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Abstract
The present study considers finite element analysis of non-adhesive,
frictionless elastic/elastic–plastic contact between a rigid flat plane and a
self-affine fractal rough surface using the commercial finite element package
ANSYS. Three-dimensional rough surfaces are generated using a modified
two-variable Weierstrass–Mandelbrot function with given fractal
parameters. Parametric studies are done to consider the general relations
between contact properties and key material and surface parameters. The
present analysis is validated with available experimental results in the
literature. Non-dimensional contact area and displacement are obtained as
functions of non-dimensional load for varying fractal surface parameters in
the case of elastic contact and for varying rates of strain hardening in the
case of elastic–plastic contact of fractal surfaces.
contacts [11–14] use these parameters for the analysis of of surface summits. However, the values of these parameters
contact between rough surfaces. However, due to the are scale-dependent, i.e. they strongly depend on the sample
multiscale nature of the surfaces it is found that the variances of length and the resolution of the measuring instrument.
slope and curvature depend on the resolution of the roughness A realistic multiscale roughness description can only be done
measuring instruments or any other form of filter, and thus using scale-independent fractal parameters. A 3D fractal
not unique for a surface. Roughness measurements on a surface topography can be generated using a modified
variety of surfaces show that the power spectra of the surface (truncated) two-variable Weierstrass–Mandelbrot function that
profiles follow power laws. This suggests that when a can be written as [32]
surface is magnified appropriately, the magnified image looks
(D−2)
ln γ 1/2
M nmax
very similar to the original surface. This property can be G
mathematically described by the concepts of self-similarity and z(x, y) = L γ (D−3)n
L M m=1 n=0
self-affinity. The fractal dimension, which forms the essence of
fractal geometry, is both scale-invariant and is closely linked
2π γ n (x 2 + y 2 )1/2
to the concepts of self-similarity and self-affinity [23]. It is × cos φm,n − cos
L
therefore essential to use the fractal dimension to characterize
rough surfaces and provide the geometric structure at all −1 y πm
length scales [24–26]. Finite element analysis of fractal × cos tan − + φm,n . (1)
x M
surface contact is limited in the literature. Komvopoulos and
Ye [27, 28] considered finite element analysis of head-disc Here L is the sample length, G is the fractal roughness, D is
layered interface with fractal topography description. But the the fractal dimension (2 < D < 3), γ (γ > 1) is a scaling
effect of strain hardening was not included in these studies. parameter, M is the number of superposed ridges used to
Hyun et al [29] adopted a fully three-dimensional (3D) finite construct the surfaces, n is a frequency index, with nmax =
element analysis for elastic contact between rough surfaces int[log(L/Ls )/ log γ ] representing the upper limit of n, where
with a range of self-affine fractal scaling behaviour. They Ls is the cut-off length and φm,n is a random phase. The scaling
found a linear relationship between area and load, with a parameter γ controls the density of frequencies in the surface
proportionality constant lying between the analytic predictions profile. Based on surface flatness and frequency distribution
of Bush et al [30] and Persson [7]. However, the pressures density considerations, γ = 1.5 [32]. For a truncated series,
predicted by this work for realistic surface roughness are often i.e. starting at n = 0 rather than n = −∞ as in equation (1), the
high enough to produce plastic deformation. In addition, the scaling property is approximate, i.e. scaling is satisfied only to
exponent characterizing the power law distribution of cluster within a small additive term [33]. Thus, the surface function
size was larger than in the experiments [2]. In order to address given by equation (1) possesses a scale-invariant (fractal)
these questions, Pei et al [31] extended the results established behaviour [34] only within a finite range of length scales,
for elastic contact [29] to the case of elasto-plastic asperities outside of which the surface topography can be represented by
considering a wide range of self-affine surface topographies a deterministic function. It may be noted here that the smallest
and varying the ratio of the yield stress to the Young’s length corresponds to the instrument resolution and the upper
