Search Results (109)

To address the wear life prediction challenge of Guide Cones in passive compliant connectors under dynamic loads within specialized equipment, this study proposes a dynamic wear modeling and life assessment method based on the improved Archard model. Through integrated theoretical modeling, finite element simulation, and experimental validation, we establish a bidirectional coupling framework analyzing dynamic contact mechanics and wear evolution. By developing phased contact state identification criteria and geometric constraints, a transient load calculation model is established, revealing dynamic load characteristics with peak contact forces reaching 206.34 N. A dynamic contact stress integration algorithm is proposed by combining Archard’s theory with ABAQUS finite element simulation and ALE adaptive meshing technology, enabling real-time iterative updates of wear morphology and contact stress. This approach constructs an exponential model correlating cumulative wear depth with docking cycles (R² = 0.997). Prototype experiments demonstrate a mean absolute percentage error (MAPE) of 14.6% between simulated and measured wear depths, confirming model validity. With a critical wear threshold of 0.8 mm, the predicted service life reaches 45,270 cycles, meeting 50-year operational requirements (safety margin: 50.9%). This research provides theoretical frameworks and engineering guidelines for wear-resistant design, material selection, and life evaluation in high-reliability automatic docking systems. Full article

This study investigates the development of a tire wear model using finite element techniques. Experimental testing was conducted using the Hoosier R25B slick tire mounted onto a Mustang Dynamometer (MD-AWD-500) in the Automotive Center of Excellence, Oshawa, Ontario, Canada. A general acceleration/deceleration procedure was performed until the battery was completely exhausted. A high-fidelity finite element tire model using Virtual Performance Solution by ESI Group, a part of Keysight Technologies, was developed, incorporating highly detailed material testing and constitutive modeling to simulate the tire’s complex mechanical behavior. In conjunction with a finite element model, Archard’s wear theory is implemented algorithmically to determine the wear and volume loss rate of the tire during its acceleration and deceleration procedures. A novel application using a modified wear theory incorporates the temperature dependence of tread hardness to measure tire wear. Experimental tests show that the tire loses 3.10 g of mass within 45 min of testing. The results from the developed finite element model for tire wear suggest a high correlation to experimental values. This study demonstrates the simulated model’s capability to predict wear patterns, ability to quantify tire degradation under dynamic loading conditions and provides valuable insights for optimizing performance and wear estimation. Full article

The wear failure of vertical shaft planetary mixer blades under complex working conditions directly affects the quality and productivity of concrete. Given that it is time-consuming and labor-intensive to obtain the wear characteristics of mixer blades by experimental methods, this study used numerical simulation to analyze the effects of different factors on the wear characteristics of mixer blades based on the Hertz–Mindlin with JKR cohesive contact model and the Archard wear model. The results of this study show that under the influence of different factors, the blade is subjected to tangential cumulative contact energy and contact force is significantly larger than that in the normal direction, the wear of the blade is judged to be the form of abrasive wear accompanied by impacts, and the wear on the outer middle and lower edge regions of the blade is the most serious. Specifically, for every 5 rpm increase in mixing speed, the blade wear rate increases by 24.14% on average; for every 5° increase in blade angle, the blade wear rate decreases by 2.9% on average; for every 10% increase in the mass ratio of stone aggregate, the blade wear rate increases by 5.95% on average; conical aggregates have the most serious effect on blade wear, while spherical aggregates have the most minor effect. This study provides the theoretical basis and numerical support for understanding the reasons for blade wear loss and enhancing the service life of mixer blades. Full article

The paper offers an overview of the motor vehicle brake pad wear process. Considering the types of wear that occur between the pads and the disc, the study begins by presenting Archard’s fundamental wear law. It explains how the hardness and roughness of materials can influence the wear rate. Furthermore, the analysis describes factors influencing the wear coefficient, including chemical affinity between materials, surface quality, thermo-elastic instability (TEI) of the materials, and environmental effects. The paper also presents detection systems for brake pad wear, such as sensors-based monitoring and artificial neural networks (ANNs). These systems monitor brake pad wear in real time, thereby improving the driving safety by alerting the driver to the condition of the brake pads. The principles and systems analyzed form the basis for predictive maintenance, minimizing the risks of brake failure due to excessive wear. Full article

