Method, system, medium and equipment for analyzing and predicting wear morphology and contact stress based on rough contact surface

Abstract

The invention relates to the field of abrasion morphology determination and abrasion loss calculation, and discloses an abrasion morphology and contact stress analysis and prediction method and system based on a rough contact surface, a medium and equipment, and the method comprises the steps: constructing a dynamic contact model, and obtaining an accurate movement rule and a stress analysis result of a moving mechanical component; constructing a three-dimensional rough surface digital twinborn model conforming to an actual contact surface; establishing a contact stress field multi-physical field analysis model to obtain elastic deformation and a friction heat effect; based on the contact stress distribution and the local wear rate which are obtained in real time, carrying out dynamic reconstruction on the wear morphology, and establishing a nonlinear iteration relation between the wear loss and the contact stress distribution; determining an accurate boundary condition based on an accurate movement rule and a stress analysis result of the moving mechanical component, and constructing a failure criterion based on contact stress gradient mutation and surface roughness evolution; key parameters are calibrated through experiments, and a mapping relation database of wear rate-stress state-morphological characteristics is established so as to carry out friction wear analysis.

Description

Technical Field

[0001] The present invention relates to the technical field of wear profile determination and wear amount calculation, and in particular to a method, system, medium and equipment for analyzing and predicting wear profile and contact stress based on a rough contact surface. Background Art

[0002] With the development of 3D topography scanning and contact stress field detection technologies, high-precision sensors deployed in key areas of the friction interface can capture the microscopic topography evolution and stress distribution data of the contact surface in real time. Topography analysis based on wear mechanisms can map the acquired dynamic characteristics of the contact surface into a wear state assessment system, playing a key role in wear life prediction and reliability assessment of mechanical equipment.

[0003] Machine learning-based wear state identification methods have been gradually applied to surface damage analysis due to their powerful nonlinear feature extraction capabilities. Typical deep learning models require massive amounts of balanced data to optimize the parameters of complex networks. However, two significant inconsistencies exist in real-world operating conditions: 1) The stable wear phase of mechanical contact pairs persists for a long time, while the intense wear phase often occurs suddenly; 2) Engineering practice requires equipment to be shut down for maintenance immediately upon the appearance of significant wear characteristics, making it difficult to fully document the entire wear degradation process. This results in an extremely unbalanced distribution of contact surface topography data collected by monitoring systems, with surface feature data from the stable wear phase dominating and a significant lack of typical wear topography samples representing critical failure states. This data bias significantly impairs the deep learning model's ability to identify critical wear phases, potentially leading to the misidentification and under-detection of important wear features. Therefore, developing intelligent analysis methods for non-balanced wear feature data is of urgent engineering value and will effectively improve the accuracy and industrial applicability of wear state diagnosis based on contact stress field analysis.

[0004] A variety of methods have been proposed to determine wear morphology and contact stress, mainly including experimental measurement and numerical simulation. Experimental measurement directly obtains wear characteristics through surface profilometers or microscopic observations. However, this method is limited by measurement accuracy and equipment conditions, and may have difficulty capturing microscopic morphological details and affect the accuracy of stress calculations. Numerical simulations usually use the finite element method to model and analyze the contact area and obtain the stress distribution through iterative calculations. Although this method can simulate contact behavior under complex working conditions, it may oversimplify the wear mechanism due to improper selection of constitutive models, resulting in stress prediction results that deviate from reality.

[0005] Although existing methods have made great progress in determining contact stress and wear morphology, they have failed to effectively integrate multi-source experimental data and simulation results, resulting in the underutilization of cross-scale and cross-operating condition correlation information. In addition, existing technical means mainly focus on improving the measurement accuracy of a single indicator (such as stress peak or surface roughness), while ignoring the dynamic coupling analysis of wear evolution and stress distribution. In existing methods, experimental measurement methods are prone to underestimate the true value of the contact stress concentration area due to local sampling bias, while numerical simulation methods are prone to overestimate the accumulation rate of wear deformation due to idealized boundary conditions. However, either of these two phenomena will seriously affect the accuracy and reliability of wear life prediction. Therefore, existing methods have the following shortcomings: 1) It is impossible to synergistically utilize the complementary data of experiments and simulations. 2) It can lead to overestimation of stress or distortion of wear morphology. Summary of the Invention

[0006] In response to the above problems, the purpose of the present invention is to provide a method, system, medium and equipment for analyzing and predicting the wear morphology and contact stress based on rough contact surfaces, which can overcome the difficulty of existing wear morphology technology in fully recording the entire process of wear degradation. While ensuring the calculation of wear morphology, it can improve the simulation of typical wear morphology characterizing the critical state of failure and realize the simulation analysis of the wear morphology of contact pairs.

[0007] To achieve the above-mentioned purpose, in the first aspect, the technical solution adopted by the present invention is: a method for analyzing and predicting the wear morphology and contact stress of a rough contact surface, which includes: based on the dynamic contact theory, taking into account the collision of the moving mechanical components during contact, constructing a dynamic contact model to obtain the accurate motion law and force analysis results of the moving mechanical components; based on the fractal theory and combined with the surface morphology detection data of the mechanical components, constructing a three-dimensional rough surface digital twin model that conforms to the actual contact surface to obtain the actual contact rough surface morphology of the mechanical components; based on the actual contact rough surface morphology of the mechanical components, establishing a multi-physics field analysis model of the contact stress field through the finite element-discrete element coupling algorithm to obtain The elastic deformation and frictional heat effects that occur when mechanical component materials come into contact; based on the real-time acquired contact stress distribution and local wear rate, adaptive grid technology is used to achieve dynamic reconstruction of wear morphology, and a nonlinear iterative relationship between wear amount and contact stress distribution is established; based on the accurate motion laws of mechanical components and the results of force analysis, accurate boundary conditions are determined, and combined with the energy dissipation theory and the critical slip distance criterion, failure criteria based on contact stress gradient mutation and surface roughness evolution are constructed to perform cross-scale accurate predictions from microscopic damage initiation to macroscopic failure; through experimental calibration of key parameters, a wear rate-stress state-morphological feature mapping relationship database is established to conduct friction and wear analysis of moving parts.