modulus and the rate of strain hardening in the constitutive length to the length of the profile. Since frequencies outside
law. These studies [29, 31] do not consider the effect of the range determined by the lower and upper wavelengths
variation of fractal parameters on contact behaviour involving do not contribute to the observed profile, self-similarity is
area, load, displacement, etc. Moreover, these studies are satisfied at all scales only approximately. The fractal roughness
computationally very intensive. Use of commercial finite
G is a height scaling parameter independent of frequency
element software to model this type of effects instead of
within the scale range where fractal power-law behaviour is
having to write a program to do it may be of great interest
observable. Physically, higher G values correspond to rougher
to the community of scientists and engineers investigating
(less dense) surface topographies. The magnitude of the fractal
contact between surfaces. Thus the present study aims at
analysing the elastic as well as elastic–plastic contact of self- dimension D determines the contribution of high and low
affine fractal surfaces with due consideration to variation in frequency components in the surface function z(x, y). Thus,
fractal parameters as well as strain hardening with the help of high values of D indicate that high-frequency components
commercial FEM software. Three-dimensional rough surfaces are more dominant than low-frequency components in the
are generated using a modified two-variable Weierstrass– surface topography profile. The physical significance of
Mandelbrot function [32] with given fractal parameters and D is the extent of space occupied by the rough surface,
used in the commercial finite element package ANSYS 8.0 for i.e. larger D values correspond to denser profiles (smoother
contact analysis. The contact morphology including contact topography). The surface height function given by equation (1)
area, load and displacement is analysed for varying fractal is continuous, non-differentiable, scale-invariant within the
dimension and fractal roughness. The elastic–plastic contact range determined by the upper and lower wavelengths used in
behaviour is also considered to evaluate the effect of varying the truncated series, and self-affine asymptotically according
rates of strain hardening. to the analysis of Blackmore and Zhou [35]. The self-affinity
implies that as the surface is repeatedly magnified, more and
2. Surface modelling more surface features appear and the magnified image shows
a close resemblance to that of the original surface obtained at
Rough surface topographies have been conventionally a different scale. These properties make the function given
quantified in terms of the height variance, slope and curvature by equation (1) suitable for constructing surfaces possessing
4246
Finite element contact analysis of fractal surfaces
Figure 1. A sample Weierstrass–Mandelbrot surface. Figure 2. Geometry of finite element mesh in rough solid.
topographies closely resembling the actual surfaces with applicable to 3D structural and coupled field contact analyses.
the same fractal parameters D and G. Figure 1 shows a This element is located on the surface of a rough solid.
sample Weierstrass–Mandelbrot (W–M) surface produced in To validate the capability of the software ANSYS 8.0
MATLAB 7.0 using D = 2.3, G = 1.36 × 10−11 m, L = in solving contact problems, it is used to analyse the elastic
9 × 10−7 m, Ls = 1.5 × 10−7 m, M = 10 and γ = 1.5 (height contact of a sphere with a rigid plane. The FEM results for
scale is in m). a sphere-plane model are compared with the Hertz elastic
solution [10]. The contact force differs from the Hertz solution
3. Finite element modelling by no more than 2% and the contact radius differs by a
maximum of 10%. The favourable comparison of the results
The finite element analysis was carried out using the static illustrates the suitability of the finite element software to
analysis of ANSYS 8.0 which calculates the contact area after resolve contact problems. However, the capacity and accuracy
the application of the load. MATLAB 7.0 is used to generate of the present finite element model involving contact of
the z(x, y) values from equation (1) as per the supplied x and fractal rough surfaces is established through comparison with
y values. The length of the sample is set to be 9 × 10−7 m with the results of contact experiments available in the literature
M = 10 and Ls = 1.5 × 10−7 m. The points so generated are (discussed later).
