Contact Pressure Distribution Research Articles

Modeling the Normal Contact Characteristics between Components Joined in Multi-Bolted Systems

This article is concerned with the modeling and calculation of the contact layer between components joined in a multi-bolted system for assembly conditions. The physical model of the multi-bolted connection is based on a system consisting of an elastic flange component, which is joined to an elastic support using a rigid-body bolt model. The contact layer between the joined components is described by a non-linear Winkler model. A model of the contact joint with consideration of the experimental normal elastic characteristics is presented. Examples of normal contact pressure distributions are included.

Determination of Mechanical Power Loss of the Output Mechanisms with Serially Arranged Rollers in Cycloidal Gears While Taking into Account Manufacturing Tolerances

Despite their complex design, cycloidal gearboxes are characterized by high efficiency. Nevertheless, due to friction, some power is lost during gearbox operation. Basically, these losses occur in two structural nodes: the cycloid gearing and the output mechanism. Since the first of these nodes has been well discussed in the literature, the output mechanism will be discussed in this article. The design of the output mechanism has a significant impact on mechanical power losses. There are several mechanism design solutions. One of them is a mechanism with serially arranged rollers. Three solutions that are different in design but work identically will be discussed. Due to this affinity, a single, common mathematical model will be used to determine the value of losses. As will be shown, the value of losses is directly affected by the backlash, number, and diameter of the rollers used in the output mechanism and indirectly by the ratio and eccentricity of the cycloidal gearbox. Sample calculations were carried out using the developed model of mechanical power losses in the output mechanism. This made it possible to analyze the distribution of backlash created by manufacturing tolerances. It was also shown that the backlash has a significant effect on the number of rollers involved in torque transmission, as well as on the distribution of loads, contact pressures, and mechanical power losses.

The effect of highly elongated micro-contacts on rolling contact stress field

This study presents a boundary element model to analyze contact pressure distribution and the subsurface stress field in rough rolling elements. The methodology is demonstrated by the stress field of the backup roll and work roll in the cold/temper rolling process and characterized by a parallel orientation of roughness lay with rolling direction, resulting in a cluster of highly elongated elliptical micro-contacts. The numerical outcomes revealed that the amplitude of in-plane and out-of-plane shear stress components are strongly dependent on the ellipticity of the micro-contacts. Comparison with experimental results shows that the crack plane is oriented transversal to the rolling direction and the crack initiation location corresponds to the location where the shear stress components are maximum.

Three-dimensional mechanical characteristics analysis of double-shoulder tool joint under complex loads

Taking a new type of special threaded drill pipe joint as the research object, a 3D nonlinear finite element model of the double-shoulder tool joint (DSJ) including the engage and retract groove structure is established by considering the factors of structural asymmetry and contact of each engaging surface. ABAQUS/Explicit finite element method (FEM) is used to study the stress and contact pressure distribution characteristics of the critical structure of DSJ under complex loads. The accuracy of the finite element model was verified by combining with the physical test, and the connection strength and sealing performance of DSJ are evaluated. The results show that the stress concentration occurs at the key structure of DSJ under the make-up torque. The geometry size and structural discontinuity at the transition fillet of the double-shoulder structure have a significant effect on the stress and contact pressure distribution on the shoulder. Under axial tension, the stress level and stress concentration area of the whole joint and the key structure change, especially in the thread section. The sealing performance on the shoulder decreases significant, while that of the thread section increases slightly. The test results are consistent with the finite element simulation results, and this joint shows good mechanical properties, which can meet the design requirements of drilling tool manufacturers and provide data support for its optimal design and application.