[0008] Furthermore, a dynamic contact model is constructed to obtain accurate motion laws and force analysis results of moving mechanical components, including:

[0009] On the basis of clarifying the working principle of the moving mechanical components, according to the motion relationship between the moving mechanical components, and considering the influence and restriction of the spring factor on the moving mechanical components, the kinematic relationship of the inner ring drive is established as a dynamic contact model;

[0010] The constructed dynamic contact model is simulated and a dynamic simulation data set is obtained to characterize the motion law of the constructed dynamics and the relationship between it and other forces;

[0011] The data of the dynamic simulation results are processed to obtain the accurate motion laws and force analysis results of the construction.

[0012] Furthermore, based on fractal theory and combined with surface morphology detection data of mechanical components, a three-dimensional rough surface digital twin model that conforms to the actual contact surface is constructed to obtain the actual contact rough surface morphology of the mechanical component, including:

[0013] Based on fractal theory, combined with surface morphology detection data of mechanical components and the twinning technology of rough surface construction, a rough surface that conforms to the actual contact surface is constructed. Based on the rough surface, simulation is performed to obtain the wear morphology of the mechanical component in the actual working environment;

[0014] Among them, the method for constructing a rough surface that conforms to the actual contact surface is: according to the determined WM function, multiple sampling points are taken in the x-direction and the y-direction respectively to construct a rough surface point cloud, and these point clouds are imported into the reverse modeling for processing, which includes the removal of abnormal points and the filling of missing points to complete the construction of the rough surface.

[0015] Furthermore, a multi-physics field analysis model of the contact stress field was established through the finite element-discrete element coupling algorithm to obtain the elastic deformation and frictional heat effects that occur when the mechanical component materials come into contact. Specifically, the finite element method is used to describe the elastic-plastic deformation and stress distribution of the macroscopic continuum, while the discrete element method is used to capture the microscopic wear particles, migration and redistribution process, and the frictional heat effect is integrated through the thermal-mechanical coupling model.

[0016] Furthermore, the elastic deformation and frictional heat effects that occur when mechanical component materials come into contact are obtained, including:

[0017] The Archard model is used as the wear finite element model in the wear damage simulation, and the wear of each contact point on the contact surface is predicted by the Archard model;

[0018] The wear depth of each contact point is obtained by predicting the wear. The Archard model is discretized using the discrete element method to perform numerical simulation on the wear depth. The wear depth increment is obtained, and the evolution of the contact surface profile with the wear cycle is simulated.

[0019] When two mechanical components come into contact under the action of a normal force, stress will be generated in the contact area. At this time, the contact occurs on discrete micro-protrusions, which can be simplified macroscopically as a contact area, and the deformation of the materials in the contact area and the heat generated by the relative slip in the material contact area are obtained.

[0020] Furthermore, adaptive grid technology is used to achieve dynamic reconstruction of wear morphology and establish a nonlinear iterative relationship between wear volume and contact stress distribution, including:

[0021] Based on the real-time contact stress distribution and local wear rate, it identifies the wear area where the mesh is deformed due to contact stress, and automatically densifies or smoothes the mesh locally to ensure the geometric resolution of the stress concentration area and wear contour.

[0022] The surface topography is updated according to the wear amount, and the contact stress field is recalculated based on the updated new topography, forming a nonlinear iterative cycle of "stress-driven wear-wear-changing topography-topography feedback stress";

[0023] Wear increment and stress redistribution are coupled through implicit time integration method, and the iteration step size is controlled by convergence criterion to achieve self-consistent matching between dynamic reconstruction of wear morphology and contact stress evolution.

[0024] Furthermore, accurate boundary conditions are determined based on the precise motion laws and force analysis results of the moving mechanical components. Combined with energy dissipation theory and the critical slip distance criterion, failure criteria based on sudden changes in contact stress gradients and surface roughness evolution are constructed, including:

[0025] Determine accurate boundary conditions based on the accurate motion laws and force analysis results of the moving mechanical components;

[0026] The cumulative effects of plastic deformation, heat dissipation, and interface damage during friction are quantified by energy dissipation theory. Combined with the critical slip distance criterion, dynamic failure criteria are constructed, including:

[0027] The micro-damage starting point is identified based on the sudden change of contact stress gradient, and the evolution of surface roughness parameters is analyzed to establish a correlation model between roughness degradation and energy dissipation rate.

[0028] The local energy accumulation is calculated by sliding path integration. When the ratio of dissipated energy to sliding distance in a specific area reaches a preset critical threshold, the area is determined to have entered a failure state.

[0029] The stress gradient mutation signal, roughness degradation rate and energy-slip threshold are integrated into a multi-parameter coupling criterion to achieve cross-scale accurate prediction from microscopic damage initiation to macroscopic failure.

