The Observation of the Steady State Phase on Rolling Contact Using Finite Element Analysis

Abstract

The study of the mechanical components on the micro/nano‐scale requires the investigation on stress, contact pressure and deformation of the contacting components particularly. On the micro/nano‐scale, the discussion on the rolling contact between two mechanical components takes place not only on the general surface but also covers the asperity level on the rough surface scale. During rolling contact of the mechanical components, the model can be simplified to the contact between a roller on a rough surface. This model is occupied in finite element analysis to observe the steady state phase during rolling contact. The steady state phase is the second phase of the new components life‐cycle where the plastic deformation, contact stress and contact pressure found their stabilized form and the optimal condition on the contact loading is reached. The steady state phase takes place after running‐in phase where the aforementioned parameters still occur in the transient mode and still vary with time. In this paper, two‐dimensional model of a cylinder rolls over a surface are employed in the simulation by considering the elastic‐plastic material with strain hardening behavior. The contact stress and residual stress of the rough surface due to rolling contact are observed to determine the steady state phase. The results show that the steady state of the contact stress and residual stress has been obtained on the second repeated rolling contact. The stability of the contact and residual stress on the second cycle is not only influenced by the strain hardening behavior but it is also influenced by the flattening of the asperity which produces larger contact area such that the contact load is homogenously distributed on the truncated asperity.