A Mesoscopic Friction and Wear Model of Elastoplastic Metallic Materials Considering the Three-Dimensional Rough Surface

Abstract The prediction of friction and wear is crucial in engineering, and current measurement methods primarily rely on experimentation. However, experimental measurements are limited by high costs, lengthy cycle times, and dependence on specific working conditions. To address these challenges, we propose a mesoscopic friction and wear model of elastoplastic metallic materials to reduce the dependence on friction and wear testing. This model integrates a mesoscopic coupled plasticity-damage model with a three-dimensional non-Gaussian rough surface characterization method. Based on this model, taking the connecting rod-bearing bushing contact pair of a diesel engine as an example, the effects of sliding displacement, normal force, and temperature on the friction and wear are simulated, and the prediction ability of the model is verified through friction and wear testing. Finally, we investigate the necessity of incorporating size effects into the mesoscopic friction and wear model. The study indicates that since the material has obvious size effects at the asperities, it must be considered in the mesoscopic friction and wear model.