Prediction of electrical contact endurance subject to micro-slip wear using friction energy dissipation approach

Jiang, Xinyu; Pan, Fengqun; Shao, Guoqiang; Huang, Jin; Hong, Jun; Zhou, Aicheng

doi:10.1007/s40544-018-0230-x

Cited by 11 publications

(8 citation statements)

References 21 publications

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“…The correctness of the model before wear was verified by comparing it with the analytical solution of the Hertzian stress distribution. Under a normal load F, the Hertzian contact halfwidth a is given as 19 a = 4FR πE *…”

Section: Validation Of the Modelmentioning

confidence: 99%

“…Ming et al [18] developed a finite element model considering local deformation of the thread surface to simulate the self-loosening phenomenon of bolts under lateral loads. Jiang et al [19] studied the electrical contact durability and electromagnetic induction failure under fretting wear. The surface roughness has a great influence on the wear, fatigue, temperature rise [20][21][22][23][24], and friction characteristics [25] of the connecting structure.…”

Section: Introductionmentioning

confidence: 99%

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Fretting wear mechanical analysis of double rough surfaces based on energy method

Wang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part J:

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A fretting wear model of a rough surface that conforms to the actual situation is established to accurately reveal the wear mechanism of the connection structure. In the ABAQUS software, the UMESHMOTION subroutine and the energy dissipation model are used to simulate the fretting wear of double rough surfaces. The new model, a single rough surface model, and a smooth model are compared to analyze their differences. In addition, the influence of surface roughness, material, and friction coefficient on the fretting wear of rough surfaces is systematically explored through finite element simulation. The results show that the model's reliability has been verified through Hertz's theory and experiments. The stress and wear of the contact surface are more realistically reflected by the double roughness model. Besides, with the increase of surface roughness and material rigidity and the decrease of friction coefficient, the wear of the double rough surface model becomes more severe. The research work provides a theoretical basis for the design and performance prediction of the connection structure.

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Section: Validation Of the Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Fretting wear mechanical analysis of double rough surfaces based on energy method

Wang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part J:

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“…Terhorst et al [19] developed an electro-thermomechanical contact model to calculate the current density and temperature in the bulk metal forming process. Jiang et al [20] employed a frictional energy-based wear model to simulate the fretting wear profile of an electrical connector under the micro-slip loading condition. However, the electrical and thermal behaviors were ignored in the simulation.…”

Section: Arc Erosionmentioning

confidence: 99%

“…where d is the contact width. Then the theoretic values of ECR can be obtained by using Equations ( 19) and (20). Figure 6b illustrates the comparison between the simulation and theoretic results of the ECR.…”

Section: Comparison With Experimental Fretting Wear Profilementioning

confidence: 99%

Numerical Study of Coupled Electrical-Thermal-Mechanical-Wear Behavior in Electrical Contacts

Shen

2021

Metals

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Electrical contacts involve complicated electrical, thermal, and mechanical phenomena. Fretting wear as a surface damage mechanism significantly weakens the performance of electrical contact components. In this study, a numerical approach is developed to investigate the electrical-thermal-mechanical-wear coupling behavior of electrical contacts. An electrical contact conductance law is used with the current conservation model to evaluate the electrical behavior. A transient heat transfer model, including the Joule heating behavior and a thermal contact conductance law, is employed to calculate the temperature field. Both contact conductance laws are related to the contact pressure distribution obtained by the contact stress analysis. Based on the predicted contact stress and relative slip on contact surfaces, the energy wear model is used to study the evolution of fretting wear depth and contact surface geometry. The material properties in these models are temperature-dependent. The proposed numerical approach is implemented in a finite element modeling of electrical contacts, which is validated by comparing the predicted and experimental results of the wear scar profile. The effects of the fretting wear on the electric potential, current density, contact resistance, temperature, and contact pressure are numerically studied.

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“…The Archard model has been used to study wear simulation of various engineering parts. Jiang et al (2019) established a finite element model of fretting wear of electrical connectors under cyclic loads and investigated the evolution of characteristic parameters of connector contact interfaces and contact interface characteristic parameters of connectors. Wang et al (2021) predicted the wear of the contact part of the reciprocating connecting piece using the Archard model.…”

Section: Introductionmentioning

confidence: 99%

Study on simulation of multifield coupled wear in reciprocating electrical contact

Yang

Wang

2022

ILT

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Purpose Conventional wear models cannot satisfy the requirements of electrical contact wear simulation. Therefore, this study aims to establish a novel wear simulation model that considered the influence of thermal-stress-wear interaction to achieve high accuracy under various current conditions, especially high current. Design/methodology/approach The proposed electrical contact wear model was established by combining oxidation theory and the modified Archard wear model. The wear subroutine was written in FORTRAN, and adaptive mesh technology was used to update the wear depth. The simulation results were compared with the experimental results and the typically used stress-wear model. The temperature of the contact surface, distribution of the wear depth and evolution of the wear rate were analyzed. Findings With the increase in the current flow, the linear relationship between the wear depth and time changed to the parabola. Electrical contact wear occurred in two stages, namely, acceleration and stability stages. In the acceleration stage, the wear rate increased continuously because of the influence of material hardness reduction and oxidation loss. Originality/value In previous wear simulation models, the influence of multiple physical fields in friction and wear has been typically ignored. In this study, the oxidation loss during electrical contact wear was considered, and the thermo-stress-wear complete coupling method was used to analyze the wear process.

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Prediction of electrical contact endurance subject to micro-slip wear using friction energy dissipation approach

Cited by 11 publications

References 21 publications

Fretting wear mechanical analysis of double rough surfaces based on energy method

Fretting wear mechanical analysis of double rough surfaces based on energy method

Numerical Study of Coupled Electrical-Thermal-Mechanical-Wear Behavior in Electrical Contacts

Study on simulation of multifield coupled wear in reciprocating electrical contact

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