Fretting wear is a kind of material damage in contact surfaces caused by microrelative displacement between two bodies. It can change the profile of contact surfaces, resulting in loosening of fasteners or fatigue cracks. Finite element method is an effective method to simulate the evolution of fretting wear process. In most studies of fretting wear, the coefficient of friction was assumed to be constant to simplify model and reduce the difficulty of solving. However, fretting wear test showed that the coefficient of friction was a variable related to the number of fretting cycles. Therefore, this paper introduces the coefficient of friction as a function of the number of fretting cycles in numerical simulation. A wear model considering variable coefficient of friction is established by combining energy consumption model and adaptive grid technique. The nodes of contact surfaces are updated through the UMESHMOTION subroutine. The effects of constant coefficient of friction and variable coefficient of friction on fretting wear are analyzed by comparing the wear amount under different loading conditions. The results show that when compared with coefficient of friction model, fretting wear is obviously affected by variable coefficient of friction and the variable coefficient of friction model has a larger wear volume when the fretting is in partial slip condition and mixed slip condition. In gross slip condition, the difference of wear volume between variable coefficient of friction model and coefficient of friction model decreases with the increase in the displacement amplitudes.
Fretting wear is a major form of fretting damage involving various factors, such as material properties, surface roughness, surface topography, lubrication conditions, environment temperature, type of loading, and loading phase difference. In this study, ABAQUS is used to establish three models to simulate the variation of wear depth with the amplitude of additional load. The influence of the phase difference between additional load and original load is considered. Four phase difference angles are involved, i.e. 0°, 90°, 180°, and 270°. Results indicate that the rule of the variation of wear depth with the additional load amplitude increasing varies under different phase differences. It is observed that for the 0° phase difference, the wear depth firstly decreases then increases with the increase of the additional load. However, the wear depth increases monotonously in the case of the 180° phase difference. The variation of wear depth with additional load amplitude for 90° phase difference is similar to that of the 270° phase difference. The depth of wear is firstly kept at a relatively low level and then increases sharply, with the increase of the additional load. It is found that the distribution of shear stress and relative slip at the contact interface is also affected by the phase difference.
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