Finite Element Simulation Method for Fretting Wear Considering Double-Side Wear Behavior

Fretting-wear-induced failure of contacting surfaces threatens the safety of assemblies, which means the wear behavior on both contacting surfaces should be fully considered. In this paper, a finite element simulation method was proposed to reveal fretting wear behavior, which simultaneously considered double-side wear of both contacting surfaces. The user subroutine UMESHMOTION based on Archard’s equation was used to describe the fretting wear behavior. The finite element model was tested and validated using results obtained from cylinder-on-flat tangential fretting wear tests conducted under varying fretting amplitudes. The topography and cross-sectional profile characteristics of fretting scar were compared. The dynamic wear behaviors and fretting regime were analyzed from the tangential force–displacement curves and the ratio of shear stress to contact pressure. Besides, the variation of wear volume with fretting cycles was also analyzed. The results obtained from model considering double-side wear shown a better agreement with the experimental results compared to those from model considering single-side wear.