A modified elastic contact stiffness model considering the deformation of bulk substrate

Abstract

Establishing an accurate and effective stiffness model of the elastic contact surface is the basis for further modeling and analysis of machine tool dynamics. In this paper, a new elastic contact stiffness model is proposed that considers the bulk substrate deformation and modifies the Greenwood and Williamson microcontact model (GW model) of rough surfaces. Based on the Hertz contact theory and fixed-point iteration method, a single asperity contact model is created to analyze the effects of bulk substrate deformation and coating materials. To make the contact stiffness model more accurate and effective, two aspects are improved: One is to introduce the triangular distribution function to make the asperity heights distribution more consistent with the actual machined surface, and the other is to correct the defects in the micro-contact process. Comparing the finite element simulation results with the modal test data, the correctness of the proposed contact stiffness model is verified. The simulation results reveal the influence of distribution function, surface roughness and coating material on the contact characteristics of the joint surface.