OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 27 No. 2 2025 the inherent variability in their measurements using these repetitions of the center point experiments. This helps in accounting for experimental error introduced due to uncontrollable factors, such as environmental conditions. These experiments quantify the error, which is essential for evaluating the statistical significance of the findings. The consistency of the center point repetitions strengthens confidence in the predictive capabilities of the model. Numerical Approach The workflow for simulating the tribological analysis of a PTFE composite using a pin-on-disc setup with FEA is shown in Fig. 3. The pin-on-disc setup model was generated in SOLIDWORKS, followed by simulation using ANSYS 2021 R2 Workbench. The properties of the corresponding materials were imported into FEA to accurately simulate the model, which provides reliability in the prediction ability of the model. In ANSYS Workbench, the disc and pin were assigned frictional contact with asymmetric behavior, and their motion was restricted to specific degrees of freedom by assigning them ground joints [21]. The disc was modeled as a rigid body, whereas the pin was treated as a flexible body to incorporate its deformation. A translation joint was assigned to the pin in the vertical direction; however, the disc was assigned a revolute joint. The detection method was set to nodal normal to the target, aligning with the applied force on the pin. Similarly, the trim contact was disabled to allow for aggressive stiffness updates, which helped to accelerate convergence and reduce simulation time. Meshing was performed using the auto-meshing capabilities of ANSYS Mechanical APDL. The 3D elements were meshed with a combination of tetrahedral and hexahedral elements. The tetrahedral elements easily conform to the complex geometry, whereas hexahedral elements are used in regular shapes for better accuracy [22]. Analysis settings were configured, and Archard’s wear model was incorporated, defining its wear coefficient (K) as 0.988 × 10−4 to predict the volume loss. Fig. 3. Flow chart of numerical simulation Archard’s wear law establishes the wear rate as a linear function of the applied load, sliding speed, softer material hardness, and wear coefficient. However, this law focuses mainly on contact surfaces and ignores the effect of surface roughness or duration of the run. ANSYS Workbench was employed to model the FEA modeling of the pin-on-disc arrangement for simulation. Transient structural analysis was performed by providing the respective properties of the disc and pin material. Initially, sample trials were performed and validated with the experimental results. Power law In tribo-systems, the behaviour of materials under different operating conditions can be effectively captured by using a power law. The relationship between dependent variables, such as wear and coefficient of friction, and independent variables, such as sliding speed, load, and temperature, is defined for predictive analysis. It is expressed as: k y ax , (1)
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