Contact Stress Research Articles

Development of high-efficient asphalt pavement modeling software for digital twin of road infrastructure

To develop digital twin (DT) of road infrastructure, one critical element is computation of pavement responses (strains, stresses, and deflections) under traffic and environmental loading. This study aims to develop high-efficient asphalt pavement modeling software based on semi-analytical finite element method (SAFEM) for DT application. The algorithms address important aspects in vehicle-tire-pavement interaction modeling, such as dynamic vehicular loading, three-dimensional (3-D) non-uniform tire contact stress, viscoelastic behavior of asphalt material, and interface bonding condition. The simulation accuracy is verified by comparison with full-scale test and field measurements, and the relative differences are around 5 % to 20 %. Techniques including optimized discrete Fourier transform, parallel computing, graphics processing unit (GPU) acceleration, and sparse matrices are implemented for computation efficiency. As compared to the traditional 3-D FEM, SAFEM shows significant savings in computation time and storage usage. The high efficiency and accuracy make the software full of potential to be applied for DT of roadway infrastructure.

Multi-objective optimization of helical gear transmission geometric parameters using MOPSO

Abstract Helical gears are widely used in mechanical devices, but insufficient tooth strength can easily lead to premature failure, which is an urgent problem to be solved. To overcome this challenge, this paper introduces a multi-objective particle swarm optimization algorithm, which comprehensively considers the comprehensive effects of modification coefficient, number of teeth, and modulus on the performance of helical gears. By constructing a mathematical model with the geometric parameters of helical gears as the core design variables, aiming to minimize the difference between the maximum bending stress of helical gear roots and the contact stress on the tooth surface, we have achieved optimization of gear performance. Using MATLAB for algorithm programming, the established model was efficiently optimized and solved. After optimization, the bending strength difference and tooth surface bearing capacity of the gear pair have been significantly improved, ensuring the stability and reliability of the operation of the high-pressure sleeve disassembly transmission device.

Frictional Contacts Between Rough Grains With Fractal Morphology

AbstractSurface morphology plays a crucial role in friction between two contacting geomaterial surfaces, yet many questions remain unanswered regarding how detailed frictional responses deviate from analytical solutions for smooth surfaces due to the presence of roughness. In this study, we revisit the Cattaneo‐Mindlin problem for contacts between two fractally rough elastic or elasto‐plastic spheres generated based on ultra‐high degree (e.g., up to 2,000) spherical harmonics with the corresponding wavelength less than a thousandth of the mean grain diameter. Transverse contacts are simulated by finite element method, validated by the extended Cattaneo‐Mindlin solution to full slide regime for smooth sphere contacts. Extensive simulations are conducted to study contacts between two rough spheres with various surface geometries, micro friction coefficients, normal contact distances, relative roughness, fractal dimensions, and wavelength ranges. Out results indicate that: (a) the new analytical solution can approximately predict the macro contact response except for extremely high relative roughness and narrow wavelength range; (b) deviations induced by roughness from smooth sphere contacts can be neutralized by plasticity, high normal contact interference, and high micro friction coefficient; and (c) fractal dimension impacts frictional contacts less than relative roughness. The main cause of these phenomena can be credited to the underlying microscale contact information. Contact area and stress distributions and their evolutions provide concrete evidence of these observed behavior. This work provides a pathway for applying computational contact mechanics to many geophysical fields, such as the asperity model in earthquake science and the mechanics of granular materials.

Numerical investigation on machining of additively manufactured CFRP composite with different build orientations and layer widths

