A novel finite element formulation for frictionless contact problems

This article advocates a new methodology for the finite element solution of contact problems involving bodies that may undergo finite motions and deformations. The analysis is based on a decomposition of the two-body contact problem into two simultaneous sub-problems, and results naturally in geometrically unbiased discretization of the contacting surfaces. A proposed two-dimensional contact element is specifically designed to unconditionally allow for exact transmission of constant normal traction through interacting surfaces.     

Smooth C1‐interpolations for two‐dimensional frictional contact problems

Finite deformation contact problems are associated with large sliding in the contact area. Thus, in the discrete problem a slave node can slide over several master segments. Standard contact formulations of surfaces discretized by low order finite elements leads to sudden changes in the surface normal field. This can cause loss of convergence properties in the solution procedure and furthermore may initiate jumps in the velocity field in dynamic solutions. Furthermore non‐smooth contact discretizations can lead to incorrect results in special cases where a good approximation of the contacting surfaces is needed. In this paper a smooth contact discretization is developed which circumvents most of the aformentioned problems. A smooth deformed surface with no slope discontinuities between segments is obtained by a C¹‐continuous interpolation of the master surface. Different forms of discretizations are possible. Among these are Bézier, Hermitian or other types of spline interpolations. In this paper we compare two formulations which can be used to obtain smooth normal and tangent fields for frictional contact of deformable bodies. The formulation is developed for two‐dimensional applications and includes finite deformation behaviour. Examples show the performance of the new discretization technique for contact. Copyright © 2001 John Wiley & Sons, Ltd.     

Combined interior‐point method and semismooth Newton method for frictionless contact problems

In the present paper, a solution scheme is proposed for frictionless contact problems of linear elastic bodies, which are discretized using the finite element method with lower order elements. An approach combining the interior‐point method and the semismooth Newton method is proposed. In this method, an initial active set for the semismooth Newton method is obtained from the approximate optimal solution by the interior‐point method. The simplest node‐to‐node contact model is considered in the present paper, that is, pairs of matching nodes exist on the contact surfaces. However, the discussions can be easily extended to a node‐to‐segment or segment‐to‐segment contact model. In order to evaluate the proposed method, a number of illustrative examples of the frictionless contact problem are shown. The proposed combined method is compared with the interior‐point method and the semismooth Newton method. Two numerical examples that are difficult to solve using the semismooth Newton method are solved effectively using the proposed combined method. It is shown that the proposed method converges within far fewer iterations than the semismooth Newton methods or the interior‐point method. Copyright © 2009 John Wiley & Sons, Ltd.     

Three‐dimensional numerical solution for wear prediction using a mortar contact algorithm

A finite element formulation to compute the wear between three‐dimensional flexible bodies that are in contact with each other is presented. The contact pressure and the bodies displacements are calculated using an augmented Lagrangian approach in combination with a mortar method, which defines the contact kinematics. The objective of this study is to characterize the wear rate coefficients for bimetallic pairs and to numerically predict the wear depths in new component designs. The proposed method is first validated with the classical pin‐on‐disc problem. Then, experimental results of wear for the metallic pairs used in internal combustion engine valves and inserts are presented and are taken as a reference solution. An example is provided that shows agreement of the numerical and experimental solution. Finally, the proposed algorithm is used to predict the wear in an application example: the wear in an internal combustion engine valve. Copyright © 2013 John Wiley & Sons, Ltd.     

Vertex‐to‐face contact searching algorithm for three‐dimensional frictionless contact problems

This article presents a new vertex‐to‐face contact searching algorithm for the three‐dimensional (3‐D) discontinuous deformation analysis (DDA). In this algorithm, topology is applied to the contact rule when any two polyhedrons are close to each other. Attempt is made to expand the original contact searching algorithm from two‐dimensional (2‐D) to 3‐D DDA. Examples are provided to demonstrate the new contact rule for vertex‐to‐face contacts between two polyhedrons with planar boundaries. Copyright © 2005 John Wiley & Sons, Ltd.     

