On the origins of third-body particle formation during adhesive wear

The process of material removal during adhesive sliding contact (i.e. adhesive wear) remains one of the least understood areas in the field of tribology. The main reason for this limited understanding is that, direct observation and modeling of third body formation during adhesive contact present notorious challenges [1]. Recent coarse-grained 2D atomistic simulations [2] revealed the existence of a critical junction size, with larger asperity junctions forming third-body wear particles and smaller junctions smoothing plastically. In this study, we examine the critical junction size model in a three-dimensional configuration. We present a 3D coarse-grained model potential and large scale 3D simulations of third-body particle formation in an idealized single asperity contact. Our simulations validate the prediction of the critical junction size model [2] for the formation of third-body wear particles. Directions for future studies on computer modeling of wear processes are discussed. •Using a 3D coarse-grained model potential, we simulate the formulation process of a third body wear particle in an idealized asperity contact.•The junction size model, that is recently formulated based on 2D simulations (Aghababaei et. al., 2016 Nature Comm.), has been validated in an idealized 3D asperities contact.•The longstanding origins of third body formation during adhesive sliding and the absence of third body formation in the previous wear simulations are discussed.•Challenges and directions for future studies on computer modeling of wear processes are discussed.