Frictionless vs. Frictional Contact in Numerical Wear Predictions of Conformal and Non-conformal Sliding Couplings

The role of friction on wear evolution is manifold since it interplays with lubrication regime, nominal contact point, and contact pressure distribution. Nevertheless, in the literature many wear models simulate wear assuming frictionless contact conditions to simplify the analyses. That assumption, physically not realistic, often appears as a contradiction, permitted in numerical simulations where friction and wear can be considered independent phenomena. This study aims to validate the frictionless assumption in wear models with steady nominal contact point, such as in many common configurations, e.g. pin on plate/pin on disc. Wear was simulated according to the Archard wear law for both non-conformal and conformal pin-on-plate contact pairs in reciprocating motion, assuming frictionless and frictional contact conditions, varying the coefficient of friction f in the range 0–0.4. Finite Element wear models were developed in Ansys® both with implicit and explicit kinematics. Results demonstrate that the effect of friction on contact pressure distribution and worn profiles and on their evolution is negligible (differences lower than 0.05%). Thus, wear can be predicted using models in frictionless conditions which allow to extremely reduce the computational costs that represent a limit of FE wear simulations. Additionally, a procedure with implicit kinematics was compared to the explicit one resulting valid and computationally convenient, especially in case of non-conformal contact.