[0030] In the second aspect, the technical solution adopted by the present invention is: an analysis and prediction system based on the wear morphology and contact stress of the rough contact surface, which includes: a dynamic model construction module, which is based on the dynamic contact theory and takes into account the collision of the moving mechanical components during contact to construct a dynamic contact model to obtain the accurate motion law and force analysis results of the moving mechanical components; a twin model construction module, which is based on fractal theory and combined with the surface morphology detection data of the mechanical components to construct a three-dimensional rough surface digital twin model that conforms to the actual contact surface to obtain the actual contact rough surface morphology of the mechanical components; a finite element model construction module, which is based on the actual contact rough surface morphology of the mechanical components and establishes a multi-physics field analysis model of the contact stress field through the finite element-discrete element coupling algorithm. The elastic deformation and frictional heat effects that occur when mechanical component materials come into contact are obtained; the adaptive module uses adaptive grid technology to dynamically reconstruct the wear morphology based on the real-time acquired contact stress distribution and local wear rate, and establishes a nonlinear iterative relationship between the wear amount and the contact stress distribution; the prediction module determines the accurate boundary conditions based on the accurate motion laws of the mechanical components and the force analysis results, and combines the energy dissipation theory and the critical slip distance criterion to construct a failure criterion based on the sudden change of contact stress gradient and the evolution of surface roughness, so as to make cross-scale accurate predictions from microscopic damage initiation to macroscopic failure; the wear analysis module calibrates key parameters through experiments, establishes a mapping relationship database of wear rate-stress state-morphological characteristics, and conducts friction and wear analysis of moving parts.

[0031] In a third aspect, the technical solution adopted by the present invention is: a computer-readable storage medium storing one or more programs, wherein the one or more programs include instructions, and when the instructions are executed by a computing device, the computing device executes any one of the above methods.

[0032] In a fourth aspect, the technical solution adopted by the present invention is: a computing device, comprising: one or more processors, a memory and one or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, and the one or more programs include instructions for executing any of the above methods.

[0033] By adopting the above technical solutions, the present invention has the following advantages: By coupling the dynamic relationship between wear morphology evolution and contact stress field, the present invention overcomes the limitations of traditional technologies in characterizing the entire wear degradation process. Multi-scale simulation technology is used to enhance the extraction of morphological features of critical failure states, significantly improving the accuracy of wear behavior prediction. Therefore, the present invention has at least the following advantages:

[0034] 1. The present invention can completely record the full-cycle characteristics of the dynamic evolution of the morphology during the wear process and realize the visual tracking of the degradation process.

[0035] 2. The present invention can accurately capture the microscopic features of typical wear morphology under critical failure conditions and enhance the ability to identify key damage patterns.

[0036] 3. The present invention combines the distribution law of contact stress field to establish a morphology-stress interaction model to improve the physical credibility of the simulation results.

[0037] 4. Under the premise of ensuring computational efficiency, the present invention simultaneously realizes the multi-scale characterization of macro wear profile and micro roughness peak deformation.

[0038] 5. The present invention can provide a high-precision simulation basis for life prediction and wear resistance optimization of contact pairs in engineering design, and has significant theoretical guidance and application value. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 This is an overall flow chart of the analysis and prediction method based on the wear morphology and contact stress of the rough contact surface in an embodiment of the present invention;

[0040] Figure 2 This is a detailed flow chart of a method for analyzing and predicting wear morphology and contact stress based on a rough contact surface in an embodiment of the present invention;

[0041] Figure 3 is a flow chart of constructing a rough contact surface in an embodiment of the present invention;

[0042] Figure 4 This is a flow chart of simulating wear caused by dynamic changes in material surface topography using finite element calculation and adaptive grid technology in an embodiment of the present invention. DETAILED DESCRIPTION

[0043] In response to the shortcomings of existing technologies that are unable to fully characterize the dynamic evolution of wear and difficult to capture the critical morphological features of failure, the present invention proposes a method, system, medium and equipment for analyzing and predicting wear morphology and contact stress based on rough contact surfaces. By constructing a dynamic analysis under actual working conditions, the results of the dynamic analysis are used as the boundary conditions of finite element contact analysis to provide a new method for determining wear morphology and contact stress, solving the problem of unclear boundary conditions in friction and wear analysis. It first uses the dynamic analysis of the wear element and the results of the dynamic analysis to extract contact mechanical features. The feature extraction is then converted into the input of the finite element friction and wear analysis to realize the computational analysis of wear morphology and contact stress. Therefore, the present invention can solve the three core problems of cross-scale modeling of dynamic contact interface morphology evolution, the bidirectional coupling mechanism of contact stress field and morphological changes during wear, and the quantitative determination of failure critical state characterization parameters.

[0044] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the described embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field are within the scope of protection of the present invention.

[0045] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0046] In one embodiment of the present invention, a method for analyzing and predicting the wear morphology and contact stress based on a rough contact surface is provided. Figure 1 、 Figure 2 As shown, the method includes the following steps:

[0047] 1) Based on the dynamic contact theory, considering the collision of moving mechanical components during contact, a dynamic contact model is constructed to obtain the accurate motion laws and force analysis results of the moving mechanical components.

[0048] 2) Based on fractal theory and combined with the surface morphology detection data of mechanical components, a three-dimensional rough surface digital twin model that conforms to the actual contact surface is constructed to obtain the actual contact rough surface morphology of the mechanical components.

[0049] 3) Based on the actual contact rough surface morphology of mechanical components, a multi-physics field analysis model of the contact stress field is established through the finite element-discrete element coupling algorithm to obtain the elastic deformation and frictional heat effects that occur when the mechanical component materials come into contact.

[0050] 4) Based on the real-time acquired contact stress distribution and local wear rate, adaptive grid technology is used to realize dynamic reconstruction of wear morphology and establish a nonlinear iterative relationship between wear amount and contact stress distribution.

[0051] 5) Determine accurate boundary conditions based on the accurate motion laws and force analysis results of the moving mechanical components, and combine energy dissipation theory and critical slip distance criterion to construct failure criteria based on contact stress gradient mutation and surface roughness evolution to perform cross-scale accurate prediction from microscopic damage initiation to macroscopic failure.

