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RESEARCH PAPERS

Elastic-Plastic Contact Between Rough Surfaces: Proposal for a Wear or Running-In Model

[+] Author and Article Information
D. Nélias, V. Boucly, M. Brunet

LaMCoS, UMR 5514 CNRS/INSA Lyon, 69621 Villeurbanne Cedex, France

J. Tribol 128(2), 236-244 (Nov 02, 2005) (9 pages) doi:10.1115/1.2163360 History: Received April 15, 2005; Revised November 02, 2005

A semi-analytical thermo-elastic-plastic contact model has been recently developed and presented in a companion paper. The main advantage of this approach over the classical finite element method (FEM) is the treatment of transient problems with the use of fine meshing and the possibility of studying the effect of a surface defect on the surface deflection as well as on subsurface stress state. A return-mapping algorithm with an elastic predictor/plastic corrector scheme and a von Mises criterion is now used, which improves the plasticity loop. This improvement in the numerical algorithm increases the computing speed significantly and shows a much better convergence and accuracy. The contact model is validated through a comparison with the FEM results of Kogut and Etsion (2002, J. Appl. Mech., 69, pp. 657–662) which correspond to the axisymmetric contact between an elastic-perfectly plastic sphere and a rigid flat. A model for wear prediction based on the material removal during cyclic loading is then proposed. Results are presented, first, for initially smooth surfaces and, second, for rough surfaces. The effects of surface shear stress and hardening law are underlined.

FIGURES IN THIS ARTICLE
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Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 1

Plastic zone evolution for 2<w∕wc<11 (from (6) for the right-hand side)

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Figure 2

Plastic zone evolution for 12<w∕wc<110 (from (6) for the right-hand side)

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Figure 3

Equivalent plastic strain versus w∕wc for w∕wc<110

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Figure 4

Interference ratio w∕wc versus friction coefficient when the plastic zone reaches the surface. The windows indicate the equivalent plastic strain after unloading for different normal loads (interference ratio) and friction coefficients.

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Figure 5

Proposal of Ludwik suggesting that fracture occurs at a point F, where flow stress and fracture stress versus strain curves intersect (from (16))

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Figure 6

Micrograph showing plastic deformed region (PDR) bordered by dark etching region (DER) for a gear material after a nital etch (from (5))

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Figure 13

Contact between an initially isotropic rough surface and a smooth one—stabilized state after seven cycles—(a) and (b) under loading, (c) and (d) after unloading: (a) Contact pressure, (b) equivalent Tresca stress, (c) hydrostatic pressure, and (d) equivalent plastic strain

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Figure 12

Contact between an initially isotropic rough surface and a smooth one, final surface (worn geometry), after cyclic loading

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Figure 11

Contact between an initially isotropic rough surface and a smooth one—first cycle—(a) and (b) under loading, (c) and (d) after unloading: (a) contact pressure, (b) equivalent Tresca stress, (c) hydrostatic pressure, and (d) equivalent plastic strain

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Figure 10

Initial profile of the isotropic rough surface

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Figure 9

Contact between two initially smooth surfaces, state after 13 loading cycles—(a) and (b) under load, (c) and (d) after unloading: (a) contact pressure, (b) equivalent Tresca stress, (c) hydrostatic pressure, and (d) equivalent plastic strain

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Figure 8

Contact between two initially smooth surfaces, wear profile after cycling loading (13cycles)

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Figure 7

Contact between two initially smooth surfaces—first cycle—(a) and (b) under loading, (c) and (d) after unloading: (a) contact pressure, (b) equivalent Tresca stress, (c) hydrostatic pressure, and (d) equivalent plastic strain

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