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Abstract
Understanding dual-mode wear behavior, including fatigue and abrasive wear, is essential for determination of surface damage under the sliding-impact condition, which can induce early motion-pair failure. A new dual-mode wear model is presented in this article for plane–cylinder contact pairs with fractal surfaces. First, fractal theory is employed for elastic–plastic contact analysis of the mating surfaces. Then the negative inhibitory effect of the abrasive surface damage on subsurface fatigue crack propagation is considered to explore abrasion–fatigue interactions at the asperity level. Subsequently, dual-mode wear behaviors are derived for the asperity and fractal surface based on four wear-combination scenarios of the abrasive and fatigue mechanisms. Furthermore, the validity of the proposed prediction model is evaluated by comparisons between the expected results and laboratory tests with 100Cr6 plane and C45E4 cylinder steel pairs. The results show that the new model can reasonably explain the dual mode wear behavior and predict the wear rate of friction pairs. These insights can potentially help in guiding the tribological design of these dual-mode wear scenarios.