Spectral wear modelling of rubber friction on a hard substrate with large surface roughness

Soft-hard matter friction is a long-standing tribology problem that remains unclarified, requiring engineers to empirically predict the wear life. To clarify this issue, this study examines the transient running-in regime of rubber friction on a hard rough substrate and models the temporal wear progression using the spectrum curves of surface roughness for both materials. Performing a series of friction tests and three-dimensional surface-height measurements, the time-dependent behaviours of the power spectral densities (PSDs) are divided into two phases, namely the initial non-steady and long-term steady phases. The detailed spectral analyses of worn rubber surfaces in the initial phase lead to a blended PSD function between self-affine and K -correlation surface models, consisting of one variable (the Hurst exponent) that is saturated by the substrate self-affinity. Supported by the Greenwood–Williamson theory concerning rough contact mechanics, the volumetric estimate with the blended PSD function is used to assess the volume rate of wear debris in the steady phase, which is validated experimentally. These findings not only improve the wear predictions of soft materials from the initial measurements of worn surfaces but also help clarify the constrained multiscale mechanism of wear.