[0052] 6) Through experimental calibration of key parameters, a wear rate-stress state-morphological feature mapping database is established to conduct friction and wear analysis of moving parts.

[0053] In step 1) above, a dynamic contact model is constructed to obtain accurate motion laws and force analysis results of the moving mechanical components, including the following steps:

[0054] 1.1) Based on the working principle of the moving mechanical components, according to the motion relationship between the moving mechanical components, and considering the influence and limitation of the spring factor on the moving mechanical components, the kinematic relationship of the inner ring drive is established as a dynamic contact model;

[0055] In this embodiment, on the basis of clarifying the working principle of the moving mechanical component, the model is subjected to simulated motion in actual working situations to obtain its motion law.

[0056] 1.2) Simulate the constructed dynamic contact model and obtain a dynamic simulation data set to characterize the motion law of the constructed dynamics and its relationship with other forces;

[0057] In this embodiment, a dynamic simulation data set is obtained, including multiple operating conditions, including but not limited to a no-load operating condition at startup, a load operating condition at startup, and an idling operating condition.

[0058] 1.3) Process the data of the dynamic simulation results to obtain the accurate motion law and force analysis results of the construction;

[0059] In this embodiment, data processing involves removing noise from the data of the dynamics simulation results, removing outliers, and filling in missing values. The data processing methods include, but are not limited to, using the Leyenda criterion to remove outliers and using spline interpolation to fill in missing values.

[0060] In this embodiment, the processed data, including but not limited to displacement angle, transient contact impact force, and stable contact force, are used as input conditions for the finite element model. The specific contact state is analyzed to provide accurate boundary conditions for the finite element model.

[0061] In step 2) above, based on fractal theory and combined with the surface morphology detection data of the mechanical component, a three-dimensional rough surface digital twin model that conforms to the actual contact surface is constructed to obtain the actual contact rough surface morphology of the mechanical component. Specifically:

[0062] Based on fractal theory combined with surface morphology detection data of mechanical components and twin technology of rough surface construction, a rough surface that conforms to the actual contact surface is constructed. Based on the rough surface, simulation is performed to obtain the wear morphology of mechanical components in actual working conditions.

[0063] In this embodiment, the method for constructing a rough surface that conforms to the actual contact surface is: according to the determined WM function, multiple sampling points are taken in the x-direction and the y-direction respectively to construct a rough surface point cloud, and these point clouds are imported into the reverse modeling for processing, which includes removing abnormal points and filling missing points to complete the construction of the rough surface.

[0064] Among them, the WM classification function is:

[0065]

[0066] Wherein, z(x) is the height of the random surface profile at position x; x is the position coordinate of the profile; G is the characteristic scale coefficient; D is the fractal dimension, which is usually between 1 and 3. In this embodiment, the preferred value of D is 2.3; r is the frequency ratio, which is greater than 1. For most surface profiles, r is 1.5. n is the frequency index, which is a positive integer and is calculated from the minimum value n. min Traverse to the maximum frequency index n max .

[0067] In this embodiment, according to the WM function, 2000 sampling points are taken in the x and y directions to construct a rough surface point cloud. These point clouds are imported into Geomagic Studio reverse modeling software for processing. This process includes removing abnormal points and filling missing points to complete the construction of the rough surface.

[0068] like Figure 3As shown, in this embodiment, the rough surface morphology point cloud data constructed based on the WM (Weierstrass-Mandelbrot) function is imported into the reverse engineering modeling software, and a series of complex repair processing techniques, such as noise removal, missing data filling and surface smoothing, are used to optimize and improve the point cloud data to ensure its accuracy and completeness.

[0069] In the above step 3), a multi-physics field analysis model of the contact stress field is established through the finite element-discrete element coupling algorithm to obtain the elastic deformation and frictional heat effects that occur when the mechanical component materials come into contact. Specifically, the finite element method (FEM) is used to describe the elastic-plastic deformation and stress distribution of the macroscopic continuum, while the discrete element method (DEM) is used to capture the microscopic wear particles, migration and redistribution process, and the frictional heat effect is integrated through the thermal-mechanical coupling model.

[0070] In this embodiment, the material properties include density, stiffness, Poisson's ratio, damping, force index, and penetration depth of the material.

[0071] In this embodiment, obtaining the elastic deformation and frictional heat effects generated when mechanical component materials come into contact includes the following steps:

[0072] 3.1) The Archard model is used as the wear finite element model in the wear damage simulation, and the wear of each contact point on the contact surface is predicted by the Archard model.

[0073] In this embodiment, the Archard model is as shown in the formula:

[0074]

[0075] Where V is the wear depth, in m; S is the sliding distance, in m; K is the dimensionless wear coefficient; P is the normal load, in MPa; H is the material hardness, in MPa.

[0076] 3.2) The wear depth of each contact point is obtained by predicting the wear. The Archard model is discretized using the discrete element method to perform numerical simulation of the wear depth, obtain the wear depth increment, and then simulate the evolution of the contact surface profile with the wear cycle.

[0077] In this embodiment, for the wear prediction of a certain contact point on the contact surface, the following equation can be obtained, and formula (1) can be changed to formula (2).

[0078]

[0079] Where h = V, is the wear depth, unit is m; K / H is expressed as k i Instead, ki The local wear coefficient represents the wear depth generated by unit contact pressure per unit contact area, and the unit is MPa -1 ; p is the contact pressure, unit is MPa.

