A stochastic model for predicting the evolutions of wear profile and surface height probability density function (PDF) of initial line contacts during running-in under mixed lubrication condition is presented. A numerical approach was developed on the basis of stochastic solution of mixed lubrication, which combined the Patir and Cheng's average flow model for calculation of the hydrodynamic pressure and the Kogut and Etsion's (KE) rough surface contact model for calculation of the asperity contact pressure. The total friction force was assumed to be the sum of the boundary friction at the contact asperities and the integration of viscous shear stress in the hydrodynamic region. The wear depth on the contact region was estimated according to the modified Archard's wear model using the asperity contact pressure. Sugimura's wear model was modified and used to link the wear particle size distribution and the variation of surface height PDF during wear. In the wear process, the variations of profile and surface height PDF of initial line contacts were calculated step by step in time, and the pressure distribution, friction coefficient, and wear rate were updated consequently. The effect of size distribution of wear particles on the wear process was numerically investigated, and the simulation results showed that the lubrication condition in which small wear particles are generated from the asperity contact region is beneficial to reduce friction coefficient and wear rate, and leads to a better steady mixed lubrication condition.

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