simple furnace sintering at a moderate temperature is able to yield an abrasion-resistant CoCrFeNi HEA suitable for structural applications.

TiO2-hBN nanocomposite coating with excellent wear and corrosion resistance on Ti6Al4V alloy prepared by plasma electrolytic oxidation

Hexagonal boron nitride (hBN) is recognized for its promising application prospects in anti-friction and corrosion resistance due to its self-lubrication and excellent impermeability to gases and liquids. In this study, the TiO2-hBN nanocomposite coatings are prepared via the liquid plasma-assisted particle deposition sintering (LPDS) technology, enabling compact and uniform growth of hBN on the Ti6Al4V surface. Results indicate that the dense and stable plasma at the coating/electrolyte interface facilitates the deposition and sintering of hBN particles, effectively filling surface defects and achieving a coating density of 86.7 %. The friction coefficient of the TiO2-hBN nanocomposite coating significantly decreases from 0.54 (titanium alloy) to 0.28, remaining stable even after 2000 sliding cycles. Compared to the substrate, the wear rate (4.3 × 10−4 mm3N−1 m−1) of nanocomposite coating drops by 70.8 %, which is primarily attributed to the self-lubricating property of hBN, reducing the frictional shear stress. Moreover, the TiO2-hBN nanocomposite coating also has excellent corrosion resistance due to the hBN sheet filling internal defects and inhibiting the corrosion reaction. All these merits render the LPDS technology competitive in expanding the severe service conditions of titanium alloys in aerospace and marine engineering equipment.

Synthesis, microstructure, mechanical and tribological properties of high-entropy carbides (WZrNbTaTi)C-SiCw

In this work, composite high-entropy carbides (WZrNbTaTi)C-x SiCw (x = 0, 5 %, 10 %, 15 %, 20 %) are prepared using the two-step fast hot-pressing sintering (TSFHPS) method. The whiskers in the samples are evenly dispersed and well integrated with the ceramic matrix, forming high density materials. The mechanical properties and tribological properties at room temperature are studied, revealing that the addition of SiCw improves the performance of the materials. When the whisker content is 15 %, the hardness and fracture toughness of composite ceramics are the highest, which are 22.6 GPa and 6.8 MPa m1/2, respectively. The bending strength of the samples increases monotonically with the increase of whisker content, and reaches 639.2 MPa at 20 % content. At the same time, the addition of an appropriate amount of SiCw prevents the propagation of micro-cracks and the expansion of oxidative wear, thereby reducing the friction coefficient and wear rate, and improving the wear resistance of high-entropy carbides.

Improvement of wear resistance of polyarylene ether nitrile composites through synergistic effect of PTFE and ZnO

Semi-crystalline polyarylene ether nitrile (PEN) has good thermal and mechanical properties, but its wear resistance needs to be improved, which limits its application in extreme environments. In this work, PEN was used as a matrix resin, disc-shaped zinc oxide (ZnO) was used as a wear-resistant reinforcing filler and nucleating agent, and polytetrafluoroethylene (PTFE) solid lubricating phase was introduced to fabricate the PEN/ZnO/PTFE composites. The lowest coefficient of friction and wear rate of PEN-based composites were observed when filled with 7.5 wt% of PTFE. To further improve the hardness and elastic modulus, the PEN/ZnO/PTFE composites were subjected to heat treatment, and the wear rate was decreased by 26.1 %. In addition, the properties of the composites were investigated under different loading conditions and the results showed a significant improvement in the tribological properties. This study further confirms that the synergistic effect of the rigid filler (ZnO) and solid lubricant (PTFE) can substantially reduce friction and wear. Thus, it is a significant advancement in the development of high-performance wear resistant PEN- based composites.

Design and performance analysis of carbon brush collector ring end-face contact for hydro generator

Abstract In hydro generators, the conventional radial contact method often results in unstable contact between carbon brush collector rings due to collector ring deflection. This paper presents a novel end-face contact method designed to enhance stability. The trajectory equations of the brush/ring contact are established when the collector ring swings and the “loss of contact” gaps of the two contact methods are compared. Further comparative analysis is conducted on the current-carrying friction wear of carbon brushes and collector rings in two contact modes. The results show that compared with the radial contact method, the brush/ring in the end-face contact method has a smaller gap and shorter time, the carbon brushes are less susceptible to spark erosion, the increase in friction coefficient and wear rate is small, and the contact resistance is lower and more stable. Scanning electron microscope analysis also shows that the spark erosion on the surface of the carbon brushes in the end contact mode is significantly weaker than that in the radial contact mode.

