Simulating Wear in COMSOL Multiphysics
Nagi Elabbasi | August 8, 2014
Today, we invite guest blogger Nagi Elabbasi of Veryst Engineering to share the work they performed on simulating wear in COMSOL Multiphysics.
Using COMSOL Multiphysics, we implemented a wear model and validated it by simulating a pin-on-disc wear test. We then used the model to predict wear in an automotive disc brake problem. The results we found showed good agreement with published wear data.
Wear is the process of the gradual removal of material from solid surfaces that are subjected to sliding contact. It is a complex phenomenon that is relevant to many problems involving frictional contact, such as mechanical brakes, seals, metal forming, and orthopedic implants. The rate of wear depends on the properties of the contacting materials and operating conditions.
Archard’s law is a simple but widely used wear law that relates the volume of material removed due to wear W to the normal contact force F_N, sliding distance L_T, material hardness H, and a material-related constant K
In our work, we considered a modified version of Archard’s law:
This modified law relates the wear depth w at any point to the normal contact pressure p_N, magnitude of sliding velocity V_T, and a constant k that is a function of the material and temperature. The wear constant k may be computed from experimental wear data, which is typically in the form of weight loss for a specific contact pressure and velocity.
Wear equations are not directly available in finite element analysis (FEA) codes, although their implementation in COMSOL Multiphysics is straightforward. We incorporated the wear equations within our simulations by defining boundary ordinary differential equations (ODEs) on the destination contact surfaces with the wear depth w as the independent variable. The wear depth w is then used as an offset between contacting surfaces (e.g., brake pad and disc) within the contact formulation in COMSOL Multiphysics. In particular, contact is enforced when the penetration between the contact surfaces is equal to the wear depth w, as shown in image below.
Modification of contact gap calculation: w is the wear depth, g is the gap, and \lambda is the contact pressure.
This wear algorithm is very efficient since it does not involve altering the nodal locations to account for material loss due to wear. It is only suitable, however, for cases where the wear depth is significantly less than the width of the contact surface.
You can enhance this wear algorithm by including more sophisticated effects, such as anisotropic wear behavior, dependence on the mean and deviatoric stresses in the solid (not just the contact pressure), threshold pressure/stress below which no wear occurs, and more. The assumption of small wear depth must still hold for this modeling approach to be accurate.
Simulating a Pin-On-Disc Wear Test
We validated the new, contact-offset-based wear model implementation by simulating a pin-on-disc wear test. Only a small section of the disk is modeled, as shown below.
Pin-on-disc wear test model.
The disc in this model is much stiffer than the pin and all the wear is assumed to occur in the pin. A force is applied to the pin, resulting in a circular, Hertzian-type contact pressure distribution. A constant tangential velocity is then applied to the disc. The graph below shows how the wear depth varies radially along the pin at four time instances. The total volume loss, calculated as the integral of wear depth over the contact surface, was similar to the value calculated using Archard’s law.
Wear depth vs. radial distance in the pin-on-disc model.
We also used the model to predict wear in an automotive disc brake problem, which is similar to the Heat Generation in a Disc Brake model that can be downloaded from the COMSOL Model Gallery. We developed a 3D thermal-structural disc brake model involving representative brake disc/rotor and brake pads.
Disc brake model used in the COMSOL Multiphysics wear simulation.
The structural and thermal processes are coupled through frictional heat generation, thermal expansion, and thermal contact. Both physics fields are also coupled to the wear depth evolution boundary ODE. We used a fully-coupled direct solver that converged rapidly, keeping solution times similar for problems with and without wear.
The results for both the pin-on-disc validation example and the disc brake problem were in good agreement with published wear data. In the disc brake example, the model captured the non-uniform wear rate that is typically observed on brake pads; it was higher near the outer radius and leading edge, as shown below.
Typical brake pad wear depth profile.
We will present more of our results, including contact pressure and wear contours, at both the Cambridge and Boston stops of the COMSOL Conference 2014.
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