Evaluation of Nominal Contact Area and Contact Pressure Distribution in a Steel-Steel Interface by Means of Ultrasonic Techniques.

Abstract

Analysis of contact interfaces represents one of the most critical engineering problems and involves a huge number of practical applications such as roller bearings, tooth gears, wheel-rail interaction, electrical and thermal couplings, biomechanics etc. While theoretical and numerical approaches to the problem have been extensively studied over the years, only a few experimental techniques have been devised either to validate analytical results, or to infer information non invasively about the state of contact. From the late 1950s onwards, when a relationship was discovered between the amount of energy reflected or transmitted through the contact region and the charac· teristics of contact, researchers have been employing ultrasonic waves to inspect contact interfaces. Since then, many efforts have been directed towards improving the experimental technique and enhancing the theoretical understanding of ultrasonic waves propagation over an incomplete contact interface. In the light of these consider· ations, the application of a simple 'pulse-echo' technique able to investigate the elastoplastic contact of a steel sphere-plate system is proposed in this paper. The main purpose of the analysis is to assess the reliability of the ultrasonic method as a useful tool for assessing a number of contact parameters such as size and shape of contact area, distribution of contact pressure and so on. Experimental data were compared with numerical results obtained using a Finite Element Model (FEM) code. Ultrasonic reflection data were in· good agreement with calculated values, thus confirming the effectiveness of the ultrasonic technique as a fast, reliable and non­ invasive method in evaluating contact parameters in loaded metallic interfaces.