Simulation of wear and effective friction properties of microstructured surfaces

Wear and friction characteristics are simulated on metal forming tools with tailored surfaces generated by micro milling. Friction homogenisation is applied to study surface cut-outs on the meso-scale where the structures are resolved by means of finite element methods and where asperities are represented by a combined friction law appropriate for metal forming. Dissipation based and pressure based Archard wear relations are implemented in a postprocessor, and wear distributions as well as effective friction properties are investigated. Sinusoidal surface structures are able to provide anisotropic structural resistance throughout the progress of wear. A bionic surface structure shows quasi-isotropic structural resistance where sliding directions across the edge directions are benefitial with regard to the wear progress. Experimental measurements from a wear experiment give hints which support the dissipation based Archard relation while more experimental evidence is necessary.