含涂层真实粗糙表面的弹塑性接触特性研究

运用有限元法、线性规划法和塑性增量理论对含涂层真实粗糙表面的弹塑性接触问题进行了分析。通过改变涂层材料的弹性模量、屈服极限及涂层厚度，研究了不同条件下接触面积与接触压力、平均间隙与接触压力的关系及变化规律，给出了3种数值方法的解与弹性解的比较，分析了各主要因素对接触压力、接触面积及平均间隙的影响。     

渗氮钢粗糙表面的弹塑性接触研究

利用弹塑性有限元和单纯形法求解弹塑性接触模型，分别模拟了屈服强度呈梯度变化的渗氮钢、未经处理的匀质材料和硬涂层材料粗糙表面的弹塑性接触行为。与未经处理的匀质材料相比，渗氮钢可承受更大接触载荷。在相同载荷作用下，渗氮钢表面粗糙峰接触面积较小，平均间距较大，接触体内材料不易发生屈服，从而显著提高接触性能。和硬涂层材料相比，渗氮钢接触体内等效von Mises应力分布平缓，没有应力突变。最后讨论了渗氮层和硬涂层的厚度对粗糙表面接触特性的影响。     

弹塑性粗糙表面实际接触面积演变规律研究

粗糙表面的实际接触面积直接影响精密机电设备配合表面的摩擦因数、热导/电导率、接触应力等.然而,针对弹塑性接触行为进行系统性地研究很少,弹塑性粗糙表面实际接触面积的演变规律尚不明确.针对这一问题,通过理论研究获得了弹塑性粗糙表面实际接触面积的影响因素,并引入弹塑性接触力学数值计算方法,对具有不同材料参数和表面形貌特征的弹塑性粗糙表面的接触行为进行数值仿真计算,得到各种情况下的表面实际接触面积随着平均接触压力的变化曲线,总结出了实际接触面积演变规律与这些影响因素之间的映射关系,并最终得到实际接触面积的计算公式,为弹塑性接触力学的相关工程应用奠定了基础.     

热障涂层粗糙表面弹塑性接触应力分析

含热障涂层的发动机零部件能有效提高抗热性能,但微接触作用下的部件涂层表面的应力分布规律及失效形式直接影响发动机可靠性。以热障涂层与榫头接触作用为背景,将其抽象为含规则粗糙峰的刚性表面与热障涂层微接触模式,利用弹塑性接触有限元方法分析涂层表面下的压力及应力分布,研究压入深度、涂层厚度、弹性模量和屈服强度对于涂层压力及残余应力分布的影响。     

二维自适应粗糙表面弹塑性接触模型

提出一种基于自适应粗糙表面描述的弹塑性接触模型。根据某一给定阈值,去除粗糙表面上对接触力学行为影响较小的结点以减少计算时间。采用在计算区域划分及结点排布上较为灵活性的无网格伽辽金—有限元耦合方法求解自适应粗糙表面弹塑性接触模型。算例表明,当接触压力相对误差约为5%时,自适应接触模型的计算时间相对于非自适应接触计算可减少约50%。分析不同阈值对接触压力分布、接触间隙及接触体弹塑性应力分布的影响。     

材料属性温度相关热弹塑性接触问题研究

应用有限元方法建立了可考虑屈服应力温度相关效应的粗糙表面热弹塑性接触模型.研究了摩擦力和不同热输入情况下圆柱体与弹塑性平面的接触力学特性.求解了考虑屈服应力温度相关效应的粗糙表面热弹塑性接触问题,探讨了摩擦热效应对表面温升、接触压力、平均间隙及接触体应力分布的影响.提出了考虑热膨胀系数温度相关效应的热弹塑性接触模型.通过刚性圆柱体与半无限大平面的热弹塑性接触研究了热膨胀系数温度相关效应对接触体应力分布的影响.     

材料属性温度相关热弹塑性接触问题研究

应用有限元方法建立了可考虑屈服应力温度相关效应的粗糙表面热弹塑性接触模型。研究了摩擦力和不同热输入情况下圆柱体与弹塑性平面的接触力学特性。求解了考虑屈服应力温度相关效应的粗糙表面热弹塑性接触问题,探讨了摩擦热效应对表面温升、接触压力、平均间隙及接触体应力分布的影响。提出了考虑热膨胀系数温度相关效应的热弹塑性接触模型。通过刚性圆柱体与半无限大平面的热弹塑性接触研究了热膨胀系数温度相关效应对接触体应力分布的影响。
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基于ANSYS的真实粗糙表面微观接触分析

基于材料弹塑性变形理论,采用激光测量仪测取零件表面微观形貌数据,使用小波对测量数据进行处理,提取不同层次的粗糙度,利用有限元分析软件ANSYS及其APDL工具,建立真实粗糙表面不同尺度上的微观接触参数化有限元模型,仿真分析了粗糙表面接触的弹塑性变形全过程。提出了基于ANSYS重启动分析、网格重划的多载荷步求解算法,以解决有限元微观接触分析过程中的网格畸变问题。通过通用后处理模块/POST1,提取了有限元分析结果文件中的真实接触面积、接触载荷、接触微凸体个数等接触参数,分析了多种不同粗糙度表面相互接触时接触参数的关系,以及不同尺度的粗糙面对接触参数的影响,为研究结合面的接触机理和连接性能提供了方法。     

