FEM computation of groove ridge and Monte Carlo simulation in two-body abrasive wear

Abrasion is a stochastic process. It has been realized by some researchers that Monte Carlo simulation is a powerful tool to predict the wear rate of materials. The important issue for the simulation is to collect necessary basic data of worn materials, such as, ductility, plasticity, hardness, etc. The most difficult work, however, is to get parameters related to wear system. A factor, which divides the percentage of debris from total groove volume, is a dominant parameter to predict wear rate of materials. The previous work by the present authors has used the data and results from Azarkhin and Boklen. The curve proposed by Boklen is based on a normal indentation of cone and the data from Azarkhin were obtained from a calculation of upper bound approach. Those results are not adequate for the simulation of groove wear. Therefore, three-dimensional finite element method (FEM) analysis was used in this investigation. Stress and strain of a half infinite plane indented by a sliding sphere tip were calculated with an elastic-linear strengthen plastic deformation model by a commercial software. The curves proposed by Azarkhin and Boklen were modified by the FEM calculation. Monte Carlo simulations of wear rate for AISI 1020, AISI 1045 and AISI 1080 steels were carried out. At the same time, scratch tests were also carried out and profilemeter measurement was done after the scratch test as to propose a groove ridge description expression. The present simulation showed good agreement with the experimental data. (C) 2004 Elsevier B.V. All rights reserved.