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Topology Optimization of Composite Materials for Wear: A Route to Multifunctional Materials for Sliding Interfaces

Predicting and optimizing the wear performance of tribological systems is of great interest in many mechanical applications. Wear modeling based on elastic foundation models can be used to predict the wear behavior of composite materials. Topology optimization has previously been used to improve the wear performance of a bi‐material composite surface without direct experimental validation. In this paper, three multi‐material composite wear surfaces are presented and fabricated that are the product of topology optimization. The wear surfaces are designed for optimal wear performance including minimized run‐in wear volume lost. In this work, the designs are evaluated with high‐accuracy simulations prior to fabrication. Extensive testing is conducted including for wear volume, wear rate, surface height distribution, and profile measurements throughout the wear process. The effects of boundary conditions and the importance of taking wear sliding directionality into account in the modeling process are discussed.