On non-symmetrical plane contacts

Plane elastic contact problems are considered, with particular emphasis on asymmetrical punch profiles, in the case of ‘complete’, ‘partially complete’ and ‘incomplete’ contact. An explicit, analytical solution is presented for the case of a single area of contact where the overlap is described by a generic spline function, and examples presented. The interior stress field and strength of the contact, under full or partial slip conditions, are also discussed, and some example shown for representative cases. It is found also that the direction of sliding has a significant effect for the strength of non-symmetrical contacts.     

Fabrication of clean cut surface on high strength steel using a new shaving die design

A shaving process is commonly applied to achieve a smooth cut surface thorough the workpiece thickness and a square cut-edge, also known as a finishing operation. However, this process is rarely successful for high-strength steel sheets, which is a major problem. In the present study, finite element method (FEM) simulation was used to clarify the main causes of this problem by comparing the shaving mechanisms between medium carbon steel grade SPCC (JIS) and high-strength steel grade SPFH 590 (JIS). Results show that in the case of SPFH 590 based on material flow, stress distribution, and strain distribution analyses, the shaved chip was difficult to form by sliding along the punch face. Moreover, the tensile stress generated in the shearing zone was increased and readily generated cracks. The shaving process was developed in the present study by generating the cutting-edge angle and rake radius on the punch. The cutting edge angle was designed to generate high compressive stress in the cutting-edge vicinity and shearing zone, and the rake radius was designed to tear a shaving allowance off and move it along the rake radius instead of moving downward along the punch movement direction, thereby decreasing the tensile stress in the shearing zone. Under these mechanisms, the increases in the generated tensile stress in the shearing zone could be delayed, and cracks could thus be prevented. The effect of the punch geometry on the cut surface characteristics and cutting forces were also investigated. Laboratory experiments were performed to validate the FEM simulation results. Experimental results agreed well with the FEM simulation results. Therefore, a smooth cut surface thorough the workpiece thickness of high-strength steel sheets could be successfully achieved by using the developed shaving process.

     

Notes on contributors

Various metallic pairs were tested under conditions of unlubricated solid contact. Experiments were conducted for repetitive impulsive and continuous sliding contact. Wide ranges of materials and conditions (nominal contact stress and relative transverse sliding velocity) and a variety of loading modes (pure normal impact at various frequencies, compound impact at various sliding velocities, and pure sliding under various stress levels) were explored.Particular attention was focused on the establishment of subsurface material zones developed in the tests, in situ. These zones exhibit dependences on velocity, stress, material, test duration and loading mode. The experimental findings, based on several analysis techniques, serve to characterize subsurface zone composition and morphology. Both surface and subsurface features were examined by optical and electron microscopy and analyzed by energy-dispersive X-ray techniques to allow interpretations concerning the role of external parameters, material transport and debris formation, as well as insight into operative mechanisms which act on specific materials under prescribed conditions to cause wear.     

Velocity fields in grease lubricated contacts

This paper examines the behaviour of a grease lubricant in open contacts. Analytical expressions of velocity profiles for a Bingham fluid are presented for three cases: flow where all the film thickness is sheared; where a non-sheared core zone is attached to one contact surface; and where a core zone floats in the middle of the film. An experimental study is described which used visualization through illumination across contact surfaces. Results are presented for two modes of operation: contact of cylinder and fixed plane surface, and pure rolling of two cylinders. In the former case, nine zones of operation are identified.     

On the plane contact problem of a functionally graded elastic layer loaded by a frictional sliding flat punch

This article is concerned with the contact mechanics of a functionally graded layer loaded by a frictional sliding flat punch. The coefficient of friction is assumed to be constant and the lower side of the graded layer is firmly attached to a rigid foundation. The graded, nonhomogeneous property of the medium is represented in terms of an exponential variation of the shear modulus, while Poisson’s ratio is taken to be constant. Based on the use of plane elasticity equations and the Fourier integral transform technique, the formulation of the current contact mechanics problem lends itself to a Cauchy-type singular integral equation of the second kind for the unknown contact pressure, which is solved numerically. As a result, the effects of several parameters, i.e., the material nonhomogeneity, the friction coefficient, the punch width, and Poisson’s ratio, on the distributions of the contact pressure and the in-plane surface stress component are presented.     

