Wear-caused deflection evolution of a slide rail, considering linear and non-linear wear models

The research presented in this paper details an experimental-numerical approach for the quantitative correlation between wear and end-point deflection in a slide rail. Focusing the attention on slide rail utilized in white-goods applications, the aim is to evaluate the number of cycles the slide rail can operate, under different load conditions, before it should be replaced due to unacceptable end-point deflection. In this paper, two formulations are utilized to describe the wear: Archard model for the linear wear and Lemaitre damage model for the non- linear wear. The linear wear gradually reduces the surface of the slide rail whereas the non- linear one accounts for the surface element deletion (i.e. due to pitting). To determine the constants to use in the wear models, simple tension test and sliding wear test, by utilizing a designed and developed experiment machine, have been carried out. A full slide rail model simulation has been implemented in ABAQUS including both linear and non-linear wear models and the results have been compared with those of the real rails under different load condition, provided by the rail manufacturer. The comparison between numerically estimated and real rail results proved the reliability of the developed numerical model, limiting the error in a ±10% range. The proposed approach allows predicting the displacement vs cycle curves, parametrized for different loads and, based on a chosen failure criterion, to predict the lifetime of the rail.