A new computational approach to contact mechanics using variable‐node finite elements

In this paper, a new computational strategy for two‐dimensional contact problems is developed with the aid of variable‐node finite elements within the range of infinitesimal deformations. The variable‐node elements, which are among MLS (moving least square)‐based finite elements, enable us to transform node‐to‐surface contact problems into node‐to‐node contact problems. This contact formulation with variable‐node elements leads to an accurate and effective solution procedure, needless to mention that the contact patch test is passed without any additional treatment. Through several numerical examples, we demonstrate its simplicity and the effectiveness of the proposed scheme. Copyright © 2007 John Wiley & Sons, Ltd.     

A 3D contact smoothing method using Gregory patches

In this work, a method is developed for smoothing three‐dimensional contact surfaces. The method can be applied to both regular and irregular meshes. The algorithm employs Gregory patches to interpolate finite element nodes and provide tangent plane continuity between adjacent patches. The resulting surface interpolation is used to calculate gaps and contact forces, in a variationally consistent way, such that contact forces due to normal and frictional contact vary smoothly as slave nodes transition from one patch to the next. This eliminates the ‘chatter’ which typically occurs in a standard contact algorithm when a slave node is situated near a master facet edge. The elimination of this chatter provides a significant improvement in convergence behaviour, which is illustrated by a number of numerical examples. Furthermore, smoothed surfaces also provide a more accurate representation of the actual surface, such that resulting stresses and forces can be more accurately computed with coarse meshes in many problems. This fact is also demonstrated by the numerical examples. Published in 2002 by John Wiley & Sons, Ltd.     

A monolithic smoothing‐gap algorithm for contact‐impact based on the signed distance function

A new algorithm has been developed for smoothing the surfaces in finite element formulations of contact‐impact. A key feature of this method is that the smoothing is done implicitly by constructing smooth signed distance functions for the bodies. These functions are then employed for the computation of the gap and other variables needed for implementation of contact‐impact. The smoothed signed distance functions are constructed by a moving least‐squares approximation with a polynomial basis. Results show that when nodes are placed on a surface, the surface can be reproduced with an error of about one per cent or less with either a quadratic or a linear basis. With a quadratic basis, the method exactly reproduces a circle or a sphere even for coarse meshes. Results are presented for contact problems involving the contact of circular bodies. Copyright © 2002 John Wiley & Sons, Ltd.     

A level‐set‐based large sliding contact algorithm for easy analysis of implant positioning

A finite element analysis of implant positioning inside a bone requires the creation of many meshes that model various implant orientations. This process can be very labour intensive and is difficult to automate. In order to facilitate this type of modelling, we present a large sliding contact algorithm that does not require the creation of a conforming discretization for the bone. The cavity inside the bone, necessary to accommodate the implant, is modelled with a Heaviside function calculated on the level set field, which is defined in terms of material coordinates of the bone. The algorithm is based on the minimization of the energy functional with a constraint term, formulated as in classical contact mechanics; however, instead of the distance function, we use the above‐mentioned level set function. The presented numerical 2D and 3D examples validate the algorithm against the solutions obtained with commercial finite element software. Copyright © 2011 John Wiley & Sons, Ltd.     

A mortar‐finite element formulation for frictional contact problems

In this paper a finite element formulation is developed for the solution of frictional contact problems. The novelty of the proposed formulation involves discretizing the contact interface with mortar elements, originally proposed for domain decomposition problems. The mortar element method provides a linear transformation of the displacement field for each boundary of the contacting continua to an intermediate mortar surface. On the mortar surface, contact kinematics are easily evaluated on a single discretized space. The procedure provides variationally consistent contact pressures and assures the contact surface integrals can be evaluated exactly. Copyright © 2000 John Wiley & Sons, Ltd.     

