A Finite Element Study on the Influence of Residual Stress Profiles on Sliding Contact of Precision Machined Components

Abstract

Precision machining may induce very different residual stress profiles. However, the effects of machining induced residual stresses on component performance in sliding contact have received little attention. This study develops a two dimensional finite element simulation model of sliding contact to study the effects of the distinct residual stress profiles induced by hard turning and grinding on sliding contact. A parametric simulation study based on the design-of-experiment method was also performed to assess the influence the sliding parameters of the applied load, speed, and friction of coefficient on sliding contact mechanics. The results have shown that the initial residual stress profiles have great influence on the normal stress in sliding direction, but have little effects on other stress components. Sliding relaxes initial residual stress and shifts the maximum subsurface stress to the top surface. The normal strains are slightly influenced by the residual stress, while the shear strain is hardly affected. Compared with friction of coefficient and sliding speed, the applied load has the greatest influence on contact stresses and strains. The increasing load shifts peak normal stress in sliding direction and von Mises stress from the subsurface to surface. The peak Hertz pressure, shear stress and von Mises stress increase nonlinearly with the applied load.© 2006 ASME