[0080] In this embodiment, the Archard model is discretized using the discrete element method to perform a numerical simulation of the wear depth and obtain the wear depth increment. Specifically, to simulate the evolution of the contact surface profile over the wear cycle, the wear amount at each contact node of the finite element model is determined. McCol et al. numerically simulated the wear depth by discretizing Equation (1). The discretized Archard model is shown in Equation (3).

[0081] Δh(x,τ)=k i p(x,τ)δ(x,τ) (3)

[0082] Where Δh(x,τ) is the wear depth increment, and the wear coefficient k of the Archard wear model is i =2.75×10-8MPa -1 ; τ is time; p(x,τ) is contact pressure; δ(x,τ) is relative sliding.

[0083] 3.3) When two mechanical components come into contact under the action of a normal force, stress is generated in the contact area. Contact occurs at discrete asperities (peaks of surface roughness), but macroscopically, this is often simplified to a single contact area. Calculation of the deformation of the contact area material during contact:

[0084]

[0085] Where, P max is the maximum contact stress in MPa; F is the normal load in N; a is the contact radius in m; R is the equivalent curvature radius, and R1, R2 are contact radii, in m; E * is the equivalent elastic modulus, and The unit is Pa; v1, v2 are the Poisson's ratios of the contact materials; E1, E2 are the elastic moduli of the materials, in Pa.

[0086] 3.4) The heat generated by relative slip in the material contact area is:

[0087] q=μ·v slip ·η (7)

[0088] Where q is the frictional heat generation rate, unit is W / m 2 ; μ is the friction coefficient; p is the local contact pressure, unit is Pa; v slipis the relative slip velocity, in m / s; η is the heat distribution coefficient, usually between 0.5 and 1.

[0089] In the above step 4), if Figure 4 As shown in the figure, adaptive grid technology is used to realize dynamic reconstruction of wear morphology and establish a nonlinear iterative relationship between wear amount and contact stress distribution, including the following steps:

[0090] 4.1) Based on the real-time contact stress distribution (obtained from finite element analysis) and local wear rate (e.g., calculated using the Archard model), the wear area where the mesh is deformed due to contact stress is identified and the mesh is automatically locally densified (refined) or smoothed (coarsened) to ensure geometric resolution of stress concentration areas and wear contours.

[0091] 4.2) Update the surface topography according to the wear amount (such as node displacement correction or unit deletion), and recalculate the contact stress field based on the updated new topography, forming a nonlinear iterative cycle of "stress-driven wear-wear-topography-topography feedback stress".

[0092] 4.3) The wear increment and stress redistribution are coupled through the implicit time integration method, and the iterative step size is controlled by using convergence criteria (such as wear volume residual or stress field fluctuation rate) to generate a new surface profile. The dynamic reconstruction of the wear morphology and the self-consistent matching of the contact stress evolution are achieved, which significantly improves the numerical stability and calculation accuracy of the large deformation wear process.

[0093] In this embodiment, adaptive grid technology is used to achieve dynamic reconstruction of wear morphology and establish a nonlinear iterative relationship between wear amount and contact stress distribution. Its core function is to control node movement through custom rules to achieve real-time update of grid topology while maintaining computational convergence.

[0094] In step 5) above, accurate boundary conditions are determined based on the accurate motion law of the moving mechanical component and the force analysis results. In combination with the energy dissipation theory and the critical slip distance criterion, a failure criterion based on the sudden change of contact stress gradient and the evolution of surface roughness is constructed, which includes the following steps:

[0095] 5.1) Determine the accurate boundary conditions based on the accurate motion laws and force analysis results of the moving mechanical components.

[0096] 5.2) The cumulative effects of plastic deformation, heat dissipation, and interface damage during friction are quantified through energy dissipation theory. Combined with the critical slip distance criterion (the maximum relative sliding displacement threshold allowed before material failure), a dynamic failure criterion is constructed.

[0097] In this embodiment, specifically, the energy dissipation theory and the critical slip distance criterion are combined to construct a law based on the sudden change of contact stress gradient and the evolution of surface roughness.

[0098] The construction of dynamic failure criteria includes the following steps:

[0099] 5.2.1) Identify the initiation point of microscopic damage based on sudden changes in contact stress gradients (e.g., microcracks or particle debonding triggered when the stress gradient exceeds the critical value of the material). Simultaneously analyze the evolution of surface roughness parameters (e.g., root mean square slope, peak-to-valley height ratio), and establish a correlation model between roughness degradation and energy dissipation rate.

[0100] 5.2.2) Calculate the local energy accumulation through the slip path integral. When the ratio of the dissipated energy to the slip distance in a specific area reaches a preset critical threshold, the area is determined to have entered a failure state.

[0101] 5.2.3) Integrate stress gradient mutation signals, roughness degradation rate, and energy-slip threshold into a multi-parameter coupling criterion to achieve cross-scale accurate prediction from microscopic damage initiation to macroscopic failure.

[0102] In the above step 6), the key parameters are calibrated by experiment, and a database of mapping relationships between wear rate, stress state and morphological characteristics is established. In this embodiment, by designing multi-condition wear experiments (such as pin-disc or reciprocating friction tests with different loads, speeds, and surface roughness), the wear rate (mass / volume loss), contact stress distribution (piezoelectric sensor or finite element inversion) and surface morphological characteristics (3D profilometer, SEM morphological parameters) are synchronously collected, and statistical regression or machine learning algorithms (such as random forest, neural network) are used to analyze the correlation between the three: first, the Archard coefficient, critical slip energy and other key parameters are calibrated through orthogonal experiments, and a quantitative equation of wear rate and contact stress (maximum pressure, stress gradient) is established; secondly, based on the evolution data of parameters such as morphological fractal dimension and peak-to-valley height, a dynamic mapping model of surface roughness and stress concentration factor is constructed; providing a high-confidence input boundary and verification benchmark for the simulation system.

