Vibration-Based Wear Evolution Characterisation of Lubricated Rolling-Sliding Contact

This paper presents a comprehensive study on the vibration-based wear evolution characterisation by coupling the dynamic behaviour, surface roughness, and lubrication effects under rolling-sliding contact. Initially, a dynamic model is developed to examine the contact vibration characteristics induced by a randomly rough surface. A contact resonance frequency (CRF) can be obtained, and it is only positively correlated with the load, while the amplitude of CRF (CRFA) negatively correlates with the load and positively correlates with the velocity and surface profile height. Thereafter, a mixed-EHL model is employed to simulate the wear and lubrication progression of rolling-sliding contact. The surface roughness, contact load ratio (CLR), and contact area ratio (CAR) within this process are assigned specific physical interpretations and incorporated into the dynamic model. Given the nonlinear and coupled interactions of these three factors, the CRF and CRFA can distinguish the normal wear and severe wear stages. When the tribo-pair is in a normal wear stage, the CRF and CRFA show an increasing trend with the increase in surface roughness. Upon reaching a severe wear stage, the CRF gradually stabilises while the CRFA exhibits noticeable irregular fluctuations as the roughness increases. Finally, experiments are conducted to demonstrate the effectiveness of this method.