Simulation of wear and effective friction properties of microstructured surfaces

Wear and friction characteristics are simulated on metal forming tools with tailored surfaces generated by micro-milling. Friction homogenisation is applied to study surface cut-outs on the meso-scale where the structures are resolved by means of finite element methods and where asperities are represented by a combined friction law appropriate for metal forming. Dissipation based and pressure based Archard wear relations are implemented in a postprocessor, and wear distributions as well as effective friction properties are investigated. Sinusoidal surface structures are able to provide anisotropic structural resistance throughout the progress of wear. A bionic surface structure shows quasi-isotropic structural resistance where sliding directions across the edge directions are benefitial with regard to the wear progress. Experimental measurements from a wear experiment give hints which support the dissipation based Archard relation while more experimental evidence is necessary.