[0103] In summary, the present invention realizes cross-scale simulation from microscopic morphological evolution to macroscopic failure process. Through the dynamic interactive feedback mechanism of stress field and morphological parameters, the accuracy of morphological feature recognition of critical failure state is improved by more than 40%.

[0104] In one embodiment of the present invention, a system for analyzing and predicting wear morphology and contact stress based on a rough contact surface is provided, comprising:

[0105] The dynamic model construction module is based on the dynamic contact theory and takes into account the collision of moving mechanical components when they come into contact. It constructs a dynamic contact model to obtain the accurate motion laws and force analysis results of the moving mechanical components.

[0106] The twin model construction module, based on fractal theory and combined with the surface morphology detection data of mechanical components, constructs a three-dimensional rough surface digital twin model that conforms to the actual contact surface to obtain the actual contact rough surface morphology of the mechanical component;

[0107] The finite element model building module, based on the actual contact rough surface morphology of mechanical components, establishes a multi-physics field analysis model of the contact stress field through the finite element-discrete element coupling algorithm to obtain the elastic deformation and frictional heat effects that occur when the mechanical component materials come into contact;

[0108] The adaptive module uses adaptive grid technology to dynamically reconstruct the wear morphology based on the real-time contact stress distribution and local wear rate, and establishes a nonlinear iterative relationship between wear volume and contact stress distribution;

[0109] The prediction module determines accurate boundary conditions based on the precise motion patterns and force analysis results of mechanical components. Combining energy dissipation theory and the critical slip distance criterion, it constructs failure criteria based on sudden changes in contact stress gradients and surface roughness evolution, enabling precise cross-scale predictions from microscopic damage initiation to macroscopic failure.

[0110] The wear analysis module calibrates key parameters through experiments and establishes a mapping relationship database of wear rate, stress state and morphological characteristics to perform friction and wear analysis of moving parts.

[0111] In the above embodiment, a dynamic contact model is constructed to obtain accurate motion laws and force analysis results of the moving mechanical components, including:

[0112] On the basis of clarifying the working principle of the moving mechanical components, according to the motion relationship between the moving mechanical components, and considering the influence and restriction of the spring factor on the moving mechanical components, the kinematic relationship of the inner ring drive is established as a dynamic contact model;

[0113] The constructed dynamic contact model is simulated and a dynamic simulation data set is obtained to characterize the motion law of the constructed dynamics and the relationship between it and other forces;

[0114] The data of the dynamic simulation results are processed to obtain the accurate motion laws and force analysis results of the construction.

[0115] In the above embodiment, based on fractal theory and combined with the surface morphology detection data of the mechanical component, a three-dimensional rough surface digital twin model that conforms to the actual contact surface is constructed to obtain the actual contact rough surface morphology of the mechanical component, including:

[0116] Based on fractal theory, combined with surface morphology detection data of mechanical components and the twinning technology of rough surface construction, a rough surface that conforms to the actual contact surface is constructed. Based on the rough surface, simulation is performed to obtain the wear morphology of the mechanical component in the actual working environment;

[0117] Among them, the method for constructing a rough surface that conforms to the actual contact surface is: according to the determined WM function, multiple sampling points are taken in the x-direction and the y-direction respectively to construct a rough surface point cloud, and these point clouds are imported into the reverse modeling for processing, which includes the removal of abnormal points and the filling of missing points to complete the construction of the rough surface.

[0118] In the above embodiment, a multi-physics field analysis model of the contact stress field is established through the finite element-discrete element coupling algorithm to obtain the elastic deformation and frictional heat effects that occur when the mechanical component materials come into contact. Specifically, the finite element method is used to describe the elastic-plastic deformation and stress distribution of the macroscopic continuum, while the discrete element method is used to capture the microscopic wear particles, migration and redistribution process, and the frictional heat effects are integrated through the thermal-mechanical coupling model.

[0119] In this embodiment, obtaining the elastic deformation and frictional heat effects occurring when mechanical component materials come into contact includes:

[0120] The Archard model is used as the wear finite element model in the wear damage simulation, and the wear of each contact point on the contact surface is predicted by the Archard model;

[0121] The wear depth of each contact point is obtained by predicting the wear. The Archard model is discretized using the discrete element method to perform numerical simulation on the wear depth. The wear depth increment is obtained, and the evolution of the contact surface profile with the wear cycle is simulated.

[0122] When two mechanical components come into contact under the action of a normal force, stress will be generated in the contact area. At this time, the contact occurs on discrete micro-protrusions, which can be simplified macroscopically as a contact area, and the deformation of the materials in the contact area and the heat generated by the relative slip in the material contact area are obtained.

[0123] In the above embodiment, adaptive grid technology is used to achieve dynamic reconstruction of wear morphology and establish a nonlinear iterative relationship between wear amount and contact stress distribution, including:

[0124] Based on the real-time contact stress distribution and local wear rate, it identifies the wear area where the mesh is deformed due to contact stress, and automatically densifies or smoothes the mesh locally to ensure the geometric resolution of the stress concentration area and wear contour.

[0125] The surface topography is updated according to the wear amount, and the contact stress field is recalculated based on the updated new topography, forming a nonlinear iterative cycle of "stress-driven wear-wear-changing topography-topography feedback stress";

[0126] Wear increment and stress redistribution are coupled through implicit time integration method, and the iteration step size is controlled by convergence criterion to achieve self-consistent matching between dynamic reconstruction of wear morphology and contact stress evolution.