imported to ANSYS 8.0 as key points. A surface is created In order to ensure that the results are accurate within the
by joining the key points. The surface so created is made conceptual framework used to analyse the present problem,
solid in ANSYS. The upper surface of the solid is identified mesh convergence must be satisfied. The mesh density is
as the CONTACT surface. A rigid surface is made to just iteratively increased until the contact force and contact area
touch the contact surface from the top. The rigid top surface differ by less than 1% between iterations. Depending on
is set as the TARGET surface. the fractal parameters and the expected region of contact,
The rough deformable solid body is modelled using the number of elements in the resulting mesh varies. The
3D solid element SOLID45, which is defined by eight nodes resulting mesh consists of at least 28 848 SOLID45 elements,
having three degrees of freedom at each node: translations in 577 TARGE170 elements and 3200 CONTA173 elements.
the nodal x, y and z directions. The element SOLID45 has Figure 2 shows a typical geometry of a finite element mesh
plasticity, creep, swelling, stress stiffening, large deflection in an elastic solid with a self-affine surface with D = 2.4 and
and large strain capabilities. TARGE170 is used to represent G = 1.36 × 10−10 m. In order to restrict any movement of
the 3D ‘target’ surface for the associated contact element the base of the solid, the nodes lying in the xy plane at z = 0
(CONTA173). The contact elements themselves overlie the were rigidly constrained from moving in the z direction. The
solid elements describing the boundary of a deformable body rigid plane is allowed to move in the z direction only. Each
and are potentially in contact with the target surface, defined analysis consisted of a single load step with the maximum
by TARGE170. This target surface is discretized by a set and minimum numbers of sub-steps being set to 100 and 10,
of target segment elements (TARGE170) and is paired with respectively. These values are chosen in order to establish
its associated contact surface via a shared real constant set. a small initial sub-step. Within each sub-step a maximum
One can impose any translational or rotational displacement, of 30 equilibrium iterations is allowed. To avoid element
temperature, voltage and magnetic potential on the target distortion, ANSYS uses the bisection method to increase the
segment element. One can also impose forces and moments number of load sub-steps so that the load can be applied at a
on target elements. CONTA173 is used to represent contact slower rate. The contact with the rigid plane is realized using
and sliding between a 3D ‘target’ surface (TARGE170) and a surface-to-surface contact elements that use the Augmented
deformable surface, defined by this element. The element is Lagrangian method. In our approach, a force is applied to the
4247
P Sahoo and N Ghosh
(a) (b)
(c) (d)
Figure 3. Contact area evolution at varying applied loads for a surface with D = 2.4, G = 1.36 × 10−12 m. (a) W = 2 × 10−7 N,
(b) W = 3 × 10−7 N, (c) W = 4 × 10−7 N and (d) W = 5 × 10−7 N.
(This figure is in colour only in the electronic version)
rigid plane causing it to move incrementally downward and a 4.1. Contact area evolution
node is assumed to come into contact when its distance from
Figure 3 shows the contact morphology at varying applied
the plane becomes zero. To obtain a converged solution in a
loads for a surface with D = 2.4, G = 1.36 × 10−12 m and it
reasonable period of time, the displacement tolerance was set
clearly shows the effect of increasing loads for fixed values of
to 0.001. The computations are performed on a xeon processor.
D and G. It may be noted here that in the legend of figure 3,
The run times vary according to the number of displacement
sliding refers to actual contact. It is clearly visible from this
steps involved and the machine used. However, on average
figure that contact area grows with the increase in load.
each set of results took approximately 3 h to complete.
4248
Finite element contact analysis of fractal surfaces
Figure 4. Comparison between FEM (ANSYS) results, analytical Figure 5. Comparison between FEM (ANSYS) solution and
results [32] and experimental results [36]. experimental results [37].
4249
P Sahoo and N Ghosh
4250
Finite element contact analysis of fractal surfaces
Et = 0
Et =10 Gpa
Et = 60 Gpa
Et =100 Gpa
4251
P Sahoo and N Ghosh
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