Wear simulation and validation of composites (insert-reinforced matrix) in the dry sand rubber wheel test

Composites generally possess a higher wear resistance than their constituents alone, but the governing mechanisms often remain unknown. This study numerically investigated the wear of composites (insert -reinforced matrix), caused by abrasive particles, and validated the results against the experiments. For this purpose, the dry sand rubber wheel (DSRW) abrasion test was implemented using Discrete Element Modelling (DEM). Composites and monoliths, respectively, with vol% of inserts of 0, 8, 23, 40 and 100 vol% were investigated. For all composites, the inserts possessed the same diameter and an increasing vol% of inserts resulted in a decreasing spacing between them. The inserts possessed a geometrical scale comparable to the size of the abrasive particles. Several quantities associated with wear, such as profile of the wear scar and the wear volume, were assessed. Interestingly, the composite with 40 vol% of inserts possessed less wear than the monolithic specimen fully consisting of insert material (100 vol%). For all composites, an increasing vol% of inserts increased the thickness of the particle layer between the abrasive wheel and the wear surface. Moreover, the particle motion changed, showing less sliding and more rolling. This indicated a change into a less severe wear regime and this transition was especially strong for the composite with 40 vol% of inserts, where the spacing between the inserts was closest to the average size of the abrasive particles. DEM can be used to assess the abrasion wear resistance and understand the underlying mechanisms of composites in the DSRW test. This is important for the development of wear resistant composites for bulk materials handling, such as wear liners for chutes.