Additive manufacturing (AM) is now a widely researched manufacturing technology in the past two decades to adopt in industry for its added advantage of customization and adopting complex geometries with comparatively low buy-to-fly ratio. Carbon fiber reinforced polymer (CFRP) composite has found applications in different high-performance industries for its greatest benefit of high strength-to-weight ratio. Additive manufacturing of CFRP composite (AM-CFRP) opens up the possibility of enhancing mechanical strength using different printing orientations and enables producing complex shapes maintaining sustainable manufacturing perspective. However, Limitation of AM parts of having surface irregularities and questionable dimensional accuracies. To use AM-CFRP parts in high precision assembly or industrial applications, post processing machining is often required to meet the customers’ specification of geometrical tolerances and acceptable surface finish. In this study, the influence of AM parameters on machinability of AM-CFRP composite has been evaluated using finite element analysis (FEA) based numerical simulation. The slot milling operation was simulated with a tungsten carbide end milling tool and AM-CFRP workpiece with four different printing directions, i.e., 0°-90°, 45°-135°, 0°-90°-45°-135°, two different layer widths, i.e., 50 µm and 100 µm, and two in-fill patterns, i.e., solid and perforated structures. The machinability of the 3D printed CFRP has been analyzed based on cutting forces, stress at first contact and maximum stress generation, and temperature increases at the interface during slot milling of AM-CFRP under different AM parameters. Evolution of failure mechanisms of AM-CFRPs under various machining conditions, such as, delamination, matrix rupture etc., have been discussed and chip and burr formation mechanisms have been analyzed. Finite Element analysis (FEA) package ABAQUS/Explicit was used to model 3D micro slot milling operation of AM-CFRP workpiece with appropriate damage and constitutive models, such as, damage initiation, progression and cohesion in adjacent passes and layers.

TCT-381 Safety and Effectiveness of a Novel Intravascular Lithotripsy Device Using the Hertz Contact Stress Mechanism for Calcium Fragmentation: Six-Month Outcomes of the PINNACLE I Clinical Trial

TCT-381 Safety and Effectiveness of a Novel Intravascular Lithotripsy Device Using the Hertz Contact Stress Mechanism for Calcium Fragmentation: Six-Month Outcomes of the PINNACLE I Clinical Trial

Wheel-rail wear characteristics of a modern tram passing curves with small radius

The wheel-rail wear was predicted for modern trams with independently rotating wheelset running on a groove-shaped rail. The tram vehicle-track coupled dynamics model, considering the wheel-rail multi-point contact, was developed using software UM to evaluate the dynamic responses of the vehicle and track. Hertz contact theory, the FastSim algorithm, and Archard material wear model were used to solve the normal contact stress, tangential contact stress, and wheel-ail wear, respectively. The wheel and rail profiles were updated when the wear depth reached to 0.1 mm. In calculation, the wheel and rail wear was calculated and analyzed separately. The results of groove rail and independently rotating wheelset wear predicted by this model coincided with relevant literature, which proved the effectiveness of this model. The wheel and rail wear characteristics of modern trams passing through curved tracks with small radii and the influence of wheel-rail friction coefficient on wheel and rail wear were calculated and analyzed using this model. The results show that the wheel and rail wear on the circular curve and the rear transition curve is more intense. The wheel wear is the most intense on circular curve while the rail wear is on the rear transition curve. The wear of inner and outer rails and wheels of wheelset one increases with the increase of wheel-rail friction coefficient while the wear of inner and outer wheels of wheelset three have no obvious change. The wear of the inner and outer rails is the most intense at the gauge corner position while is the lightest at the guard rail. The wear of wheelset one is more intense than that of wheelset three and the inner wheel wear is more intense than that of the outer wheel. The present analysis contributes to improve the life of tram wheel and rail and reduce the frequency of wheel-rail maintenance during operation.

Sealing Characteristics Analysis of New Subsea Wellhead Sealing Device

Subsea wellhead systems are the crucial equipment for the development of oil and gas resources offshore, while the sealing device plays a vital role as the main component of the wellhead system. Once the seal fails, it is necessary to retrieve the original wellhead system and either repair the sealing device or reinstall a new one. This will result in a delay in normal production and an increase in development costs. Therefore, a novel subsea wellhead sealing device is designed. A finite element analysis model is developed to study the underwater wellhead sealing mechanism regarding the equivalent stress and contact stress. The research results show that as the driving block gradually increases from 4 mm to 12 mm, the stress of the 12 convex parts on the sealing body also increases. The maximum equivalent stress reaches 3.5 times the yield limit, indicating that it has entered the yield stage and can achieve a more effective seal. The analysis of the contact stress of the sealing body reveals that the contact stress of the driving block increases, leading to plastic deformation of the sealing body while driving it to achieve a complete seal. In general, the finite element simulation results are consistent with the engineering practice. By analyzing the sealing characteristics, it can serve as the foundation for designing and providing theoretical support for the optimization of the metal-sealing structure.

