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C7 - Wear

Mechanism-based Modeling of Wear in Sheet-Bulk Metal Forming

Project Status: Active

Last Update: 27.02.2019


TP C7 focusses on the modelling of material wear at the contact zone in order to capture mesoscopic wear mechanisms on the macroscale. The model to be developed in this TP does not draw on a classic Archard-based context, but simulates the material wear mechanisms on the mesoscale – abrasive wear results from the local removal of surface material. This kind of modelling enables a mechanism-based prediction of material wear behaviour and thereby crucially contributes to the understanding and interpretation of the tribological system (TP A2, A4, C1).

The so-called Particle Finite Element Method (PFEM) shall be methodically applied and further developed in TP C7. This method requires continuous new remeshing of the changing reference area. Dissipative material behaviour for the lubricant as well as for the tool (C45, high speed steel 1.3343 and cold work steel 1.2379) and for the workpiece (DC04 and DP600) is presumed here. Here, the lubricant is viscous so that the resulting friction and abrasion behaviour is velocity-dependent. Furthermore, significant residual stress states evolve at the surface-near areas of the coated tool surfaces (TP B4, B5) which follow from thermal loading. In order to take these into consideration during modelling, an appropriate cooling simulation of the coating system is performed in TP C7, and the resulting stress state is taken as initial condition in the wear simulation. Apart from the prediction and better understanding of material wear behaviour on the mesoscale, TP C7 provides mechanism-based correlations which are transferred to the macroscale via homogenization. This motivates and enables the extension of, for example, the classic Archard wear relation on the macroscale (TP A7) and therefore influences the simulation-based design of tool surfaces with an improved operating lifetime.


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Working Groups



    • Schewe, M.; Menzel, A.: The Particle Finite Element Method for the modelling and simulation of solid body interactions. In: Gesellschaft für Angewandte Mathematik und Mechanik (Edt.): Proceedings in Applied Mathematics and Mechanics, 18(2018)1, Weinheim: Wiley-VCH Verlag, pp. 1-2


    • Berthelsen, R.; Wilbuer, H.; Holtermann, R.; Menzel, A.: Computational modelling of wear - application to structured surfaces of elastoplastic tools. In: GAMM-Mitteilungen, 39(2016)2, pp. 210-228



      • 21.03.2018: Schewe, M.; Menzel, A.: The Particle Finite Element Method for the modelling and simulation of solid body interactions, München