Abstract A simulation method to predict the reliability of clamped metal contacts under cyclic loading is presented. The main idea is to predict the development of contact condition of a joint by simulating a spatially variable coefficient of friction (COF) and wear. Frictional energy dissipation drives the COF evolution rule, and classic Archard's equation is employed as the evolution rule for wear depth. As both the COF and wear evolution are considered, the presented approach is capable of predicting changes in the contact condition over time. The approach is based on the Finite Element Method (FEM) and is generally applicable to industrial cases. The method is implemented as a subroutine to a FEM solver Abaqus to define a contact formulation in both normal and tangential directions. The subroutine allows full coupling between normal and tangential contact variables, which makes the approach robust also in complex industrial applications. As the effect of wear is described in the contact pressure calculation, there is no need for mesh modification. The presented approach was validated by simulating cylinder-on-plane configuration. The presented method provides similar results obtained with a simulation where geometry is updated due to wear. The results of the case study were qualitatively verified against a bolted joint type fretting experiment. The area of slip after stabilized COF distribution corresponds well with the experimental fretting scars. However, Archard's wear law seems to be limited, at least in partial slip cases, as it overestimates the amount of wear without considering entrapment of wear debris in the contact. A case study of medium speed combustion engine component is presented to show how the simulation method can be used in engine development to ensure reliable contact interfaces.

中文翻译：

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通过模拟可变摩擦系数和磨损预测接触条件和表面损伤

摘要 提出了一种预测循环载荷作用下夹紧金属触点可靠性的仿真方法。主要思想是通过模拟空间可变摩擦系数 (COF) 和磨损来预测关节接触条件的发展。摩擦能量耗散驱动 COF 演化规则，采用经典 Archard 方程作为磨损深度的演化规则。由于同时考虑了 COF 和磨损演变，所提出的方法能够预测接触条件随时间的变化。该方法基于有限元方法 (FEM)，通常适用于工业案例。该方法作为 FEM 求解器 Abaqus 的子程序实现，以定义法向和切线方向的接触公式。该子程序允许法向和切向接触变量之间的完全耦合，这使得该方法在复杂的工业应用中也很稳健。由于在接触压力计算中描述了磨损的影响，因此不需要修改网格。所提出的方法通过模拟圆柱体平面配置进行了验证。所提出的方法提供了通过模拟获得的类似结果，其中几何因磨损而更新。案例研究的结果通过螺栓连接型微动实验进行了定性验证。稳定 COF 分布后的滑动面积与实验微动疤痕很好地对应。然而，Archard 的磨损规律似乎是有限的，至少在部分滑动的情况下，因为它高估了磨损量，而没有考虑接触中磨屑的夹带。介绍了中速内燃机组件的案例研究，以展示如何在发动机开发中使用仿真方法来确保可靠的接触界面。