Theoretical Modeling and Numerical Simulation of Current-Carrying Friction and Wear: State of the Art and Challenges

Current-carrying friction and wear in contact components are key issues in modern electromechanical systems such as slip rings, electrical connectors, motors, and pantographs, directly influencing their efficiency, reliability, and lifespan. Due to the limitations of experimental methods under some extreme conditions, computational simulations have become essential for studying current-carrying friction and wear in such scenarios. This paper presents a comprehensive review of theoretical modeling and numerical simulation methods for current-carrying friction and wear. It begins with discussions of approaches to solve the electrical contact resistance (ECR), a critical parameter that governs current-carrying friction and wear behaviors. Then, it delves into various modeling strategies for current-carrying friction, with an emphasis on the coupled effects of thermal, mechanical, electrical, and magnetic fields. Finally, the review addresses modeling techniques for current-carrying wear, encompassing mechanical wear and arc erosion. By summarizing existing research, this paper identifies key advancements, highlights existing challenges, and outlines future directions, advocating for the development of efficient, universal, and industry-oriented tools that can seamlessly bridge the gap between theoretical modeling and practical applications.