Abstract: During the operation of hydro-generator set, the carbon brush is prone to excessive wear and accumulation of abrasive particles under the action of electrical, mechanical and thermal coupling, which will affect the power generation efficiency of the unit. By establishing a transient coupling finite element model of carbon brush/collector ring and combining with Archard wear model, numerical simulation of current-carrying wear behavior was carried out to study the influence of surface pattern on current-carrying wear performance of carbon brush/collector ring, and the simulation results were verified by experimental method. The experimental results showed that the wear peak value of carbon brush was mainly distributed around the pattern and the edge area under current load condition. When the surface pattern ratio was 25%, the heat dissipation performance and the matrix strength were coordinated and optimized, and the wear volume was significantly reduced. At low current density, non-uniform wear was aggravated due to insufficient contact pressure, while at high current density, material spalling was aggravated due to sharp rise in local temperature. Biomimetic ordering pattern could optimize the surface contact state, effectively alleviate stress concentration and enhance heat dissipation performance, thus significantly reducing the carbon brush wear rate.