The Subsurface Stress Field Created by Three-Dimensionally Rough Bodies in Contact with Traction

A numerical simulation technique for calculating the complete subsurface stress field for three-dimensionally rough bodies in sliding contact is described. The stresses are calculated using real digitized three-dimensional surface profiles. The effects of the surface roughness and the sliding friction are presented. Using an existing contact simulation code, the digitized surfaces are mathematically pressed together and the real areas of contact and the asperity pressures are calculated. The surfaces are assumed to remain elastic throughout the contact simulation process. The shear forces at the asperity contact interfaces are assumed to be proportional to their calculated normal pressures. The subsurface stresses are then determined with these known normal and tangential forces at the surface.     

磨粒微观滑动接触过程热效应的有限元分析

利用ANSYS有限元软件分析了磨粒与被磨损材料表面滑动接触过程中,在摩擦热和力场的耦合作用下,接触区表现出的局部温度变化、应力变化等特性。结果表明,在磨粒滑移过程中,磨粒相当于接受固定热源作用,接触区温度逐渐上升,温度存在起伏波动现象,瞬现温升最高点在磨粒接触区两侧,反映出接触状态的不连续性,接触区状态的非稳定性;被磨材料表面的各点在进入接触前、经历接触时、脱离接触时,接触区温度存在先升高再下降的变化过程,同时,接触区的应力、剪应力、接触压力也发生变化。磨粒滑动过程的热效应问题研究将有助于揭示接触过程中材料表面损伤机制。     

微动接触应力的有限元分析

以方足微动桥,试样接触几何条件为研究对象,应用ANSYS有限元分析软件对其接触面上的应力分布进行弹性有限元分析,验证用ANSYS所建计算模型的正确性,分别计算不同名义接触压力和不同摩擦因数条件下接触状态（粘着区、滑动区、张开区）和接触面应力分布,选取不同水平的循环载荷进行计算,研究接触状态和应力分布随循环载荷的变化情况。结果表明,微动疲劳过程中接触表面拉应力与剪应力在接触面的粘,滑交界区存在突变,微动疲劳裂纹正是在这一区域内萌生并扩展,计算结果与实验结果吻合很好。     

Thermal and thermomechanical effects in dry sliding

Whenever friction occurs in dry sliding of mechanical components, mechanical energy is transformed into heat through surface and volumetric processes in and around the real area of contact. This frictional heating, and the thermal and thermomechanical phenomena associated with it, can have a very important influence on the tribological behavior of the sliding components, especially at high sliding velocities. Significant developments in the study of these phenomena are reviewed in this paper. Among the topics reviewed are mechanisms of frictional heating and the distribution of heat during sliding friction, the measurement and analysis of surface and nearsurface temperatures resulting from frictional heating, thermal deformation around sliding contacts and the changes in contact geometry caused by thermal deformation and thermoelastic instability, and the thermomechanical stress distribution around the frictionally heated and thermally deformed contact spots. The paper concludes with a discussion of the influence of the thermal and thermomechanical contact phenomena on wear, thermocracking and other modes of failure of sliding mechanical components.     

Different degree of reduction and sliding phenomenon study for three-dimensional hot rolling with sandwich flat strip

Symmetric rolling of 3D sandwich flat strips with thermal-elastic–plastic coupled model was studied under the assumption of an elastic roller and the condideration of heat transfer. Aluminum–copper sandwich flat strips were used in this study.The numerical model of symmetric rolling for 3D sandwich flat strip with thermal-elastic–plastic coupled model was developed based on the large deformation–large strain theory, the update Lagrangian formulation and the incremental principle. Besides, flow stress was considered as the function of strain, strain rate and temperature. The theoretical model of finite element method containing the two-order strain rate formulation acted as the basis for determining the convergence of simulation results.The contact surface between the aluminum and copper for the sandwich flat strip was also discussed. First of all, the contact face between the aluminum and copper was assumed that it would be fixed without sliding. Symmetric hot rolling of the aluminum and copper sandwich flat strip was analyzed. A slide criterion was then introduced to study the shear stress states of the contact face between aluminum and copper of sandwich strip, which was used to compare the relation between the maximum shear stress and the yielding shear stress on the contact face. If the maximum shear stress of aluminum or copper is smaller than the yielding stress of aluminum or copper respectively, sliding does not occur on the contact face. On the contrary, the sliding may occur on the contact face between aluminum and copper.Three different degrees of reduction were simulated in this study to analyze the states of shear stress on the upper aluminum strip and lower copper strip close to the contact face. Finally, it finds that the sliding on the contact face between aluminum and copper may occur around certain degree of reduction. The average rolling force of the simulation result was compared with experimental data [8] to verify the simulation results.     