含多粗糙峰涂层等效应力的有限元分析

研究刚性平面与含粗糙峰涂层在二维与三维模型下的弹性接触问题,采用有限元法分析涂层弹性模量比、涂层厚度、粗糙峰间距、刚性平面压下深度对涂层粗糙峰表面、涂层/基体界面分布及基体等效应力分布的影响。计算结果表明压下深度对三维涂层粗糙峰表面最大应力的影响最大,涂层厚度、涂层/基体弹性模量比、粗糙峰间距的变化对应力值影响逐渐减小;增大涂层厚度、减小压下深度和粗糙峰间距、降低弹性模量比会使得三维接触模型最大等效应力值显著降低;增加涂层粗糙峰数和涂层厚度、同时降低涂层弹性模量有助于提高涂层/基体界面结合强度。相对于二维接触模型来说三维接触模型在粗糙峰表面的等效应力增大,造成这种变化的主要原因是由于涂层表面粗糙峰之间的等效应力叠加引起的。该研究为涂层粗糙峰及涂层/基体界面强度的应力分析提供依据。     

粗糙体变形特性对接触过程的应力与应变的影响

运用W-M函数生成分形粗糙表面,建立一个新的双粗糙体接触模型,采用有限元方法模拟仿真了在粗糙体不同变形特性条件下的接触过程,并分析了接触表面的应力分布及不同接触位置的塑性应变随深度的变化规律．结果表明双粗糙接触表面的应力主要集中在个别的较高微凸体上,其应力最大值出现在微凸体肩部区域的位置;等效塑性应变在不同位置沿深度的变化,呈现出不同的规律,微凸体顶部区域沿深度方向的最大等效塑性应变均发生在次表层,材料表层下的塑性应变将会导致材料表层中的夹杂或微观缺陷周围萌生微孔和裂纹源,对比不同变形特性的模型,得出弹塑性一刚体模型的最大应力及应变值都大于弹塑性一弹塑性模型。     

ANALYSIS ON THERMAL ELASTO-PLASTIC ASPERITY CONTACTS OF LAYERED MEDIA

A thermal elasto-plastic asperity contact model is investigated, which takes into account the steady-state heat transfer and the asperity distortion due to thermal elasto-plastic deformations. A hard coating and a soft coating are applied to study the correlations between contact area and contact pressure, average gap and contact pressure, coating thickness and contours of the contact stress distribution, etc. The effects of material properties, coating thickness, frictional coefficient, and the heat input combinations on the stress distribution are investigated and discussed. The frictional heat input increases the maximum value of yon Mises stress. Finally, the appropriate thickness of the hard coating is also discussed. To protect the substrate, one can choose hard coating and the thickness of that is suggested that can be hc=70 Rm.     

Elasto-Plastic Contact of Rough Surfaces

An isothermal elasto-plastic asperity contact model is developed and presented in this paper, which deals with micro plastic flows of materials and the influence of the elasto-plastic deformation of materials on the behavior of contacting surfaces. The model is solved with the incremental form of a simplex-type algorithm. The von Mises yield criterion is used to determine the onset of the plastic deformation. The effectiveness and validity of the model are studied through analyzing a Hertzian contact problem. Substrate stresses are calculated and differences are observed. Furthermore, the contact pressure, real area of contact, and average gap of real rough surfaces under the elastic, elastic-perfectly-plastic, and the elasto-plastic contact conditions are numerically investigated and the results are compared.     

The Effect of Scale-Dependent Hardness on Elasto-Plastic Asperity Contact between Rough Surfaces

Statistical methods are used to model elasto-plastic contact between two rough surfaces using a recent finite element model of elasto-plastic hemispherical contact and also recent advances in strain gradient modeling. The elasto-plastic hemispherical contact model used to model individual asperities accounts for a varying hardness effect due to deformation of the contact geometry that has been documented by other works. The strain gradient model accounts for changes in hardness due to scaling effects. The contact between surfaces with hypothetical material and surface properties, such as the elastic modulus, yield strength, and roughness are modeled. A model is also constructed to consider a variable asperity contact radius to evaluate if the strain gradient model will affect it differently. The models produce predictions for contact area, contact force, and surface separation. The strain gradient effects decrease the real area of contact and increase the average contact load in comparison to the model without these effects. The strain gradient model seems to have a larger influence on the predictions of contact load and area than does considering a variable asperity contact radius for the cases considered in this work.     

