Numerical simulations of rough contacts between viscoelastic materials

Abstract

The durability of the mechanical contact is often plagued by surface-related phenomena like rolling contact fatigue, wear or crack propagation, which are linked to the important gradients of stress arising in the contacting bodies due to interaction at the asperity level. The semi-analytical computational approach adopted in this paper is based on a previously reported algorithm capable of simulating the contact between bodies with arbitrary limiting surfaces and viscoelastic behaviour, which is enhanced and adapted for the contact of real surfaces with microtopography. As steep slopes at the asperity level inevitably lead to localized plastic deformation at the tip of the asperities that are first brought into contact, the viscoelastic behaviour is amended by limiting the maximum value of the pressure on the contact area to that of the material hardness, according to the Tabor equation. In this manner, plasticity is considered in a simplified manner that assures the knowledge of the contact area and of the pressure distribution without estimation of the residual state. The main advantage of this approach is the preservation of the algorithmic complexity, allowing the simulation of very fine meshes capable of capturing particular features of the investigated contacting surface. The newly advanced model is expected to predict the contact specifics of rough surfaces as resulting from various manufacturing processes, thus assisting the design of durable machine elements using elastomers or rubbers.