Finite Element Sliding Wear Simulation of 2D Steel-on-Steel Pin-on-Disc Tribometer 2018-28-0011
Wear of components is a critical factor influencing the service life of a product. Thus wear prediction and simulation has become an important part of engineering. One of the most common forms of wear in mechanical components is sliding wear. Factors affecting dry sliding wear include normal load, relative speed, geometry (both macroscopic and microscopic), temperature, material properties and environmental conditions. Sliding wear experiments are done using tribometers. However, such experiments are expensive and time consuming. In the past few decades, a Finite Element Method (FEM) based wear simulation approach has gained popularity. The objective of the present work is the numerical wear prediction of 2D steel-on-steel pin-on-disc dry sliding contact using Finite Element Method (FEM). Initially, the 2D elastic contact problem is solved using non linear finite element method to obtain the pressure at the contact nodes. The contact pressure obtained is validated with the Hertz solution. The Archard's wear law is used along with the Euler's integration scheme to obtain the material worn out at each wear incremental step. Wear is taken into account by updating the pin geometry after each step. A user-defined FORTRAN subroutine UMESHMOTION is used to apply the wear at the contact nodes. Arbitrary Lagrangian-Eulerian (ALE) technique, an adaptive meshing technique in ABAQUS, is used. This technique prevents element distortion and maintains a high quality mesh throughout the analysis. In order to reduce the computational time, the extrapolation technique is used. Pin-on-disc (PoD) experiments are performed using SAE 304 stainless steel as pin material and SAE 52100 hardened steel as disc material to validate the wear simulation results. The coefficient of friction and the wear coefficient used in the simulations are determined from the experiments. Mesh convergence study is done and the contact pressure obtained from FEM is compared with the Hertz analytical solution. The wear depth obtained from simulations is compared with the experimental results.