Microstructural evaluation and optimization of wear behaviour of vacuum arc melted AlFeCrNiSi high entropy alloy

High-entropy alloys (HEA) are equiatomic, multi-element systems that, while having several elements with various crystal geometries to form a single phase. In this study, a novel equiatomic AlFeCrNiSi HEA is prepared using the vacuum arc melting process. The resulting microstructure featured dendritic and inter-dendritic structures with formations of intermetallic compounds such as Al₃Fe₂Si, NiAl, and AlCrNi phases. EDS analysis confirmed the presence of alloying elements and EBSD analysis revealed refined grains with an average size of 1 ± 0.15 µm size. Pin-on-Disc wear test with varying test parameters is conducted to optimize the wear parameters. Signal-to-noise ratio and analysis of variance identified the most significant wear parameters, with load being the most influential, followed by sliding distance and velocity. The wear rate is minimum at the lowest conditions of applied load, sliding distance, and sliding velocity. The improved microhardness also contributed to the improved wear resistance of the cast alloy. The subsequent worn morphology revealed the formation of grooves, microcracks, and oxide layers on the worn surface.

Mechanical, tribological and modal characteristics of eco-friendly coir/sugarcane fillers reinforced polymer composites

Abstract Polymer-based composites have been drawing the attention of the research community for many decades, not only in academia but also in industry. However, continuously increasing environmental concerns have led the researchers to focus on natural composite materials. This is a challenge for researchers to develop a natural composite without compromising the composites’ excellent mechanical properties and tribological performance. In this research, coir and sugarcane are selected as the natural fillers, and epoxy resin has been chosen for matrix material. To look into the crystallinity of composites, XRD analysis was done. In addition, a mechanical study was done to look at the manufactured composites’ tensile and flexural characteristics. The tribological performance (i.e., wear rate and friction coefficient) of the composite samples is investigated by using a pin-on-disc setup. The parameters such as filler loading and normal load affecting the tribological performance of epoxy-based natural composites are studied. The results show that the wear and friction characteristics of the composite reinforced with sugarcane and coir were 10.78% and 57.80% lower than those of the neat composite, respectively.

Sustainable hard machining under zirconia nano-cutting fluid: A step towards a green and cleaner manufacturing process

The present study deals with the machinability (flank wear, surface integrity, cutting temperature and power consumption) and sustainability (Carbon emission and noise emission) investigations during hard machining under dual nozzle assisted novel ZrO2 based nano fluid MQL condition considering Taguchi L27 OA design of experiment. 0.3 % wt. ZrO2 nanofluid MQL medium effectively reduce cutting temperature and found as 65 °C, which shows the effective cooling and lubrication properties of zirconia nanofluid. Improvement in surface quality has been observed with lower rate of flank wear. Depth of cut and feed are found to be the most influential factor affecting power consumption and carbon emission with contribution of 47.213 % and 60.861 % respectively. Noise emission mostly affected by the depth of cut with a contribution of 43.40 %. Optimal parametric condition yields d: 0.1 mm, f: 0.1 mm/rev and v: 80 m/min through WASPAS and sustainable towards manufacturing industries for cleaner hard machining.

Quantitative evaluation of pyramid belt wear using light-reflection characteristic of agglomerate coating and image processing

As a new generation of coated abrasive products with a unique pyramid-shaped structure, pyramid belt offers finer and more uniform grinding effects, and has been increasingly applied in precision grinding. However, belt wear occurs inevitably, challenging the control of shape accuracy and surface quality of ground components. Current research on pyramid belt wear is relatively limited, still lacking a universal, rapid method for observing and evaluating belt wear. In response, this paper proposes a quantitative evaluation method for pyramid belt wear using light-reflection characteristic of agglomerate coating and image processing. Firstly, a detailed analysis of the wear types and characteristics of pyramid belt is conducted. Then, focusing on the agglomerate flat wear, a method utilizing the light-reflection characteristic of agglomerate coating for observing belt wear morphology is proposed, enabling clear image capture of belt wear contours. Based on this, a wear coefficient based on the geometric characteristics of agglomerate is defined, and a quantitative evaluation method for belt wear using image processing is further proposed. The wear experiment of the belt is conducted on a robotic belt grinding platform, and experimental results show that the evaluation deviation of the proposed method from the evaluation results based on optical profilometer is within 5% at a 95% confidence interval, demonstrating the effectiveness of this method. Additionally, this method has advantages such as high computational efficiency, low cost, and good usability. Finally, the temporal evolution processes and spatial distribution patterns of belt wear and material removal rate are investigated and analyzed.