In-silico study of the biomechanical effects of proximal-fibular osteotomy on knee joint contact pressure in varus-valgus misalignment

The aim of this work is to investigate in-silico the biomechanical effects of a proximal fibular osteotomy (PFO) on a knee joint with different varus/valgus deformities on the progression of knee osteoarthritis (KOA). A finite element analysis (FEA) of a human lower extremity consisting of the femoral, tibial and fibular bones and the cartilage connecting them was designed. The FEA was performed in a static standing primitive position to determine the contact pressure (CP) distribution and the location of the center of pressure (CoP). The analysis examined the relationship between these factors and the degree of deformation of the hip-knee angle in the baseline condition. The results suggested that PFO could be a simple and effective surgical treatment for patients with associated genu varum. This work also reported that a possible CP homogenization and a CoP correction can be achieved for medial varus deformities after PFO. However, it reduced its effectiveness for tibial origin valgus misalignment and worsened in cases of femoral valgus misalignment.

Omnidirectional simulation analysis of thermo-mechanical coupling mechanism in inertia friction welding of Ni-based superalloy

The coupling between heat and pressure is the kernel of inertia friction welding (IFW) and is still not fully understood. A novel 3D fully coupled finite element model based on a plastic friction pair was developed to simulate the IFW process of a Ni-based superalloy and reveal the omnidirectional thermo-mechanical coupling mechanism of the friction interface. The numerical model successfully simulated the deceleration, deformation processes, and peak torsional moments in IFW and captured the evolution of temperature, contact pressure, and stress. The simulated results were validated through measured thermal history, optical macrography, and axial shortening. The results indicated that interfacial friction heat was the primary heat source, and plastic deformation energy only accounted for 4% of the total. The increase in initial rotational speed and friction pressure elevated the peak temperature, reaching a maximum of 1525.5 K at an initial rotational speed of 2000 r/min and friction pressure of 400 MPa. The interface heat generation could form an axial temperature gradient exceeding 320 K/mm. The radial inhomogeneities of heat generation and temperature were manifested in a concentric ring distribution with maximum heat flux and temperature ranging from 2/5 to 2/3 radius. The radial inhomogeneities were caused by increasing linear velocity along the radius and an opposite distribution of contact pressure, which could reach 1.7 times the set pressure at the center. The circumferential inhomogeneity of thermo-mechanical distribution during rotary friction welding was revealed for the first time, benefiting from the 3D model. The deflection and transformation of distribution in contact pressure and Mises stress were indicators of plastic deformation and transition of quasi-steady state welding. The critical Mises stress was 0.5 times the friction pressure in this study. The presented modeling provides a reliable insight into the thermo-mechanical coupling mechanism of IFW and lays a solid foundation for predicting the microstructures and mechanical properties of inertia friction welded joints.

Research on the Mechanical Properties and Structural Optimization of Pipe String Joint under Deep Well Fracturing Operation

In order to reduce the failure accidents caused by the insufficient strength of fracturing string joints, theoretical calculation and string design methods were adopted to conduct finite element calculations on commonly used long circular threads. The distribution laws of stress and contact pressure of long round threads were obtained, a non-standard special thread was designed, and a finite element model of the joint of the casing was established. Considering different make-up torques, tensile loads, and tensile torque loads within a certain range, the stress variation law of the special casing threaded joint under this design size was analyzed. Finally, the stress and contact pressure variation law on the threaded tooth was analyzed under different structures, working conditions, and wall thickness parameters. The thread strength and sealing function were compared under various parameters. The results showed that the smaller the wall thickness of the joints, the greater the contact pressure at the threaded tooth. Among them, the contact pressure of the external threaded tooth is too high, and is prone to the sticking phenomenon. The distribution of contact pressure in the middle section is relatively reasonable. Compared with the original structure, the new structure significantly reduces the contact pressure at the head and tail ends of the threaded connection, reducing the risk of sticking.

