Numerical Modeling of Fretting Wear

Abstract

Abstract:In this paper, a review of some techniques proposed in the literature for modelling fretting wear is presented. Fretting wear occurs when surfaces are degraded and materials are removed due to a small relative oscillatory motion between two contact surfaces. Due to the continuous change in the shape of a structure during its lifetime, the design of engineering components subjected to fretting wear is a challenge to engineers and scientists. The available predictive tools in the literature, which make use of analytical solution of the contact pressure in the first cycle ignoring the wear effect and removal of materials in the subsequence cycles, provide inaccurate results. Numerical modelling techniques such as Finite Element Analysis (FEA) can be used to model any type of structures with configuration taking into account many complicated details such as large deformation, material non-linearity, change in geometry and time integration effect. Therefore, FEA is a very desirable technique for fretting wear analysis and lifetime prediction. This review covers modelling fretting wear using numerical modelling methods, which can be divided into three main techniques, namely the FEA method, Boundary Element Method (BEM) and Finite Discrete Element Method (FDEM). Keywords: Fretting wear, Finite Element Method, Contact mechanics INTRODUCTIONFretting wear is a phenomenon, in which surface degradations and removal of materials take place due to a small relative oscillatory motion and quasi-static load between two contact surfaces. There are many parameters that affect fretting wear including normal load, contact stress, frequency, slip amplitude, material properties, surface roughness of the contact bodies, etc. The design of engineering components subjected to fretting wear, such as couplings and splines, jointed structures etc.[1], is still a challenge to engineers. This is because of the continuous change in the component shape during fretting wear. Therefore, a predictive technique that takes into account the wear progress during life cycle is desirable. Analytical solutions of wear problems are very difficult and limited to simple 2-D configuration steady state analysis [2]. In contrast, numerical modeling techniques such as finite element analysis (FEA), boundary element analysis (BEA) can be used for any type of structures in 3-D configuration taking into account many complicated details such as large deformation, material non-linearity, change in geometry and time integration effect. In this paper different numerical modeling methods of fretting wear are reviewed. FEA MODELINGWith the rapid development of high performance computers and the methods for solving non-linear problems, FEA have applied to simulate the process of fretting wear. Simulation of wear involves solution of a general contact problem, which is highly non-linear due to the contact boundary conditions between the interfaces [3].In the last ten years literature, there are two main methods to simulate the process of fretting wear according ...