The experimental and numerical analysis of quasi-steady wear processes for a sliding spherical indenter

The wear process on a frictional interface in a relative sliding motion of a punch on a substrate induces shape evolution of contact interface. For fixed contact zone the process tends to a steady state with fixed contact stress and strain distribution. Such steady state wear regimes were analyzed in the previous papers [1], [2], [3], [4], [5] by applying the principle of minimum wear dissipation rate. However, when the contact zone evolves in time due to wear process, as in the case of sliding spherical indenter, a quasi-steady state is reached with stress intensity dependent on the contact size parameter. On the other hand, the contact pressure distribution satisfies the condition of steady state. The simplified numerical analysis of wear process is presented by applying the quasi-steady conditions. The numerical predictions are confronted with experimental test results for two specific cases of soft and hard substrates. The quantitative specification of wear parameters is provided, first assuming constant values throughout the whole wear process, next assuming linearly or exponentially varying during the initial period and tending to constant values.     

Analysis of the elastic punch-substrate contact under fretting: Monotonic and cyclic loading of the punch

The object of this paper is to analyze the elastic behaviour of a 2-D contact problem between a right-angled flat punch and a semi-infinite substrate, subjected to a constant normal compressive load and a cyclic shear load using a finite element code. The knowledge of the stress and strain fields produced close to the corners of the punch under different loading conditions as a function of the friction coefficient will allow insight to be gained into the fretting fatigue problem associated to this cyclic loading. In order to better understand the behaviour and analyze the possibility of using fracture mechanics approaches to study the stress field close to the punch corners, two different models have been compared to each other: one without continuity solution between the punch and the substrate and the other with a couple of contact surfaces between them. Using the continuous model, a particularization of the general analytic solutions of Williams has been proposed. The complete stress field around the corners of the punch for this model has been obtained for any values of the punch size, normal and shear loads. Some general guides for understanding and systematizing the punch-substrate behaviour have been extracted from the above solution and that of a sliding wedge, provided by the literature, which enable a systematic numerical analysis of the problem. Further on, a more detailed study of the slip between punch and substrate, as well as of the stress field, has been accomplished using finite element analysis guided by the previous semi-analytical results. The study has been completed for the whole load process: compressive normal load, monotonic shear load, and cyclic shear load.     

汽车覆盖件模具凸型面拉延方法

针对汽车覆盖件这种具有复杂曲面特征的零件,在传统的全型面拉延成形方法基础上提出一种新的凸型面拉延成形方法。该方法根据拉延成形过程中凸、凹模工作型面上只有凸型面接触板料的特点,通过成形仿真获得全型面拉延的成形极限图(Forming limit diagram, FLD)和凸、凹模与板料的接触区域分布。然后将板料相对凸、凹模工作型面上的起皱区域及双面接触区域所对应的单元剔除,将单面接触区域中面积较小且形态狭长的单面接触区域合并转化为双面接触区域,同时将未转化的单面接触区域外周节点拟合成曲线后导入到CAD中对凸、凹模工作型面进行分割获得所需的凸型面。算例表明该方法在保证拉延成形质量的前提下可以有效地减小凸、凹模工作型面的面积,降低拉延模具的生产成本。     

Increasing punch life in cold cup extrusion with active friction

The stress at the end surface of the punch in the cold extrusion of a U-shaped hollow cylinder (a cup) is determined by modeling with regression equations. The results of such extrusion with active and reactive friction at blank–matrix contact are compared. With active friction, the punch life is greater by a factor of 1.5.     

