A NUMERICAL APPROACH TO THE CONTACT OF NOMINALLY FLAT SURFACES

Abstract

Machined surfaces can be described by heights and wavelengths of the surface asperities that show a statistical variation. Considering that a regular wavy surface with a sinusoidal profile is the crudest model for a rough surface, studying the contact of regular wavy surfaces is a good approximation for the contact of nominally flat surfaces. Such contact problems exhibit periodicity that can be simulated with the aid of computational techniques derived for contact mechanics in the frequency domain. The displacement calculation, which is a necessary step in the resolution of the contact problem, is mathematically a convolution product that can be calculated in the frequency domain with increased computational efficiency. The displacement induced by a unit surface load can be expressed in the frequency domain by the frequency response functions, which are counterparts of the space domain solutions to half-space fundamental problems such as the Boussinesq problem. The displacement induced by a periodic pressure distribution can be computed by executing the convolution product between the frequency response function and pressure on a single period. It should be noted that the convolution calculation in the spectral domain implies that the contributions of all neighbouring pressure periods are accounted for. The need to treat numerically only a single period results in remarkable computational efficiency, allowing for high density meshes that can capture the essential features of any textured real surface. The displacement calculation promotes the solution of the contact problem by an iterative approach. The advanced method is benchmarked against existing analytical solutions for the 3D contact of surfaces possessing two-dimensional waviness. This essentially deterministic model, supported by a direct numerical solution that can be obtained for samples of real rough surfaces, presents itself as a worthy alternative to the existing statistical models for rough contact interaction.