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Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes
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Published on: December 13, 2016

Bushing Wear Prediction of High-Speed Press Conditions.

Alibek Yuldoshev1, Inseo Kim1, Joonhee Park1

  • 1Department of Mechanical Engineering, Sogang University, Seoul 04107, Republic of Korea.

Materials (Basel, Switzerland)
|June 26, 2026
PubMed
Summary

This study introduces an advanced wear prediction model for high-speed press bushing components. The model accurately forecasts wear by integrating experimental data with finite element analysis, improving system reliability.

Keywords:
archard wear modelbushing wearfinite element analysishigh-speed press systemprofilometry

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Area of Science:

  • Mechanical Engineering
  • Tribology
  • Materials Science

Background:

  • High-speed press systems experience severe dynamic loading, leading to accelerated bushing wear.
  • Existing wear studies primarily focus on automotive and aerospace, leaving high-speed press conditions underexplored.
  • Bushing wear significantly impacts system reliability and maintenance costs.

Purpose of the Study:

  • To develop and validate a novel wear prediction model for bushing components in high-speed press systems.
  • To investigate the influence of contact pressure distribution and shaft misalignment on bushing wear.
  • To enhance the accuracy of wear prediction beyond the standard Archard model.

Main Methods:

  • Integration of experimental measurements with 3D finite element analysis (FEA).
  • Development of a controlled experimental setup to simulate high-speed press operating conditions.
  • Utilizing high-resolution profilometry for wear profile measurement and FEA for contact pressure distribution.

Main Results:

  • The proposed extended Archard wear model demonstrates strong predictive capability with an RMSE of 0.98 μm and MAE of 0.57 μm.
  • The model successfully captures asymmetric wear patterns caused by shaft misalignment.
  • It resolves the underestimation of high-pressure peaks compared to the baseline Archard model.

Conclusions:

  • The developed wear prediction model offers enhanced accuracy for high-speed press applications.
  • Incorporating contact pressure and misalignment effects is crucial for precise bushing wear forecasting.
  • This research contributes to improved reliability and reduced maintenance costs in high-speed press systems.