Dynamic Analysis of Fretting-wear in 3D Structures in Contact with Friction

This work addresses the dynamic analysis of fretting-wear in three-dimensional structures subject to dry friction, particularly in turbomachinery applications like bladed disks. Fretting-wear, caused by micro-sliding at contact interfaces under high pressure and oscillatory motion, can significantly reduce component lifespan. The study proposes a novel multi-scale modeling approach based on temporal homogenization, accounting for both fast dynamic loading and slow wear evolution. A finite element model is reduced using Component Mode Synthesis, and wear effects are introduced via a penalty term in the augmented Lagrangian formulation. The dynamic behavior is resolved using a Harmonic Balance Method (HBM) combined with the Alternating Frequency Time (AFT) technique. This DLFT approach enables accurate resolution of contact forces and displacements by bridging time and frequency domains while satisfying Coulomb friction conditions. The slow evolution of wear is modeled through numerical integration schemes, with implicit solvers offering enhanced stability. Semi-analytical Jacobian computations and a prediction-correction strategy are employed to improve non-linear convergence. Numerical results highlight the interplay between vibration and wear, demonstrating the method’s effectiveness. The methodology eliminates the need for remeshing and allows long-term prediction of fretting-wear in complex dynamic systems.