Simulation and experimental verification of the orthogonal friction continuous wear of PTFE-Kevlar fabric liner

Woven fabric liners, which are customizable and maintenance-free, have extensive applications in self-lubricating spherical bearings. However, owing to the orthogonal anisotropy and non-homogeneous characteristics, their frictional and wear behaviors are complex. Currently, average performance testing is primarily based on long-term macroscopic wear experiments. However, unobservable parameters such as mesoscopic stress and pressure distribution in liners are bottlenecks in the experimental exploration of wear sources and mechanisms. Therefore, an innovative strategy for modeling orthogonal friction and continuous wear in non-homogeneous liners is presented. This approach has the potential to overcome experimental limitations and significantly expedite liner design and cost-effective validation. The initial step involves establishing a mesoscopic voxel-based planar model of the liner that maintains the topological relationship during wear processes. This is achieved by introducing a circular voxel mesh and spatial transformation methods. Based on orthogonal friction and wear assumptions, separate constitutive models for orthogonal friction and wear are developed. Using the CETR UMT-3 friction and wear testing machine, GCr15 is selected as the counterface material, the pin disc wear method is adopted to conduct sliding test on PTFE and Kevlar fibers, and the required wear constitutive parameters are fitted. Furthermore, incremental equations for the total wear are derived. An element wear fusion strategy is introduced. This approach leads to the development of a continuous wear algorithm for liners and subsequently to the establishment of a voxel-based finite element model with continuous wear capability in the form of a circular voxel grid. This method transcends experimental methods and allows for the determination of the mesoscopic contact pressure, stress distribution, and variations in the contact material composition patterns of liner. The accuracy of the average macroscopic wear prediction is validated experimentally. This method has the potential for practical applications in bearing design.