Archard Model-Based Finite Element Method Analysis of Wear in Metal C-Rings

As a critical mechanical sealing component, the tribological behavior of metal C-rings directly affects the safety and service life of equipment. This study systematically examines the friction and wear characteristics of metal C-rings under ambient temperature conditions by integrating the Archard wear model with finite element analysis. Special attention is given to the influence of pre-compression, sliding velocity and fluid medium pressure on wear volume, wear depth, and contact pressure. Through an extensive literature review, the critical parameters of the Archard wear model were identified and quantified, including the wear coefficient and material hardness. A two-dimensional axisymmetric finite element model of the metal C-ring and its mating surface was established using the SpaceClaim module within ANSYS Workbench. The finite element model incorporated appropriate boundary conditions (fixed constraints, displacement loads, and pressure loads) that accurately represented actual operating scenarios. To ensure computational precision, adaptive meshing technology was utilized with a refined element size of 0.1 mm. Transient structural analysis was subsequently performed to simulate contact pressure, stress distribution, and wear evolution under diverse operational scenarios. The results indicate a nonlinear increase in wear volume with increasing pre-compression. Specifically, as pre-compression rises from 0.03 mm to 0.05 mm, the growth rate of wear volume increases from 18.7% to 43.9%. This is primarily attributed to elevated contact pressure and material softening caused by frictional heating. Additionally, wear volume demonstrates nonlinear growth with increasing velocity, with the growth rate decreasing from 7.89% to 4.04% as velocity increases from 5 mm/s to 20 mm/s. This trend suggests enhanced micro-cutting effects at higher velocities. Moreover, an increase in fluid medium pressure enhances both normal load and contact pressure, thereby accelerating wear progression. This study offers profound insights into the wear mechanisms and nonlinear behavior of metal C-rings via systematic numerical simulations and rigorous theoretical analysis. The results provide essential theoretical guidance for optimizing seal design, selecting suitable operating parameters, and enhancing service life. Specifically, for downhole safety valve applications under severe conditions, these findings hold substantial engineering significance in improving equipment reliability and operational safety. Future research should consider additional factors, such as thermal coupling effects and microstructural evolution, to develop more precise wear prediction models.