A simplified spherical roller bearing model and its application in the wind turbine main bearing system finite element modeling

Different from most bearing design guidelines, deformation of bearing rings and supporting structures usually influences the bearing performance significantly. Finite element analysis (FEA) can be used in bearing system design considering the structure deformation, but the contact region between rolling elements and raceways modeling is very complex and usually causes non-convergent problems. As to a spherical roller bearing (SRB), the model must also consider both its misalignment ability and roller contact stiffness. This paper presents a simplified SRB model considering the angular misalignment ability. In order to define the SRB roller raceway load deformation relationship, a lamina model is developed. And this simplified model is validated by solid roller model of a bearing sector. A wind turbine main bearing system is analyzed using the developed SRB model. Load distribution considering the system deformation and angular misalignment are discussed. With the help of fine meshed solid elements roller raceway contact model, the raceway contact pressure and subsurface stress distribution can also be obtained.

The role of muscle forces in neck comfort for static seating: a pilot study

Aircraft seats play a key role in the competition between aircraft companies seeking to differentiate themselves in terms of passengers’ inflight experience. The seat design process relies on computational and experimental methods based on subjective measures, such as comfort rating questionnaires, and objective comfort indicators of seat-occupant interaction, such as contact pressure distribution and muscle activation. Previous studies around muscle activity for seating comfort assessment have primarily focused on more active scenarios or active systems. As such, there are limited studies about the role of muscle force in normal and relaxed sitting conditions, common in aircraft settings. This paper explores the relationship between activities of the neck muscles, sternocleidomastoid, and upper trapezius, measured from human participants seated sedentarily on conventional business aircraft seats and their perceived comfort with different backrest inclinations. The results show, for normal seating without neck pillow, no significant association is found between the backrest inclination and the neck’s comfort or muscle activation. For general seating across different backrest inclinations, a positive medium correlation between muscle activation and comfort is found in upper trapezius (R = 0.5332, p = 0.0187). This work serves as a pilot study of this new approach of comfort evaluation using muscle feedback in seat designing processes and highlights the posterior’s effect to seating experience in the neck region.

An efficient method for electro-thermo-mechanical coupling effect in electrical contact on rough surfaces

In this study, a numerical strategy based on the boundary element method (BEM) is developed to simulate the electrical contact behavior on rough surfaces. By using the Fourier transform, the solutions of the electric potential, temperature rise, and displacement fields in the Fourier space are derived with finite boundaries, in which the electro-thermo-mechanical coupling effect is considered. With the consideration of the contact condition, an iterative algorithm is proposed to seek the solutions of rough surface electrical contact under a given contact force and total electric potential drop. The contact pressure, real contact area, electrical contact resistance, electric current, and temperature rise distribution are predicted. For the validation, the electrical contact results of a spherical punch-half space contact and a rough surface-elastic substrate contact are calculated based on the finite element method. The good agreement between the results from the BEM-based method and the finite element method indicates the accuracy of the presented method. Then, the effect of the total electric potential and the thermal expansion on the electrical contact behavior, the relationship between the contact conductance and contact stiffness, and the probability density function of the contact pressure and temperature rise distributions are evaluated using the proposed method.

A crosstalk-free interdigital electrode piezoresistive sensor matrix-based human-machine interaction system for automatic sitting posture recognition

Sedentarism with poor posture has been a significant concern for students and office workers. In this work, for inappropriate sitting posture monitoring, we developed a human machine interaction (HMI) system based on a piezoresistive sensor matrix, which achieves crosstalk-free pressure distribution detection by the inserting diodes method (IDM) with a structure simplified by the interdigital electrode (IDE) configuration. To measure the pressure distribution, a sensor matrix of 9×14 piezoresistive sensing pixels is fabricated by the standard flexible printed circuit (FPC) technique. The single sensing pixel shows a high sensitivity in the pressure below 20 kPa, covering the range of the human-seat contact pressure, and demonstrates the highest sensitivity of 9.865% kPa−1. The combination of the IDE and the IDM eliminates the crosstalk error completely, enabling the sensor matrix to accurately measure the human-chair contact pressure distribution. To develop an HMI system for sitting posture detection, pressure distribution data from subjects of different body shapes, including sitting upright, leaning forward, slumped sitting, crossing right legs, and crossing left legs, is collected using the proposed sensor matrix and used for training and evaluation of the convolution neural network (CNN) model. Accurate posture classification is achieved both in within-group and cross-group tests, showing the highest accuracy of 99.14% and an excellent generalization performance. With an excellent performance of crosstalk-free pressure distribution detection, the device in this study exhibits great application potential in daily sitting posture monitoring.

