A new approach of fretting fatigue and wear process analysis integrating total wear behaviour of initial and steady-state wear was proposed as a simulation technique used commercial FEM cord Wear rate and coefficient of friction for number of fretting cycles were determined from fretting fatigue test and the relationship between contact slip amplitude and the coefficient of friction that was obtained by FEM analysis It was difficult to predict fretting fatigue lives by wear analysis considering only steady-state wear However, the fatigue lives near fatigue limit were successfully estimated by considering initial and steady-state wear behaviour in wear process analysis