Fretting wear simulation based on dynamic behavior of debris layer considering surface morphology influence

Fretting wear is a critical failure mode in engineering contact structures, which is dominated by the dynamic behavior of wear debris. This study explores the combined effects of surface topography and wear debris dynamics on fretting wear through experiment and simulation. A new fretting wear simulation framework is developed to clarify how relative sliding velocity, contact pressure, and debris layer thickness affect fretting wear. A statistical surface reconstruction method based on Pearson distribution is proposed for equivalent surface modeling, achieving an error within 5 % for key topographic parameters. Using this equivalent topography to calculate contact surface friction, with deviations of 6.7 % and 7.1 % for friction force and friction coefficient respectively. A meshless model is introduced for dynamic debris simulation, focusing on high nonlinearity in debris evolution and analyzing the ratio of debris transfer velocity to relative sliding speed. By combining the friction work model and debris transfer rate model, debris generation and expulsion are formulated, reducing the relative error from 40.7 % to 18.5 % on wear profiles prediction under various fretting conditions. The wear profiles are highly consistent with experimental observations, especially in reproducing step-like inflections caused by different debris expulsion rates between contact edges and central regions.