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<p>This study investigates the wear behavior of a polymer–metal interface between polyoxymethylene and SKH 51 steel through pin-on-disc experiments and finite element (FE) simulation. Experiments conducted under loads ranging from 98 to 196&#xa0;N and up to 60,000 cycles revealed characteristic wear features, including material pile-up of up to 0.020&#xa0;mm and an increase in surface hardness from 16.57 HV to 17.23 HV. A two-step FE simulation was developed to incorporate plastic deformation effects. The first step simulated elastic-plastic deformation with modulus degradation, accurately reproducing pile-up behavior, while the second step applied Archard’s wear law using an arbitrary Lagrangian–Eulerian based adaptive meshing approach. The stress-dependent wear coefficient was calculated from experiments, capturing local maximum contact pressures up to 265&#xa0;MPa. The simulation results showed strong agreement with measurements, with wear-depth prediction accuracy exceeding 90% for cycles above 2000. These findings demonstrate that incorporating plastic deformation significantly improves the prediction of wear depth and surface evolution in polymer-metal sliding interfaces.</p>

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Numerical and experimental analysis of wear behavior in polymer-metal interface incorporating plastic deformation

  • 期刊论文

  • 发表日期：

    2026年3月26日

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  • Hossein Ghorbani-Menghari,
  • Yong-Bin Cho,
  • Changhee Park,
  • Sanghu Park,
  • Ji Hoon Kim

摘要

This study investigates the wear behavior of a polymer–metal interface between polyoxymethylene and SKH 51 steel through pin-on-disc experiments and finite element (FE) simulation. Experiments conducted under loads ranging from 98 to 196 N and up to 60,000 cycles revealed characteristic wear features, including material pile-up of up to 0.020 mm and an increase in surface hardness from 16.57 HV to 17.23 HV. A two-step FE simulation was developed to incorporate plastic deformation effects. The first step simulated elastic-plastic deformation with modulus degradation, accurately reproducing pile-up behavior, while the second step applied Archard’s wear law using an arbitrary Lagrangian–Eulerian based adaptive meshing approach. The stress-dependent wear coefficient was calculated from experiments, capturing local maximum contact pressures up to 265 MPa. The simulation results showed strong agreement with measurements, with wear-depth prediction accuracy exceeding 90% for cycles above 2000. These findings demonstrate that incorporating plastic deformation significantly improves the prediction of wear depth and surface evolution in polymer-metal sliding interfaces.