# Predictions of Wear Performances of AlSi7Mg0.6 Cast Aluminum Alloy Under Different Displacement and Applied Load

## TL;DR

This paper studies how displacement and load affect the wear of AlSi7Mg0.6 aluminum alloy used in high-speed rail systems, using both experiments and simulations.

## Contribution

A new finite element method with UMESHMOTION and ABAQUS ALE is developed to simulate wear in AlSi7Mg0.6 alloy with high accuracy.

## Key findings

- The maximum wear depth deviation between simulation and experiment is less than 10%.
- Wear volume simulations show up to 16.33% deviation from experiments under certain conditions.
- Simulation accuracy varies with displacement and applied load combinations.

## Abstract

AlSi7Mg0.6 aluminum alloy is widely adopted in many industrial fields due to its favorable mechanical properties and lightweight merits. In the catenary system of high-speed railways, AlSi7Mg0.6 aluminum alloy is adopted as the substrate of the positioning hook and positioning support, which exhibit abnormal wear in some railways. Thus, it is very important to reveal the underlying wear characteristics and discover the key factors involved. In this study, the influences of displacement (0.5 mm, 1.5 mm, and 3.0 mm) and applied load (20 N, 50 N, 100 N, and 200 N) on the wear performance of AlSi7Mg0.6 aluminum alloy are investigated experimentally and numerically. Wear experiments are time-consuming and costly, but the finite element method (FEM) can effectively solve this problem. A UMESHMOTION user-defined subroutine integrated with an ABAQUS Arbitrary Lagrangian–Eulerian (ALE) adaptive mesh technique was developed to simulate the wear evolution process of the aluminum alloy under varying displacements and applied loads. The results indicate that the wear evolution process of AlSi7Mg0.6 aluminum alloy can be effectively simulated using the UMESHMOTION subroutine. The maximum wear depth (MWD) from the FEM deviates from the experimental results by no more than 10%, and the deviation is smaller than the experimental values. The largest deviation occurs when the displacement is 3.0 mm and the applied load is 100 N, where the discrepancy reaches 7.53%. The wear volume (WV) obtained from the FEM shows a deviation of less than 20% compared to experimental results. For the case with a displacement of 0.5 mm, the numerical results underestimate the wear volume, while for the case with displacements of 1.5 mm and 3.0 mm, the numerical results overestimate the wear volume. The largest deviation in this case occurs for the case with a displacement of 3.0 mm and applied loading of 100 N, with a discrepancy of 16.33%.