A Numerical Study on the Effect of Debris Layer on Fretting Wear

Abstract

Fretting wear is the material damage of two contact surfaces caused by micro relative displacement. Its characteristic is that debris is trapped on the contact surfaces. Depending on the material properties, the shapes of the debris, and the dominant wear mechanisms, debris can play different roles that either protect or harm interfaces. Due to the micro scale of the debris, it is difficult to obtain instantaneous information and investigate debris behavior in experiments. The Finite Element Method (FEM) has been used to model the process of fretting wear and calculate contact variables, such as contact stress and relative slip during the fretting wear process. In this research, a 2D fretting wear model with a debris layer was developed to investigate the influence of debris on fretting wear. Effects of different factors such as thickness of the debris layer, Young’s modulus of the debris layer, and the time of importing the layer into the FE model were considered in this study. Based on FE results, here we report that: (a) the effect of Young’s modulus of the debris layer on the contact pressure is not significant; (b) the contact pressure between the debris layer and the flat specimen decreases with increasing thickness of the layer and (c) by importing the debris layer in different fretting wear cycles, the debris layer shows different roles in the wear process. At the beginning of the wear cycle, the debris layer protects the contact surfaces of the first bodies (cylindrical pad and flat specimen). However, in the final cycle, the wear volumes of the debris layers exhibit slightly higher damage compared to the model without the debris layer in all considered cases.

Numerical Modeling of the Effect of Randomly Distributed Inclusions on Fretting Fatigue-Induced Stress in Metals

“…The mesh refinement showed convergence towards the peak analytical solution for the shear traction. Finally, according to the results, a 2 µ m × 2 µ m element size is used around the contact zone, which is smaller than in most of the previous numerical studies [8,[32][33][34][35][36][37][38]. The simulation results and the theoretical results may not be exactly the same, due to numerical errors and geometric constraints [67].…”

“…For experimental methods, it is difficult to get the details of stress field and initiation of crack. Therefore, numerical modeling is an efficient way to solve the problem of fretting fatigue [8,[32][33][34][35][36][37][38] and fracture [39][40][41][42][43]. However, only few studies have taken into account the heterogeneity of material under fretting fatigue conditions [14,44,45].…”

A Review on Fretting Wear Mechanisms, Models and Numerical Analyses

“…Although some assumptions were made, i.e., a) asperities were distributed uniformly, b) asperities were spherical with uniform radius and c) asperities were rigid, this multi-scale model successfully predicted the fretting wear process with evolution of interface between the debris and the substrate, which was closer to the realistic situation. [Shipway, Williams, Leen et al (2009)] A plane strain fretting wear model with a debris layer was developed to investigate effects of debris on fretting wear damage [Yue and Abdel Wahab (2016)]. In this study, both the Young's modulus and the thickness of the debris layer were variable in this study.…”

Buckling analysis of nanoplates using IGA

“…In continuum mechanics, one of the well-known theories is the nonlocal continuum theory of Eringen [1]. Finite Element method (FEM) is a very well know numerical techniques and has been used for a wide range of applications [2][3][4][5][6][7][8][9][10][11][12][13][14][15]. Using FEM, Free vibration analysis of FG size-dependent nanobeams was studied by Alshorbagy et al [16].…”