Abstract
An efficient wear integration algorithm is crucial for the simulation of wear in complex transient contact situations. By rewriting Archard's wear law for two dimensional problems, the wear integration can be replaced by the total contact force. This avoids highly resolved simulations in time and space, so that the proposed method allows a significant acceleration of wear simulations. All quantities, including the average contact velocity, slip rate and total contact force, which are required for the pressure-force transformation, can be determined from geometric and motion analysis, or alternatively, from Finite Element simulations. The proposed CForce method has been implemented into the finite element based wear simulation tool Wear-Processor and was validated for a twin-wheel and a camshaft-follower model. A series of simulations have been carried out at high resolution. Resulting wear profiles from the conventional time integration approach and CForce method have been of excellent agreement. Further, it has been shown that the computation time can be significantly reduced. The simulation results from the CForce method remains robust against coarsening of the finite element mesh and increasing time increments.