Characterization of Contact Pressure Distribution and Bruising Prediction of Apple under Compression Loading

The pressure distribution characteristics of an apple subjected to compressive loading were investigated using the pressure-sensitive film (PSF) technique combined with apple bruise measurements. Pressure was unevenly distributed in the elliptical contact region. The average pressure had no effect on bruising because it changed slightly in the range of 0.26–0.31 MPa with increasing load. Pressures of 0.20–0.40 MPa accounted for 72% of the total pressure area. Comparatively, the area where pressure over 0.50 MPa was distributed could be ignored and showed little contribution to the bruise area. The contact edge subjected to pressure below 0.10 MPa showed that no bruising occurred. As a result, the relationship between the ≥0.10 MPa pressure area strongly correlated with the bruise area according to a linear equation, with a correlation coefficient of ≥0.99. When this relationship was applied to determine the bruise area with FE, satisfactory predicted results were obtained with minor error rates of 0–7.89% for loads of 54–80 N. But larger prediction errors occurred when the load was above 90 N, suggesting that the linear elastic FE model may not be appropriate for accurately predicting apple bruising.

A unique clamping mechanism for a cylindrical PEMFC for an enhanced performance

Polymer electrolyte membrane fuel cells with planar structures have been proven beneficial; however, cylindrical cells have higher gravimetric and volumetric power density with possible applications in aviation and portable power sources. In this study, a unique clamping mechanism for a cylindrically structured polymer electrolyte membrane fuel cell is developed to improve the performance of the cell through reduced contact resistance over the active area of the cell. The design is structurally modelled and simulated for the contact pressure distribution, followed by experimental validation of contact pressure distribution at the interface of the gas diffusion layer and current collector. The study results in a lower ohmic resistance due to the better electrical contact at the interface of gas diffusion layer and current collector using the new clamping system. The average contact pressure with the new system is observed to be 0.40 MPa, i.e. 33% higher than that of the strap clamping system. In addition, the contact resistance of the cell with new clamps is found to decrease by 18 %, thus resulting in 36 % better performance (55 mW/cm2 at 0.6 V) than that of the conventional clamping system (40 mW/cm2 at 0.6 V). Such enhancement is also attributed to more oxidant supply (12%) at the cathode current collectors due to better cell clamping design.

Modeling of the Combined Effect of the Surface Roughness and Coatings in Contact Interaction

The model of indentation of a spherical punch with a rough surface into a thin elastic layer lying on an elastic half-space has been developed. A numerical-analytical solution is suggested based on the two-scales approach. At macroscale, the integral equation of the second kind is reduced to calculate the nominal contact characteristics, taking into account the surface layer thickness and its mechanical characteristics, as well as additional compliance due to surface roughness calculated from the microscale analysis. The influence of the punch roughness and the surface layer mechanical and geometrical characteristics on the nominal contact pressure distribution, on the nominal contact area and the indentation depth, as well as on the real contact area and pressures at the individual contact spots, is analyzed. The developed contact model can be used to analyze the indentation of the punch into the layered elastic base, taking into account the roughness of the punch surface, and can also be used to give a complete analysis of the roughness effect on the contact process at both scale levels. The results can be used to control the indentation of the rough-coated bodies.

