Reduction of time for development by correlation, modeling and simulation of different test categories in the qualification of plastic / metal tribological systems

在含有摩擦学部件的机械装置的开发中，材料选择或预选的第一步是基于简单的测试配置，如销-盘或块-环配置。下面的发展反映了几何形状和操作条件的复杂性，通过5个额外的类别，直到最终单元被批准使用。这种方法一方面保证了机组在应用中可靠、安全地运行，但另一方面也涉及到巨大的实验工作量和成本。通过识别不同测试类别之间的相关性并最终进行建模和仿真，将调查和描述不同测试类别之间的关系。该项目的程序是通过在前两类(VI和V)摩擦学试验中使用不同的实验标准和中间几何结构来研究这些行为中的这些关系，并最终基于在VI类中进行的简单测试来预测V类系统的性能。这项工作的最终目的是通过模拟来完全取代V类中的实验工作，并最终减少摩擦学部件的开发周期中的成本和时间。我们尤其希望解决以下目标：*建立用于均化热量的有限元微观模型，机械和摩擦学特性。*建立热机械有限元模型来模拟变形和磨损的温度分布。*描述标准实验装置(环上块)中的热平衡。*描述标准实验装置中的热和机械引起的变形。*描述面向最终部件设计的测试装置中的热平衡和变形。*描述温度和摩擦学特性的相互作用。*比较不同系统的摩擦学特性，并基于热平衡调查相关性

In the development of mechanical units containing tribological components, the first step of materials selection or pre-selection is based on simple test configurations such as pin-on-disk or block-on-ring configurations. The following development reflects the complexity of geometry and conditions of operation by passing thru 5 additional categories until the final unit is approved for use. This approach ensures on the one hand from a reliable and safe operation of the unit in the application, but on the other hand, involves enormous experimental efforts and costs. By identifying correlations between different test categories and ultimately modeling and simulation, the relationships between different test categories will be investigated and described. The procedure in the proposed project is to investigate these relationships in the behavior by using different experimental standards and intermediate geometry in the first two categories (VI and V) of tribological testing and finally predict the system properties in category V based on simple tests performed in category VI. The ultimate aim of the work is to replace the experimental effort in category V completely by simulations und finally reduce cost and time in the development cycle of tribological components.In particular, we would like to address the following goals:* Creation of a FE micro model for homogenizing the thermal, mechanical and tribological properties.* Creation of a thermo-mechanical finite element model to simulate the temperature distribution of the deformation and wear.* Description of the heat balance in a standard experimental set up (block-on-ring).* Description of thermally and mechanically induced deformations in a standard experimental set up .* Description of the heat balance and the deformations in a final component design oriented test set.* Description of the interaction of temperature and tribological properties.* Comparison of the tribological properties of the different systems and investigate the correlation based on the heat balance