University of Oulu

A. Mäntylä, J. Hintikka, T. Frondelius, J. Vaara, A. Lehtovaara, J. Juoksukangas, Prediction of contact condition and surface damage by simulating variable friction coefficient and wear, Tribology International, Volume 143, 2020, 106054, ISSN 0301-679X,

Prediction of contact condition and surface damage by simulating variable friction coefficient and wear

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Author: Mäntylä, A.1; Hintikka, J.1; Frondelius, T.1,2;
Organizations: 1Wärtsilä Finland Oy, Järvikatu 2-4, P.O. Box 244, 65101, Vaasa, Finland
2University of Oulu, Materials Engineering Laboratory, Finland
3Tampere University, Tribology and Machine Elements, Faculty of Engineering and Natural Sciences, P.O. Box 589, 33014, Tampere, Finland
Format: article
Version: accepted version
Access: open
Online Access: PDF Full Text (PDF, 3.1 MB)
Persistent link:
Language: English
Published: Elsevier, 2020
Publish Date: 2021-11-05


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.

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Series: Tribology international
ISSN: 0301-679X
ISSN-E: 1879-2464
ISSN-L: 0301-679X
Volume: 143
Article number: 106054
DOI: 10.1016/j.triboint.2019.106054
Type of Publication: A1 Journal article – refereed
Field of Science: 214 Mechanical engineering
216 Materials engineering
Funding: This work is a part of the MaNuMiES (Dnro 3361/31/2015) and WIMMA (Dnro 1566/31/2015) research projects. The authors are grateful for the financial support provided by Business Finland Oy, Wärtsilä Finland Oy, Agco Power Oy and Global Boiler Works Oy.
Copyright information: © 2019 Elsevier Ltd. This manuscript version is made available under the CC-BY-NC-ND 4.0 license