磨粒磨损中微观接触过程的有限元分析

分析了磨粒压入被磨损材料表面、磨粒在材料表面滑动和卸载脱离接触的过程,研究了这三个接触阶段材料表层的应力应变、接触压力和接触摩擦切应力特征。结果表明,微观接触过程不仅存在材料的非线性作用和摩擦接触的状态非线性作用,而且存在着由于材料表面变形引起的几何非线性作用,被磨损材料表层的应力应变和接触压力的分布和大小与材料表面变形过程有关。     

Structure-Property Relationships in Thin Solid Poly(methyl methacrylate) Boundary Films

The interface, properties of boundary films are commonly characterized try the measurement of the interface shear stress, τ, which is defined as the, fictional force per unit area of contact. The parameter τ has been observed to be a strong function of several contact mechanical variables which include the contact pressure, the temperature, the sliding velocity and the contact time, τ is also found to be a strong function of the processing methods used in the preparation of polymer films. It is this facet of the functionality of τ that is pursued in the present paper with an emphasis upon the apparent ductile or brittle lubrication modes, the locus of the shear zone and the molecular architectures which are responsible for these resultant lubrication modes.     

旋转齿轮瞬时接触应力和温度的分析模拟

建立了高速齿轮传动轮齿瞬时接触温度的分析方法和模型;采用赫兹接触理论和有限元接触分析方法分析了标准渐开线齿廓和齿顶修形齿廓的齿面接触压力;研究了啮合过程中轮齿的相对滑动速度和齿面摩擦因数以及摩擦热流密度的计算方法;建立了轮齿本体温度的有限元温度分析模型;计算了轮齿接触面的瞬时温升;分析了标准和齿顶修形渐开线齿轮的轮齿本体温度和瞬时接触温度及相关因素对它们的影响。     

Subsurface deformation and damage accumulation in aluminum–silicon alloys subjected to sliding contact

The study of plastic deformation and damage accumulation below the contact surfaces is important in order to understand the dry sliding wear behaviour of aluminum alloys. Experimental evidence exists for the nucleation of voids and microcracks around second phase particles in the material layers adjacent to the contact surface. Propagation of these cracks at a certain depth below the surface may lead to the creation of long, thin plate-like wear debris particles. This work studied the deformation processes during sliding wear by means of metallographic observations of subsurface layers in an Al–7% Si (A356 Al) alloy and by finite element analyses. Specifically, the accumulation of subsurface stresses and strains was investigated, using a coupled structural-thermal finite element model based on the Voce-type exponential stress–strain relationship obtained from the sliding wear tests. Additionally, temperature and strain rate effects were taken into account using a constitutive equation based on Johnson–Cook and Cowper–Symonds models.Accordingly during sliding, the flow stress in subsurface layers increased rapidly and reached a saturation stress after a finite number of sliding contacts. The variation of hydrostatic pressure for different loading conditions was also determined as a function of sliding passes: as the sliding process progressed from the first to the seventh contacts, the hydrostatic pressure at the surface increased from 1150 to 1300 MPa. A total temperature increase of 45 K occurred at the surface after the seventh sliding contact. A debris formation model was proposed in which the presence of a maximum damage gradient at critical depth was considered. The model showed that, with a sliding velocity of 10 m/s, and a normal load of 150 N per unit thickness in mm, the material location where the maximum rate of damage occurred corresponded to a normalized depth (depth/counterface diameter) of 0.060. Increasing the load to 250 N/mm caused an increase in the critical depth of damage (a normalized depth of 0.085). Comparisons with the experimental subsurface crack observations indicate that the proposed damage rate calculations provide a good estimation of the subsurface crack propagation depth.     

Scraping with conical tools—a brief review

A study of the mechanics of the scraping action of conical tools is applicable to grinding or abrasive theories and the frictional contact of mating surfaces.The mechanics of wedge indentation in the simulation of conical tools are carefully reviewed. Adhesion, friction forces and stress conditions during the sliding of conical tools are discussed. Material flow, ridge formation and surface changes caused by scraping with conical tools are outlined.