Silicon-doped tetrahedral amorphous carbon (ta-C:Si) coatings are promising materials for achieving ultralow friction in water-lubricated environments, attributed to the formation of Si(OH)_x-based tribofilms. However, the deposition process via filtered cathodic vacuum arc (FCVA) often introduces large particles into the film, increasing surface roughness and causing accelerated wear during the initial sliding phase, despite the high hardness of the coating. In this study, ball-on-disk tribological tests were performed to investigate the wear behavior of ta-C:Si coatings under water lubrication. Friction coefficients, wear volume, and surface roughness were analyzed over various sliding durations. The Archard wear equation and the plasticity index were used to analyze wear and contact behavior. The friction coefficient decreased from 0.14 to 0.04 within the initial 100 m section, and the surface roughness of ta-C:Si decreased sharply from 0.35 μm to 0.01 μm based on the Rpk parameter during 10 h. Following this period, the plasticity index decreased from an initial value of 1.1 to below 0.6, transitioning to a fully elastic contact stage, marking the onset of steady-state wear after 10 h. These results indicate that the reduction in surface roughness plays a crucial role in stabilizing wear behavior and provide insights into optimizing the long-term performance of ta-C:Si coatings in aqueous environments. Full article

This paper presents a method of numerical simulation, using the finite element method for the brush wear process during the deburring of the edge of the workpiece. The work was carried out in the Ansys Workbench environment in the Ansys Mechanical module. This study reviews the effect of selected parameters of the technological process (rotational speed and depth of tool penetration into the workpiece) on the abrasive wear of the tool. The discussion examines the subject of the 3D or 2D approach in terms of results, quality, and time of computation. A series of numerical analyses (2D) were carried out to investigate the effect of process parameters on the wear rate and, consequently, on the tool life. Obtained results on the quantity of worn material were critically assessed in relation to real-world industrial conditions. The difference between the numerical model and the test performed in the industry environment varied from 3 to 46% and was discussed in this paper. Additionally, to improve the quality of the results in Ansys, an APDL script with adaptative mesh was prepared. The article contains a discussion on the possibility of numerical model development. Full article

In slurry shield tunneling projects, leakage from floating seals frequently leads to abnormal failures of disc cutters. To investigate the leakage characteristics at the floating seal end faces of the cutters, a numerical method is proposed for analyzing the dynamic leakage behavior of the floating seal end faces, considering the effects of wear. The elastohydrodynamic lubrication problem of the floating seal was addressed using the Reynolds equation and the slicing method, leading to the development of a computational model for the pressure and thickness distribution of the oil film on rough surfaces. Based on the Archard wear equation, a dynamic surface roughness model considering wear was established. Furthermore, a numerical model for dynamic leakage of the floating seal end faces in shield machine cutters, incorporating wear effects, was developed. Simulated friction and wear tests of the floating seal end faces, along with cutter seal leakage experiments, were conducted for validation. The results demonstrate that the dynamic surface roughness model considering wear can effectively predict the roughness evolution of worn surfaces. The trend of the theoretical leakage rate is generally consistent with that of the experimental results, verifying the effectiveness of the proposed model. Full article

The wear of hip prostheses represents a significant challenge for the longevity and functionality of joint implants. Recent studies have explored surface texturing of prostheses as a strategy to enhance tribological performance. This study aims to evaluate the impact of textured ceramic surfaces with dimples on wear and friction reduction in ceramic-on-ceramic (CoC) prostheses. Materials and Methods: Three-dimensional models of ceramic surfaces with and without dimples were created. Contact pressure was analyzed and wear volume was estimated using Archard’s law. Simulations were conducted using finite element methods (FEM) under various loading conditions. Results: Numerical simulations demonstrated that the wear rate for the dimpled femoral head was 0.2369 mm³/year, compared to 0.286 mm³/year for the smooth counterpart, highlighting a wear reduction of 17.2%. Conclusions: The integration of textured surfaces with dimples in ceramic prostheses can substantially improve their functionality and durability, representing a promising approach to addressing the issues associated with hip prosthesis wear. Full article