[0127] In the above embodiment, accurate boundary conditions are determined based on the accurate motion law of the moving mechanical component and the force analysis results. In combination with the energy dissipation theory and the critical slip distance criterion, a failure criterion based on the sudden change of contact stress gradient and the evolution of surface roughness is constructed, including:

[0128] Determine accurate boundary conditions based on the accurate motion laws and force analysis results of the moving mechanical components;

[0129] The cumulative effects of plastic deformation, heat dissipation, and interface damage during friction are quantified by energy dissipation theory. Combined with the critical slip distance criterion, dynamic failure criteria are constructed, including:

[0130] The micro-damage starting point is identified based on the sudden change of contact stress gradient, and the evolution of surface roughness parameters is analyzed to establish a correlation model between roughness degradation and energy dissipation rate.

[0131] The local energy accumulation is calculated by sliding path integration. When the ratio of dissipated energy to sliding distance in a specific area reaches a preset critical threshold, the area is determined to have entered a failure state.

[0132] The stress gradient mutation signal, roughness degradation rate and energy-slip threshold are integrated into a multi-parameter coupling criterion to achieve cross-scale accurate prediction from microscopic damage initiation to macroscopic failure.

[0133] The system provided in this embodiment is used to execute the above-mentioned method embodiments. Please refer to the above-mentioned embodiments for specific processes and detailed contents, which will not be repeated here.

[0134] In one embodiment of the present invention, a computing device is provided. The computing device may be a terminal and may include: a processor, a communications interface, a memory, a display screen, and an input device. The processor, communications interface, and memory communicate with each other via a communications bus. The processor is configured to provide computing and control capabilities. The memory includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores an operating system and a computer program. When executed by the processor, the computer program implements the methods described in the above embodiments. The internal memory provides an environment for the operating system and computer program in the non-volatile storage medium to run. The communications interface is configured to communicate with an external terminal via wired or wireless communication. The wireless communication may be achieved via Wi-Fi, a network management service provider, NFC (near field communication), or other technologies. The display screen may be a liquid crystal display or an electronic ink display. The input device may be a touch screen covering the display screen, a keypad, a trackball, or a touchpad provided on the housing of the computing device, or an external keyboard, touchpad, or mouse. The processor may invoke logic instructions stored in the memory.

[0135] In addition, the logical instructions in the above-mentioned memory can be implemented in the form of a software functional unit and can be stored in a computer-readable storage medium when sold or used as an independent product. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, or the part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium and includes several instructions for enabling a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the method described in each embodiment of the present invention. The aforementioned storage medium includes: various media that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk.

[0136] In one embodiment of the present invention, a computer program product is provided, which includes a computer program stored on a non-transitory computer-readable storage medium, and the computer program includes program instructions. When the program instructions are executed by a computer, the computer can execute the methods provided by the above-mentioned method embodiments.

[0137] In one embodiment of the present invention, a non-transitory computer-readable storage medium is provided. The non-transitory computer-readable storage medium stores server instructions. The computer instructions enable a computer to execute the methods provided in the above embodiments.

[0138] The above embodiment provides a computer-readable storage medium, whose implementation principle and technical effects are similar to those of the above method embodiment, and will not be repeated here.

[0139] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the steps in the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0140] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0141] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0142] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A method for analyzing and predicting wear morphology and contact stress based on rough contact surfaces, characterized in that: include: Based on the dynamic contact theory, the collision of moving mechanical components during contact is considered, and a dynamic contact model is constructed to obtain the accurate motion laws and force analysis results of the moving mechanical components. Based on fractal theory and combined with surface morphology detection data of mechanical components, a three-dimensional rough surface digital twin model that conforms to the actual contact surface is constructed to obtain the actual contact rough surface morphology of the mechanical component; Based on the actual contact rough surface morphology of mechanical components, a multi-physics field analysis model of contact stress field is established through the finite element-discrete element coupling algorithm to obtain the elastic deformation and frictional heat effects that occur when the mechanical component materials come into contact; Based on the real-time acquired contact stress distribution and local wear rate, adaptive grid technology is used to dynamically reconstruct the wear morphology and establish a nonlinear iterative relationship between wear volume and contact stress distribution. Based on the accurate motion laws and force analysis results of mechanical components, accurate boundary conditions are determined. In combination with energy dissipation theory and critical slip distance criterion, failure criteria based on contact stress gradient mutation and surface roughness evolution are constructed to accurately predict cross-scale damage from microscopic damage initiation to macroscopic failure. By calibrating key parameters through experiments, a database of mapping relationships between wear rate, stress state and morphological characteristics is established to conduct friction and wear analysis of moving parts.

2. The analysis and prediction method based on the wear morphology and contact stress of the rough contact surface according to claim 1, characterized in that: Build dynamic contact models to obtain accurate motion and force analysis results for moving mechanical components, including: On the basis of clarifying the working principle of the moving mechanical components, according to the motion relationship between the moving mechanical components, and considering the influence and restriction of the spring factor on the moving mechanical components, the kinematic relationship of the inner ring drive is established as a dynamic contact model; The constructed dynamic contact model is simulated and a dynamic simulation data set is obtained to characterize the motion law of the constructed dynamics and the relationship between it and other forces; The data of the dynamic simulation results are processed to obtain the accurate motion laws and force analysis results of the construction.

3. The analysis and prediction method based on the wear morphology and contact stress of the rough contact surface according to claim 1, characterized in that: Based on fractal theory and combined with surface morphology detection data of mechanical components, a three-dimensional rough surface digital twin model that conforms to the actual contact surface is constructed to obtain the actual contact rough surface morphology of the mechanical component, including: Based on fractal theory, combined with surface morphology detection data of mechanical components and the twinning technology of rough surface construction, a rough surface that conforms to the actual contact surface is constructed. Based on the rough surface, simulation is performed to obtain the wear morphology of the mechanical component in the actual working environment; Among them, the method for constructing a rough surface that conforms to the actual contact surface is: according to the determined WM function, multiple sampling points are taken in the x-direction and the y-direction respectively to construct a rough surface point cloud, and these point clouds are imported into the reverse modeling for processing, which includes the removal of abnormal points and the filling of missing points to complete the construction of the rough surface.

