Evaluation of the real contact areas, pressure distributions and contact temperatures during sliding contact between real metal surfaces

A three-dimensional elastic contact algorithm has been developed to analyse the normal contact problems of bodies having rough surfaces. The algorithm can evaluate the real contact areas and contact pressure distributions using measured surface roughness data.

Following an approximate elastic-plastic contact solution the analysis produces more realistic elastic and plastic contact areas; in addition results of contact pressure distributions can be predicted according to a given maximum plastic limit pressure.

The technique can simulate (in an approximate way) the elastic-plastic sliding contact behaviour in the vicinity of asperities or concentrated contact areas by ignoring the effect of the tangential forces on the vertical displacement.

Assuming a certain sliding speed and a particular coefficient of friction the local temperature distribution due to the heat generation over the real contact areas can also be calculated for 'slow sliding' problems.

The results show the moving real contact areas and the contact temperature fields for an electric spark mechanical steel surface moving over a planed bronze surface. Changes of the rigid body displacement, as well as the average and maximum pressures are also presented during sliding.

The micro-contact or asperity contact behaviour for bodies having large nominal contact area and the macro-contact behaviour for bodies being in 'concentrated contact' are also compared. In the latter case an ideal smooth steel ball was slid over the previously mentioned bronze surface.