Simulation and experimental study on contact pressure distribution of contact interface in single and double bolted connection structures

Bolted joints play an important role in aerospace, machinery manufacturing, weapons and other fields, and the contact pressure distribution at the connection interface seriously affects the service performance of the bolts. Contact pressure analysis is an essential basis and reference for structural design, calibration, inspection, and safety monitoring of bolted connection structures. Considering the preload force and frictional contact between the joint components, a block mapping hexahedron mesh generation and finite element modeling method for bolted connections is presented, and the finite element models of single and double bolted structures are constructed. Then, an experimental test platform for measuring contact pressure distribution is constructed. Comparison of finite element analysis results with experimental results for the contact pressure distribution in the single and double-bolted joints; the root mean squared error of contact pressure distribution is less than 5%, which verifies the effectiveness of the finite element models. After that, the models are used to study the contact pressure distribution in single-bolted joints and contact pressure coupling effect of double-bolted joints, and the normal stress distribution features within members and contact pressure distribution contour are revealed for single and double-bolted joint. Finally, the finite element models are adopted to investigate the effects of the clamping length, preload, material properties, hole clearance, and bolt size on contact pressure distribution in single-bolted joints. The coupling effect of contact pressure distribution in double-bolted joints under different preloads and geometric parameters are also examined.

A Theoretical Method for Calculating the Internal Contact Pressure of Parallel Wire Cable during Fretting Wear

Fretting wear of the stay cable is an important factor affecting the service life of the cable. To accurately calculate the extent of fretting wear, it is necessary to calculate the internal contact pressure in the cable. Although there are many theories and experiments on the contact behavior between wires, there are still no theoretical formulations for calculating the distribution of contact pressure in stay cables. In this paper, by studying the transfer effect of contact pressure in the cable, the PIC (parallel wire cable internal point contact pressure) model for calculating the contact pressure in the parallel wire cable is proposed, considering the effects of wire twisting, sheath compression, and cable bending on the contact pressure. A finite element model corresponding to the contact mode between steel wires is established, and the effectiveness of the PIC model is verified through numerical simulation analysis and a comparison of the existing contact models. The results indicate that contact pressure caused by wire twisting (CWT) is superimposed layer by layer inwards, with the contact pressure increasing closer to the inner layers, and its magnitude is mainly related to the axial tension and twist angle. Simultaneously, on the same layer, contact points along the diagonal experience the greatest contact pressure. Contact pressure caused by sheath compression (CSC) is assumed to conform to the Boussinesq distribution, with the outer layers exhibiting greater contact pressure compared to the inner layers. Contact pressure caused by cable bending (CCB) conforms to the two-dimensional closely arranged contact force transmission model, has a clear layering phenomenon, and the contact pressure within the same layer does not change significantly. The magnitude of the contact pressure is exponentially related to the curvature of the cable and proportional to the tension of the cable, which explains the reason why the slip occurs later for the cables with high tensile forces. Among these three types of contact pressure, CWT is the greatest, followed by CCB, while CSC is the smallest. The theoretical analysis results show that factors such as wire radius, tension, torsion angle, and wire position have an impact on contact pressure. Contact pressure is transmitted along force chains within the cable, following the superposition law between layers. It is uncertain whether slip occurs in the neutral axis or in the outermost layer because of the different distributions of tangential force and interlayer frictional resistance between the layers of wires. Fretting wear simulations of two wires demonstrate that contact pressure has a significant influence on wear patterns, and the “averaging” of contact pressure is a major reason for achieving uniform interface wear. While the contact width increases proportionally with the contact pressure, excessive contact pressure can complicate the problem by changing the contact mode from gross slip to partial slip. This study provides a theoretical method for calculating contact pressures at any contact point within the cables in engineering practice.

Biomechanical Effect of Distal Tibial Oblique Osteotomy: A Preliminary Finite-Element Analysis.