Under mixed lubrication, the macro size is affected by the wear of the surface roughness peaks, which results in degradation of the bearing accuracy. To study the wear characteristics of rolling bearings under mixed lubrication, based on the elastohydrodynamic lubrication theory and Archard wear model, and considering the coupling of the oil film and roughness, a wear prediction model of angular contact ball bearings under mixed lubrication was established, and the influence of the working parameters and hardness on bearing wear was analyzed. The results show that the wear depth of the outer grove increases with an increase in the load, or a decrease in the rotational speed or the initial viscosity of lubricating oil. The load has the most significant effect on the wear depth of the outer grove. There is a critical value for the load, rotational speed, and initial viscosity of the lubricating oil, which varies with the parameters of other working conditions and the hardness of the materials. When the increase in load exceeds the critical value or the rotational speed and initial viscosity of lubricating oil are less than the critical value, the outer groove fails because the wear depth exceeds the critical value of wear depth. The ratio of the load on the rolling element to the hardness of the outer grove at different entrainment speeds and initial viscosities of lubricating oil can be used to predict the wear degree of the outer grove. When the ratio is greater than a certain threshold, the outer grove is faulted owing to wear, and the threshold decreases with an increase in the initial viscosity of lubricating oil or the decrease in rotational speed. Full article

The protective coatings industry is expanding, offering significant improvements in abrasion and wear resistance, which are crucial for economic sustainability. Despite the advancements, there remains a research gap in understanding the tribological properties and surface morphologies of electroless Ni-P and Ni-B coatings. This study aims to fill this gap by characterizing the surface structures, friction coefficients, and wear properties of two types of Ni-P and one type of Ni-B coatings. Using a ceramic ball counterpart in an SRV5 tribometer, we compared the wear rates according to Archard’s and Liu’s models, adhering to the DIN 51834-1 standard. Scanning electron microscopy was employed to analyze the impact of surface structures on friction coefficients and wear factors. The results reveal significant differences in wear resistance and friction behaviour among the coatings, providing valuable insights for their application in various industries. Full article

Traditional revolute clearance joints assume that the shape of the contact surface of the joint is regular and ignores the effects of wear, which reduces the prediction accuracy of dynamics models. To accurately describe the collision behavior of the motion pair, an Archard formula was applied to construct a wear clearance model. Based on the absolute node coordinate method, multi-body dynamics modeling, wear prediction, and chaotic identification analysis methods for a flexible multi-link mechanism with clearance considering wear effects were proposed. The research results indicate that wear exacerbates the irregularity of the clearance surface contours, leading to increased instability in the dynamic response and the reduced motion accuracy of the mechanism. Compared with clearance size, driving speed has a more significant impact on the chaotic behavior of the system. For high-speed conditions, maintaining the clearance size within approximately 0.1 mm is beneficial for system stability, although this requirement poses challenges for cost control in manufacturing. This study provides a theoretical foundation for wear prediction and stability optimization of high-precision multi-link mechanisms. Full article

In this study, the effect of martensite volume fraction on the mechanical, tribological, and corrosion properties of API 5CT dual-phase steel is studied based on intercritical heat treatment routes at different temperatures (730, 760, and 790 °C). Hardness of the specimens increased by increasing the martensite volume fraction up to 50%. Further increase in martensite volume fraction led to an increase in wear resistance. Sliding wear pin-on-disk tests were analyzed following the ASTM G99 standard, obtaining the wear rate, the volume of lost mass, and the Archard coefficient as a function of time and temperature of the heat treatment. A comparison was made between the wear rate and the hardness data, and its proportionality was established. The corrosion behavior of DP steels in 3.5% NaCl solution was studied by the potentiodynamic polarization technique. The result showed that with increasing the martensite amount in the specimen and decreasing the ferrite amount, the corrosion rate decreased. Finally, the corrosion mechanism in DP steel depends on the self-corrosion resistance behavior of both phases (martensite-ferrite) as well as the presence of galvanic corrosion between them. Full article

