A boundary elements formulation for 3D fretting-wear problems

Computational wear modeling is an extremely time-consuming problem, especially the 3D cases. In this work, a 3D boundary element method (BEM) formulation for wear modeling is proposed and applied to simulate 3D fretting-wear problems under gross sliding and partial slip conditions. The present formulation applies the BEM to approximate the elastic response of solids, and an augmented Lagrangian formulation to solve the contact problem. Contact restrictions fulfilment is established by a set of projection functions, and wear on contact surfaces is computed using the Archard wear law. The BEM proves to be a very suitable numerical method for this kind of mechanical interaction problems, considering only the boundary degrees of freedom involved in the problem and obtaining a very good approximation of contact tractions with a low number of elements. This is very interesting in terms of computational cost reductions of wear modeling, specially in 3D problems. In that regard, an acceleration strategy is applied to the proposed algorithm. It allows to obtain very important reductions on wear simulation times. The proposed methodology is therefore an efficient numerical tool for 3D fretting-wear problems modeling.