Fretting wear modelling incorporating cyclic ratcheting deformations and the debris evolution for Ti-6Al-4V

In the fretting wear process, wear particles are referred to as the third-body flow in the contact region. During cyclic slip motions, a part of particles are ejected out of the contact region after a certain number of fretting cycles. The rest particles are attached to contact surfaces and consolidated to form a debris layer, which plays an important role in the fretting wear process. In the present work, a fretting wear model incorporating the evolution of the debris layer is proposed within the framework of finite element analysis to predict the wear profile under different fretting conditions. In order to describe the evolution of the debris layer, the dynamic volume fraction of ejected particles is related to the accumulation of trapped debris volume. Furthermore, the Ohno-Wang cyclic plasticity model is employed to describe the cyclic plastic deformation of Ti-6Al-4V alloy. The major contribution of the present work is to study the influence of the accumulative ratcheting deformation and debris layer on the wear profile. Different wear configurations are considered in the simulations to validate the predictive ability of the proposed wear model. The simulation results show that the proposed approach is able to provide a reasonable prediction of the wear profiles in different wear configurations.