Receding contact problem involving large displacements using the BEM

A new algorithm is presented for the boundary element analysis of the two-dimensional contact problem between elastic solids involving large displacements. The contact constraints are not applied node-on-node but node-on-element, using the element shape functions to distribute the geometry, displacements and tractions on each element in the contact zone. Thus, the discretizations performed along the two surfaces in contact need not necessarily be the same. The solution procedure is based on the updated Lagrangian approach and the resulting method is incremental. The algorithm guarantees equilibrium and compatibility at the nodes in the final deformed configuration and allows us to deal with problems undergoing large displacements without it being necessary to change the initial discretization of the boundary of the bodies. Only the frictionless static problem is dealt with, and the proposed algorithm is applied to the most representative receding contact problem: a layer pressed against an elastic foundation. The results obtained when the displacements are small are in good agreement with the analytical solution. When large displacements are considered, another nonlinearity appears and its influence will be shown in this paper.     

Finite deformation frictional mortar contact using a semi‐smooth Newton method with consistent linearization

A two‐dimensional, finite deformation frictional contact formulation with Coulomb's law is presented. The approach considers multibody contact and is based on a mortar formulation. The enforcement of contact constraints is realized with dual Lagrange multipliers. These alternative multiplier spaces are constructed in a way that the multipliers can easily be eliminated from the global system of equations by static condensation such that the system size does not increase. Friction kinematic variables are formulated in an objective way and enter non‐smooth complementarity functions for expressing the contact constraints. An active set strategy is derived by applying a semi‐smooth Newton method, which treats contact nonlinearities, material and geometrical nonlinearities in one single iterative scheme. By further carrying out a consistent linearization for both normal and frictional contact forces and constraints, a robust and highly efficient algorithm for linear and higher‐order (quadratic) interpolation is achieved. Efficiency of the proposed method and quality of results are demonstrated in several examples. Copyright © 2010 John Wiley & Sons, Ltd.     

A contact algorithm for the Signorini problem using space–time finite elements

The most common approach in the finite‐element modelling of continuum systems over space and time is to employ the finite‐element discretization over the spatial domain to reduce the problem to a system of ordinary differential equations in time. The desired time integration scheme can then be used to step across the so‐called time slabs, mesh configurations in which every element shares the same degree of time refinement. These techniques may become inefficient when the nature of the initial boundary value problem is such that a high degree of time refinement is required only in specific spatial regions of the mesh. Ideally one would be able to increase the time refinement only in those necessary regions. We achieve this flexibility by employing space–time elements with independent interpolation functions in both space and time. Our method is used to examine the classic contact problem of Signorini and allows us to increase the time refinement only in the spatial region adjacent to the contact interface. We also develop an interface‐tracking algorithm that tracks the contact boundary through the space–time mesh and compare our results with those of Hertz contact theory. Copyright 2004 John Wiley & Sons, Ltd.     

Development of contact algorithm for three‐dimensional numerical manifold method

This paper customizes a contact detection and enforcing scheme to fit the three‐dimensional (3‐D) numerical manifold method (NMM). A hierarchical contact system is established for efficient contact detection. The mathematical mesh, a unique component in the NMM, is utilized for global searching of possible contact blocks and elements, followed by the local searching to identify primitive hierarchies. All the potential contact pairs are then transformed into one of the two essential entrance modes: point‐to‐plane and crossing‐lines modes, among which real contact pairs are detected through a unified formula. The penalty method is selected to enforce the contact constraints, and a general contact solution procedure in the 3‐D NMM is established. Because of the implicit framework, an open‐close iteration is performed within each time step to determine the correct number of contact pairs among multi‐bodies and to achieve complete convergence of imposed contact force at corresponding position. The proposed contact algorithm extensively utilizes most of the original components of the NMM, namely, the mathematical mesh/cells and the manifold elements, as well as the external components associated with contacts, such as the contact body, the contact facet and the contact vertex. In particular, the utilization of two mutually approaching mathematical cells is efficient in detecting contacting territory, which makes this method particularly effective for both convex and non‐convex bodies. The validity and accuracy of the proposed contact algorithm are verified and demonstrated through three benchmark problems. Copyright © 2013 John Wiley & Sons, Ltd.     