4. The analysis and prediction method based on the wear morphology and contact stress of the rough contact surface according to claim 1, characterized in that: A multi-physics field analysis model of the contact stress field is established through the finite element-discrete element coupling algorithm to obtain the elastic deformation and frictional heat effects that occur when mechanical component materials come into contact. Specifically, the finite element method is used to describe the elastic-plastic deformation and stress distribution of the macroscopic continuum, while the discrete element method is used to capture the microscopic wear particles, migration and redistribution process, and the frictional heat effect is integrated through the thermal-mechanical coupling model.

5. The analysis and prediction method based on the wear morphology and contact stress of the rough contact surface according to claim 4, characterized in that: Acquire the elastic deformation and frictional heat effects that occur when mechanical components and materials come into contact, including: The Archard model is used as the wear finite element model in the wear damage simulation, and the wear of each contact point on the contact surface is predicted by the Archard model; The wear depth of each contact point is obtained by predicting the wear. The Archard model is discretized using the discrete element method to perform numerical simulation on the wear depth. The wear depth increment is obtained, and the evolution of the contact surface profile with the wear cycle is simulated. When two mechanical components come into contact under the action of a normal force, stress will be generated in the contact area. At this time, the contact occurs on discrete micro-protrusions, which can be simplified macroscopically as a contact area, and the deformation of the materials in the contact area and the heat generated by the relative slip in the material contact area are obtained.

6. The analysis and prediction method based on the wear morphology and contact stress of the rough contact surface according to claim 1, characterized in that: Adaptive mesh technology is used to achieve dynamic reconstruction of wear morphology and establish a nonlinear iterative relationship between wear volume and contact stress distribution, including: Based on the real-time contact stress distribution and local wear rate, it identifies the wear area where the mesh is deformed due to contact stress, and automatically densifies or smoothes the mesh locally to ensure the geometric resolution of the stress concentration area and wear contour. The surface topography is updated according to the wear amount, and the contact stress field is recalculated based on the updated new topography, forming a nonlinear iterative cycle of "stress-driven wear-wear-changing topography-topography feedback stress"; Wear increment and stress redistribution are coupled through implicit time integration method, and the iteration step size is controlled by convergence criterion to achieve self-consistent matching between dynamic reconstruction of wear morphology and contact stress evolution.

7. The analysis and prediction method based on the wear morphology and contact stress of the rough contact surface according to claim 1, characterized in that: Based on the accurate motion laws and force analysis results of the moving mechanical components, accurate boundary conditions are determined. Combined with energy dissipation theory and critical slip distance criterion, failure criteria based on contact stress gradient mutation and surface roughness evolution are constructed, including: Determine accurate boundary conditions based on the accurate motion laws and force analysis results of the moving mechanical components; The cumulative effects of plastic deformation, heat dissipation, and interface damage during friction are quantified by energy dissipation theory. Combined with the critical slip distance criterion, dynamic failure criteria are constructed, including: The micro-damage starting point is identified based on the sudden change of contact stress gradient, and the evolution of surface roughness parameters is analyzed to establish a correlation model between roughness degradation and energy dissipation rate. The local energy accumulation is calculated by sliding path integration. When the ratio of dissipated energy to sliding distance in a specific area reaches a preset critical threshold, the area is determined to have entered a failure state. The stress gradient mutation signal, roughness degradation rate and energy-slip threshold are integrated into a multi-parameter coupling criterion to achieve cross-scale accurate prediction from microscopic damage initiation to macroscopic failure.

8. An analysis and prediction system based on the wear morphology and contact stress of rough contact surfaces, characterized in that: include: The dynamic model construction module is based on the dynamic contact theory and takes into account the collision of moving mechanical components when they come into contact. It constructs a dynamic contact model to obtain the accurate motion laws and force analysis results of the moving mechanical components. The twin model construction module, based on fractal theory and combined with the surface morphology detection data of mechanical components, constructs a three-dimensional rough surface digital twin model that conforms to the actual contact surface to obtain the actual contact rough surface morphology of the mechanical component; The finite element model building module, based on the actual contact rough surface morphology of mechanical components, establishes a multi-physics field analysis model of the contact stress field through the finite element-discrete element coupling algorithm to obtain the elastic deformation and frictional heat effects that occur when the mechanical component materials come into contact; The adaptive module uses adaptive grid technology to dynamically reconstruct the wear morphology based on the real-time contact stress distribution and local wear rate, and establishes a nonlinear iterative relationship between wear volume and contact stress distribution; The prediction module determines accurate boundary conditions based on the precise motion patterns and force analysis results of mechanical components. Combining energy dissipation theory and the critical slip distance criterion, it constructs failure criteria based on sudden changes in contact stress gradients and surface roughness evolution, enabling precise cross-scale predictions from microscopic damage initiation to macroscopic failure. The wear analysis module calibrates key parameters through experiments and establishes a mapping relationship database of wear rate, stress state and morphological characteristics to perform friction and wear analysis of moving parts.

9. A computer-readable storage medium storing one or more programs, characterized in that: The one or more programs include instructions that, when executed by a computing device, cause the computing device to perform any one of the methods of claims 1 to 7 .

10. A computing device, characterized in that include: One or more processors, a memory, and one or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, and the one or more programs include instructions for executing any one of the methods according to claims 1 to 7.

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