Study on the Effect of Fretting Wear Behavior with Consideration of Three-Dimensional Non-Gaussian Surfaces

The mechanical joint surface is commonly simplified as smooth or Gaussian-distributed, while its actual non-Gaussian characteristics significantly affect fretting wear behavior. A non-Gaussian fretting wear model, characterized by the three-dimensional morphology of actual machined surfaces, is established to accurately reveal the fretting wear mechanism of joint interfaces. First, the fast Fourier transform is adopted to construct non-Gaussian surface models consistent with actual surface characteristics. Second, the non-Gaussian surface fretting wear model is developed through ABAQUS and the UMESHMOTION wear subroutine. Finally, the effects of kurtosis, skewness, standard deviation, material properties, and friction coefficient are explored. The conclusions illustrate that non-Gaussian surfaces demonstrating positive skewness and high kurtosis exhibit the most pronounced local stress concentration and maximum wear depth compared to smooth and Gaussian surfaces. Non-Gaussian surfaces exhibiting negative skewness and low kurtosis demonstrate more uniform stress distribution and better wear resistance under identical conditions. The wear depth in the non-Gaussian surface increases significantly with rising the standard deviation, elastic modulus of materials, and friction coefficients.