The biomechanical effect of distal tibial oblique osteotomy (DTOO) on osteoarthritic ankles has not been investigated. Using finite element (FE) models, we aimed to elucidate the effect of DTOO on the ankle contact pressure (CP) distribution. This study included two patients with ankle osteoarthritis who underwent DTOO and one asymptomatic control. Patient-specific FE models were reconstructed by matching standing radiographs with supine computed tomography scans. The joint contact area (CA) and maximumCPon the articular surface of the talus were calculated before and after DTOO and compared with those of the control. In the control, the CA was 584 mm2 and the maximum CP was 2.6 MPa. In case 1, the CA increased by 125% from 166 mm2 preoperatively to 375 mm2 postoperatively, accompanied by a 36% decrease in the maximum CP from 9.8 MPa to 6.3 MPa. Similarly, in case 2, the CA increased by 46% from 301 mm2 to 439 mm2, accompanied by a 27% decrease in the maximum CP from 6.7 MPa to 4.9 MPa. This study suggests DTOO improves the biomechanics of the ankle, but not sufficiently compared to the control. This analytical approach may enhance understanding of ankle pathophysiology and assist in the design of the ideal corrective osteotomy.

Analysis of the discrete contact characteristics based on the Greenwood-Williamson model and the localization principle

The contact of a rigid body with nominally flat rough surface and an elastic half-space is considered. To solve the contact problem, the Greenwood-Williamson statistical model and the localization principle are used. The developed contact model allows us to investigate the surface approach and the real contact area with taking into account the asperities interaction. It is shown that the mutual influence of asperities changes not only contact characteristics at the macroscale, but also the contact pressure distribution at the microscale. As follows from the results, the inclusion in the contact model of the effect of the mutual influence of asperities is especially significant for studying the real contact area, as well as the contact characteristics at high applied loads. The results calculated according to the proposed approach are in a good agreement with the experimentally observed effects, i.e., the real contact area saturation and the additional compliance exhaustion.

Measurement of the three-directional contact force using a smart tire with a force sensor

While designing tire performance, understanding the relationship between the tire belt or tread rubber and the road surface is crucial, as represented by the cornering performance and wear characteristics. To survey this relationship, the force generated when a tire moves over a force sensor installed on the drum side of a tire drum tester or a sheet-type sensor installed on the road surface is measured to estimate the contact pressure distribution. The former method does not allow measurements on a flat surface, whereas the latter uses an actual vehicle; thus, obtaining stable data is challenging. In this study, we measured the triaxial forces acting on the tread block of a tire with a slip angle applied to the tire alone and discussed the characteristics of these forces. In the proposed measurement method, a tire tread block is machined, and a small triaxial force sensor is embedded. This method enables measuring the forces between the tire belt and the road surface. Finally, the force generated via the tire/road interaction on the tread block was measured using a flat-belt tester. The characteristics of the forces generated by the tread block are reported based on the obtained results.

Study on the prediction of high-speed rotary lip seal wear in aero-engine based on heat-fluid-solid coupling

PurposeThis paper aims to investigate the effect of frictional heat on the wear of high-speed rotary lip seals in engines.Design/methodology/approachIn this research paper, the authors focus on the high-speed rotating lip seal of aircraft engines. Using the hybrid lubrication theory, a thermal-fluid-solid coupled numerical simulation model is established to investigate the influence of parameters such as contact pressure distribution, temperature rise and leakage rate on the sealing performance under different operating conditions. By incorporating the Rhee wear theory and combining simulation results with experimental data, a method for predicting the wear of the rotating seal lip profile is proposed. Experimental validation is conducted using a high-speed rotating test rig.FindingsThe results indicate that as the speed increases, the rise in frictional heat leads to a decrease in the sealing performance of the lip seal contact region. The experimental results show a similar trend to the numerical simulation results, and considering the effect of frictional heat, the predicted wear of the lip seal profile aligns more closely with the actual wear curve. This highlights the importance of considering the influence of frictional heat in the analysis of rotating seal mechanisms.Originality/valueThis study provides a reference for the prediction of wear profiles of engine high-speed rotary lip seals.