A FORMULATION OF THE QS6 ELEMENT FOR LARGE ELASTIC DEFORMATIONS

The numerical simulation of processes undergoing finite deformations requires robust elements. For a broad range of applications these elements should have a good performance in bending dominated situations as well as in the case of incompressibility. The element should be insensitive against mesh distortions which frequently occurs during finite deformations. Furthermore, due to efficiency reasons a good coarse mesh accuracy in required in non-linear analysis. The QS6 element, developed in this paper, tries to fulfil the above-mentioned requirements. The performance is depicted by means of numerical examples.     

QuickTrace: a fast algorithm to detect contact

QuickTrace is a new, fast contact detection algorithm. It searches for contact typically between a tool, modelled by some kind of geometrical surface facets, and deforming material. Contact is searched for at material surface points called contact nodes. A contact node is in contact with a facet when the contact node is inside of the tool and the negative outer normal on the material surface at the contact node ‘leaves’ the tool surface through that facet. When multiple facets are intersected, only the closest facet to the contact node should be considered. From this definition of contact, the penetration depth results automatically as a by‐product. In QuickTrace, the m facets of the tool are packaged in boxes that are hierarchically ordered in a search tree with an average depth of log₄ m. The computational complexity for one contact search is proportional to this average depth. So, for n contact nodes the computational complexity is O(n log₄ m). This places QuickTrace amongst the best performing contact detection algorithms. At the same time there are no approximations or tricks involved and the contact detection is absolutely correct. The algorithm can easily be extended to material–material or tool–tool contact. Copyright © 2002 John Wiley & Sons, Ltd.     

A novel three‐dimensional contact finite element based on smooth pressure interpolations

This article proposes a new three‐dimensional contact finite element which employs continuous and weakly coupled pressure interpolations on each of the interacting boundaries. The resulting formulation circumvents the geometric bias of one‐pass methods, as well as the surface locking of traditional two‐pass node‐on‐surface methods. A Lagrange multiplier implementation of the proposed element is validated for frictionless quasi‐static contact by a series of numerical simulations. Published in 2001 by John Wiley & Sons, Ltd.     

An algorithm for the matrix‐free solution of quasistatic frictional contact problems

A contact enforcement algorithm has been developed for matrix‐free quasistatic finite element techniques. Matrix‐free (iterative) solution algorithms such as non‐linear conjugate gradients (CG) and dynamic relaxation (DR) are desirable for large solid mechanics applications where direct linear equation solving is prohibitively expensive, but in contrast to more traditional Newton–Raphson and quasi‐Newton iteration strategies, the number of iterations required for convergence is typically of the same order as the number of degrees of freedom of the model. It is therefore crucial that each of these iterations be inexpensive to per‐form, which is of course the essence of a matrix free method. In applying such methods to contact problems we emphasize here two requirements: first, that the treatment of the contact should not make an average equilibrium iteration considerably more expensive; and second, that the contact constraints should be imposed in such a way that they do not introduce spurious energy that acts against the iterative solver. These practical concerns are utilized to develop an iterative technique for accurate constraint enforcement that is suitable for non‐linear conjugate gradient and dynamic relaxation iterative schemes. Copyright © 1999 John Wiley & Sons, Ltd.     

Hydrostatic fluid loading in non‐linear finite element analysis

Deformation dependent pressure loading on solid structures is created by the interaction of fluids with the deformable surface of a structure. Such fairly simple load models are valid for static and quasi‐static analyses and they are a very efficient tool to represent the influence of a fluid on the behaviour of structures. Completing previous studies on the deformation dependence of the loading with the assumption of finite gas volumes, the current contribution focuses on the influence of modifications of the size and shape of a finite structure containing an incompressible fluid with a free surface. The linearization of the corresponding virtual work expression necessary for a Newton‐type solution leads to additional terms for the volume dependence. Investigating these terms the conservativeness of the problem can be proven by the symmetry of the linearized form. Similarly to gas loading, the discretization of the structure with finite elements leads to standard stiffness matrix forms plus the so‐called load stiffness matrices and a rank‐one update for each filled structure part, if the loaded surface segments are identical with element surfaces. Some numerical examples show the effectiveness of the approach and the necessity to take the corresponding terms in the variational expression and the following linearization into account. Copyright © 2004 John Wiley & Sons, Ltd.