Bushing Wear Prediction of High-Speed Press Conditions

High-speed press systems operate under severe dynamic loading conditions, where bushing components are subject to accelerated wear that directly affects system reliability and maintenance cost. Despite extensive studies on bearing wear in automotive and aerospace applications, wear behavior under high-speed press conditions remains insufficiently explored. This study proposes a wear prediction model that integrates experimental measurements with finite element analysis (FEA). A key hypothesis is that bushing wear under high-speed press conditions can be accurately described by an extended Archard wear model incorporating contact pressure distribution and shaft misalignment effects. A controlled experimental setup was developed to replicate real operating conditions. Wear profiles were measured using high-resolution profilometry, while corresponding contact pressure distributions were obtained via 3D FEA simulations. Model parameters were calibrated using a subset of experimental data and validated against independent test cases. The proposed model demonstrates strong predictive capability, achieving an RMSE of 0.98 μm and an MAE of 0.57 μm across the 30-min calibration cases under the average (AVG) load-cell calibration. The extended formulation captures the asymmetric wear patterns induced by misalignment and resolves the high-pressure peak underestimation observed in the plain Archard baseline.