In this paper a numerical model for the analysis of multi-body frictional wear contact problems at finite deformations is presented. Wear phenomena are analysed and the main wear mechanics are identified. Archard’s wear law provides an estimate of the amount of wear volume produced during forming operations. Wear phenomena are incorporated into the Coulomb frictional model by considering a friction coefficient as function of an internal variable to be defined as the frictional dissipation or the slip amount.
Within the context of a displacement-driven formulation of frictional contact problems, i.e. penalty or augmented Lagrangian methods, and exploiting the computational framework developed for plasticity, two methods are considered for the time integration of the constrained frictional evolution problems: the lowest Backward Difference (BD) method, Backward Euler (BE) algorithm, and an Implicit Runge-Kutta (IRK) method, the generalized Projected Mid-Point (PMP) algorithm. The constrained frictional algebraic problem arising from the application of these time integration algorithms to the constrained frictional evolution problem, is amenable to exact linearization leading to an asymptotic quadratic rate of convergence when used within a Newton-Raphson solution scheme.
The numerical model has been implemented into an enhanced version of the computational finite element program FEAP. Numerical examples and simulation of industrial metal forming processes show the performance of the numerical model in the analysis of frictional wear contact problems.