Finite-element modeling of dry sliding wear in metals

This paper is concerned with the calibration and validation of a finite-ele ment model of dry sliding wear in metals. The model is formulated within a Lagrangian framework capable of accounting for large plastic deformations a nd history-dependent material behavior. We resort to continuous adaptive me shing as a means of eliminating deformation-induced element distortion, and of resolving fine features of the wear process such as contact boundary la yers. Particular attention is devoted to a generalization of Archards law i n which the hardness of temperature material is allowed to be a function of temperature. This dependence of hardness on temperature provides a means o f capturing the observed experimental transition between severe wear rates at low, speeds to mild wear rates at high speeds. Other features of the num erical model include surface evolution due to wear; finite-deformation J(2) thermoplasticity; heat generation and diffusion in the bulk; non-equilibri um heat-transfer across the contact interface and frictional contact. The m odel is validated against a conventional test configuration consisting of a brass pin rubbing against a rotating steel plate.