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TECHNICAL PAPERS

Elastic–Plastic Multi-Asperity Contact Analysis of Cylinder-on-Flat Configuration

[+] Author and Article Information
V. Sabelkin

Department of Aeronautics and Astronautics, Air Force Institute of Technology, Wright-Patterson Air Force Base, OH 45433

S. Mall1

Department of Aeronautics and Astronautics, Air Force Institute of Technology, Wright-Patterson Air Force Base, OH 45433 and AFIT/ENY, Building 640, 2950 Hobson Way, Air Force Institute of Technology, Wright-Patterson AFB, OH 45433-7765shankar.mall@afit.edu

1

Corresponding author.

J. Tribol 129(2), 292-304 (Jan 03, 2007) (13 pages) doi:10.1115/1.2540262 History: Received April 05, 2006; Revised January 03, 2007

The contact interaction between a rough cylindrical body (i.e., with asperities) and a deformable smooth flat was investigated using the finite-element analysis. Analysis included both elastic–plastic deformation and friction. Further, the effects of several parameters of rough surface on the evolution of the contact area with increasing contact load were investigated. These were radius, number, constraint, and placement of asperities. Contact area of rough surface is smaller than its counterpart of smooth surface, and this decrease depends on number, radius, constraint, and placement of asperities. The elastic material behavior results in considerably smaller contact area than that from elastic–plastic material behavior. The evolution of contact area with increasing contact load is of the complex nature with elastic–plastic material deformation since the yielded region widens and/or deepens with increasing load depending on number, radius, and constraint of asperities. The effect of constraint on the asperity depends upon its nature (i.e., from either sides or one side) and radius of the asperity. The effects of these several parameters on the contact area versus applied load relationships are expressed in the graphical form as well as in terms of equations wherever possible.

Copyright © 2007 by American Society of Mechanical Engineers
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Figures

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Figure 7

Normalized contact area versus normalized load at small loads (a), normalized by maximum load and area (b), and normalized by Pc and Ac (c): (1) no asperities; (2) Rasp=R∕5, one-asperity; (3) Rasp=R∕5, two asperities; (4) Rasp=R∕10, three asperities; (5) Rasp=R∕10, four asperities; (6) Rasp=R∕20, five asperities; (7) Rasp=R∕20, six asperities

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Figure 14

One-asperity indentation profile and deformation contours (a) - vertical displacement of the upper contact, (b) - vertical displacement of the lower contact, (c) horizontal displacement of the upper contact, (d) - horizontal displacement of the lower contact. All profiles are at the maximum applied load, Pmax. Scale along horizontal x axis is 1, (b) and (d) scale along vertical y axis is 30.

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Figure 15

Two-asperity indentation profile and deformation contours (a) - vertical displacement of the upper contact, (b) - vertical displacement of the lower contact, (c) horizontal displacement of the upper contact, (d) - horizontal displacement of the lower contact. All profiles are at the maximum applied load, Pmax. Scale along horizontal x axis is 1, (b) and (d) scale along vertical y axis is 30.

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Figure 1

Schematic of the model: (1) lower contact body; (2) upper bulk body; (3) cylindrical contacting segment; and (4) asperities

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Figure 3

Overall view (a) and mesh details as asperity mesh refinement (b), contact zone (c), and contact surfaces mesh refinement (d)

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Figure 4

Normal contact pressure distribution on contact surface: (1) analytical calculation, using Hertz formulation; and (2) finite-element analysis

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Figure 5

Normalized contact area versus normalized load: (a) normalized by maximum area for elastic purely plastic material and load, Amax and Pmax; and (b) normalized by Ac and Pc, area, and load at the instant of yielding: (1) elastic perfectly plastic; (2) elastic–plastic linear hardening; (3) pure elastic analytical; and (4) pure elastic FEA

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Figure 6

Contact area versus applied load relationships for: (a) one asperity; (b) two asperities; (c) three asperities; (d) four asperities, (e) five asperities; and (f) six asperities.

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Figure 12

Von Mises stresses in two-asperities contact region for 100% (a) (general view), 40% (b), 70% (c), 100% (d) of maximum load, R=1.8μm, Rasp=R∕5=0.36μm, COF=0.8

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Figure 13

Von Mises stresses in three-asperity contact region for 20% (a), 100% (b) of maximum load, Rasp=R∕5

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Figure 16

Three-asperity indentation profile and deformation contours (a) - vertical displacement of the upper contact, (b) - vertical displacement of the lower contact, (c) horizontal displacement of the upper contact, (d) - horizontal displacement of the lower contact. All profiles are at the maximum applied load, Pmax. Scale along horizontal x axis is 1 for (a) and (c); scale along vertical y axis is 30 for (b) and (d).

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Figure 8

Normalized contact area evolution for different number of asperities at: (1) 25%; (2) 50%; and (3) 100% of maximum load

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Figure 9

(a) Normalized by Amax contact area versus relative radius and (b) normalized by Ac contact area versus relative radius: (1) odd number of asperities in contact (1, 3, 5 asperities); (2)even number of asperities in contact (2, 4, 6 asperities); (3) one-asperity unconstrained contact; (4) three-asperity constrained contact; and (5) two-asperity partially constrained contact

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Figure 10

Effect of constraint on normalized contact area for Rasp=R∕5 (a)–(b); Rasp=R∕10 (c); and Rasp=R∕20 (d): (1) one asperity; (2) two asperity of equal radius; (3 & 3*) three asperity contact; (4) four asperity; (5) five asperity; and (6) six asperity

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Figure 11

Von Mises stresses in one-asperity contact region for 25% (a); 50% (b); 75% (c); 100% of maximum load (d); R=1.8μm, Rasp=R∕5=0.36μm

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