Finite element simulation of fretting wear behaviors under the ball-on-flat contact configuration

Finite element method (FEM) has been extensively applied in predicting fretting wear due to its advantage in solving problems like non-linearity of boundary conditions. This work combines FEM with energy model to simulate fretting wear under the ball on flat contact configuration. The simulation model was firstly verified experimentally. Then the mechanical, friction and wear behaviors were analyzed in detail. The results indicate that in PSR, the cross-sectional profiles of worn surface transform from “W” to “U” shape along the fretting direction, while in GSR they keep the “U” shape. The normal load and amplitude have a combined effect on the contact pressure and shear stress, and then determine the kinetic behavior, wear behavior and evolution of worn surfaces.