In the context of the “carbon peaking and carbon neutrality” era, China’s steel industry, as one of the pillars of the national economy, must accelerate the exploration and adoption of innovative production processes to effectively reduce its carbon footprint. The numerical simulation of hydrogen-based shaft furnaces is an important method for studying the internal characteristics of steelmaking processes. Its objective is to set reasonable furnace parameters to significantly enhance production efficiency and environmental friendliness, ensuring that sustainability and economic benefits coexist in the steel manufacturing process. In order to develop a new shaft furnace, which simplifies the cooling parts, the mathematical model was used to conduct a numerical simulation analysis of hydrogen-based shaft furnaces. The Discrete Element Method (DEM) was employed to focus on the stress and wear behavior of internal components within the hydrogen-based shaft furnace. The results indicated that during the charging of iron ore pellets, the outlet area experienced friction and compression from Direct Reduced Iron (DRI), resulting in a maximum stress of 47,422.1 Pa at the output section. The stresses on the loosening roller were locally concentrated due to its clockwise rotational motion, with a maximum shear stress of 219,896.1 Pa. By applying the Archard wear theory and the moving bed model, the theoretical wear degrees of the refractory materials in the reduction section and the steel shell in the cooling section were obtained; the monthly wear rate of the loosening roller was approximately 0.601 mm. Reasonably setting the parameters and feeding speed of the hydrogen-based shaft furnace can optimize the force and wear conditions of internal components, achieving optimal operating conditions. This provides a reference for factories to effectively extend the service life of hydrogen-based shaft furnaces and offers reasonable suggestions for the future industrial application of hydrogen metallurgy. Full article

A leaf spring caliper is a device used to detect the geometry and defects of the inner wall of oil and gas pipelines. The detection principle involves installing strain gauges on the detecting arm, which can be bent elastically. The strain gauge signal is connected to the voltage-detecting equipment to detect the inner wall of the pipeline through the voltage signal. This equipment has the advantages of high detection accuracy and small structure size. However, the detection arm of the leaf spring caliper works via contact detection, and the detection arm will be worn out when working, thus reducing the detection accuracy. This paper establishes a wear model of the leaf spring caliper and constructs a wear test system based on the model. The wear test system simulates wear between the detection arm material 51CrV4 (ISO 683-2-2016) and the oil pipeline material L555Q (ISO 3183:2012). By changing the coating material of the detection arm, such as nickel-phosphorus coating, epoxy acrylic resin coating, or polytetrafluoroethylene (PTFE) coating, the wear pattern of the detection arm is explored and the experimental results are analyzed and summarized to select the most suitable coating material. A polynomial fit to the test data, followed by a Reye–Archard wear model fit, was performed to finally derive the wear function for leaf springs with different coating materials. A prediction algorithm was used to predict the wear pattern of the detector arm, and the extended wear length was calibrated. The results show that the average error between the predicted data and the actual observed data is in accordance with the experimental expectations. Therefore, the wear prediction model and its corresponding wear function can be applied to wear error correction to improve the detection accuracy of leaf spring calipers. Full article

Worm drive belongs to the inclined plane transmission principle, and there is severe wear on the conjugate tooth surface. To reveal the wear mechanism and realize steel–steel meshing in the spiroid worm drive, the meshing performance model of conjugate tooth surface is established based on differential geometry theory and gear meshing principle, and the wear performance model is inferred by the Archard model and microscopic meshing performance. The wear performance of conjugate tooth surface is analyzed through the digital calculation, the pin-disk friction, and wear testing, as well as the spiroid worm drive prototype performance testing. The results show that there are good lubrication and anti-wear characteristics between the conjugate tooth surfaces, the wear amount on the right flank is twice that of the left flank, the wear depth at the loaded flank of the spiroid gear surface is smaller than that at the unloaded flank, as well as the feasibility of steel–steel meshing in worm drive has been confirmed. Full article