A statistical model of elasto-plastic asperity contact between rough surfaces

This work models statistically elasto-plastic contact between two rough surfaces using the results of a previous finite element analysis of an elasto-plastic sphere in contact with a rigid flat. The individual asperity contact model used accounts for a varying geometrical hardness effect that has recently been documented in previous works (where geometrical hardness is defined as the uniform pressure found during fully plastic contact). The contact between real surfaces with known material and surface properties, such as the elastic modulus, yield strength, and roughness are modeled. The asperity is modeled as an elastic-perfectly plastic material. The model produces predictions for contact area, contact force, and surface separation. The results of this model are compared to other existing models of asperity contact. Agreement exists in some cases and in other cases it corrects flaws, especially at large deformations. The model developed by Chang, Etsion and Bogy is also shown to have serious flaws when compared to the others. This work also identifies significant limitations of the statistical models (including that of Greenwood and Williamson).     

Three-dimensional modeling of elasto-plastic sinusoidal contact under time dependent deformation due to stress relaxation

In the current work, the effect of stress relaxation in contact between sinusoidal surfaces is studied using FE simulations. There are a few works on the elastic and elasto-plastic contact between sinusoidal surfaces, but the transient effects such as creep and stress relaxation are not considered in these works. Stress relaxation causes significant change in the contact area and pressure between the contacting surfaces. The Garofalo formula is used to model the transient behavior of stress relaxation. The results for the contact area and contact pressure are presented and discussed. Empirical equations are developed to predict contact area and pressure by fitting to the FEM results. The equations are dependent on the initial surface separation, aspect ratio, and the Garofalo constants.     

Elasto-plastic micromechanical model for determination of dynamic stiffness and real contact area from ultrasonic measurements

The interaction of ultrasonic waves with rough surfaces in contact is sensitive to the micromechanics of the contacts and to the topography of the surfaces. A continuous effort to develop a link between ultrasonic measurements and interfacial properties has evolved to the extent that elasto-plasticity occurring during loading can now be taken into account. Here, a state-of-the-art model is critically revisited in light of recent results on the micromechanics of elasto-plastic asperities in contact during unloading. A new probability density function of the asperity height is derived, which takes into account plastic deformation. This function is used to evaluate the pressure during unloading as a function of the relative approach between the mean planes of the surfaces. It is also shown that this relation can be cast in terms of the probability density function prior deformation, provided that a suitable transformation variable is utilized. These results are used to obtain a new expression for the dynamic stiffness of the elasto-plastic interface which determines the response of the latter to an incident wave. Finally, some results illustrating the behavior of the static and dynamic interfacial stiffness during a complete loading–unloading cycle are presented.     

Analysis and Convenient Formulas for Elasto-Plastic Contacts of Nominally Flat Surfaces: Average Gap,Contact Area Ratio,and Plastically Deformed Volume

Interaction of nominally flat engineering surfaces that leads to a large contact area exists in many mechanical systems. Considering periodic similarity of surface geometry, a numerical three-dimensional elasto-plastic contact model can be used to simulate the contact behaviors of two nominally flat surfaces with the assistance of the continuous convolution and Fourier transform (CC-FT) algorithm. This model utilizes the analytical frequency response functions (FRF) of elastic/plastic responses of materials and provides contact performance results, including the average surface gap, the contact area ratio, and the volume of plastically deformed material, which may be defined as performance variables. Following the digital filtration technology, rough surfaces can be numerically generated with specified autocorrelation length and the first four orders of statistical moments. A group of contact simulations are conducted with various working conditions. The effects of topographic and material properties on the contact behaviors are discussed. With a multi-variables regression method, empirical formulas are developed for the performance variables as functions of surface statistical characteristics, material properties, a hardening parameter, and the applied load in terms of pressure.     

考虑摩擦的球面切向接触刚度分形模型研究

为准确且方便地计算两球面的切向接触刚度（TCS）,在前期对两球面接触分形模型研究的基础上,通过引入考虑摩擦因素的弹塑性变形临界面积计算公式,并基于接触面切向刚度基本理论,建立了考虑摩擦因素的两球面切向接触刚度的分形模型。对模型进行了仿真分析,结果表明：切向接触刚度与法向载荷成正比关系;摩擦因数与切向接触刚度的关系因分形维数的变化而呈现出不同的规律;受到分形维数变化的影响,切向接触刚度随接触面材料特性参数和分形粗糙度幅值的增大而增大;在一定工况下,切向接触刚度在分形维数取1.5时达到最大,且当分形维数在1.5左右时,其值增大最快;球面内接触比外接触时的切向刚度大;随着曲率半径的增大,切向刚度增大。研究结果为后续开展高副结合面（如轴承等）润滑及动力学分析提供了理论基础。     

Estimation of characteristics of contact between rough surfaces,one of which has solid lubricating coating

A calculation model for estimating the contact interaction characteristics of rough surfaces, one of which has a solid lubricating coating is considered. The obtained relations are verified experimentally and are compared with the data of the other authors. The influence of the physicomechanical properties of the coating, as well as its thickness, parameters of microgeometry, and applied loads on contact deformation and real contact area of interaction surfaces is shown.