Study on the 2D equivalent nonlinear dynamics simulation model related to high speed precision bearing and spindle

The stiffness and contact stress of the bearing spindle system are the key factors affecting its machining accuracy and service life under the condition of high-speed service, which will be affected by different structural parameters and service conditions. It is essential to establish an efficient and accurate computational simulation model to understand the influence of complex factors on the nonlinear dynamic characteristics of the bearing spindle system. Firstly, in the paper, a 2D axisymmetric finite element model of the bearing, aims at the relationship between stiffness and contact stress of the bearing under high-speed service, has been built based on a classical dynamic analysis model and the reversed method of material parameters of equivalent rolling balls. Additionally, for the BT30 spindle, the 2D axisymmetric finite element model of the bearing spindle system also has been built and applied in mechanical analysis of spindle under different conditions of assembly and service, based on the bearing model. The results show that the axial force of bearings decreases as the rotational speed increases, and an augmentation in speed will result in a reduction in the axial stiffness of the BT30 spindle. In addition, the maximum contact stress exhibits a slight decline as the rotational speed increases. Furthermore, with an escalating preload, the stiffness and contact stress of the spindle undergo substantial increments, however, these parameters will cease to alter once a certain threshold is reached.

Bayesian Inference for the Calibration of Progressive Damage Model of Dovetail Specimens from Laminated Composite Fan Blade

Abstract Composite fan blades are the preferred alternative for the fan stage of most advanced high bypass ratio turbofan engines. The ability of the dovetail to safely bear this load is one of the key points of the multi-level “test pyramid” approach of compliance demonstration for special airworthiness regulation. Debonding between adjacent layers is the main damage mode of laminated composite fan blades. However, there is difficulty in measuring the as manufactured interlaminar mechanical properties used in finite element models. In this study, tensile loading was applied to simulate the interacting centrifugal force and capture mixed mode damage evolution. Structural responses and material damages were calibrated with measured tensile loads through Bayesian inversion. Posterior probability distributions of maximum interface tractions and contact stresses were solved using Markov chain Monte Carlo sampler. Results indicated the two bilinear cohesive material models had a capacity of predicting empirical means of longitudinal reaction forces as that in test considering additional discrepancy term (0.035 kN and 0.96 kN respectively), while they made an significant impact on the prediction of tensile load history especially when two delamination cracks initiated and propagated. Interface elements provided a higher matching quality in predicting loading history and capturing damage mechanism in association with in-plane progressive damage analysis. This calibrated parameter set could be functioned as benchmark in numerically determining the ultimate tensile load of dovetail elements and reducing the necessary number of physical tests at elemental length level.

Numerical Analysis in Double-Sided Polishing: Mechanism Exploration of Edge Roll-Off

Understanding the mechanism of stress concentration effects on the surface of semiconductor substrate materials—silicon wafers—in Double-Sided Polishing (DSP) is particularly important for improving polishing quality. In this study, a two-dimensional finite element model is established to study the effect of contact state and stress concentration during polishing on edge roll-off (ERO) and polishing rate uniformity. The variation in this contact state is influenced by changes in wafer thickness and the gap between it and the carrier. The model is validated by experiments and helps to further analyze and interpret the experimental results, identifying six stages of contact states during the polishing process. The research indicates that the phenomenon of stress concentration at the edge of a wafer is caused by the pads creating a large amount of compression at the edge of the wafer. Additionally, there appears to be a threshold value during the polishing process, below which the stress concentration on the wafer changes, thereby altering the magnitude of edge roll-off and, ultimately, affecting overall flatness. This study provides a basis for optimizing the process design.

Mathematical model and generation analysis for crossed helical gear system

Purpose Crossed helical gears have point contact and their surfaces are subject to high surface stress. Contact stress and root tooth stress are the most common sources of failure in crossed helical gear. This paper aims to study the load-carrying capacity and performance of crossed helical gear teeth with different gear tooth profiles. To overcome defects and reduce the sensitivity to small shaft angle changes. The combined tooth profile is designed to reduce the bending stresses, contact stresses and tooth deflection, and prevent pinion failure in the gearbox. Design/methodology/approach The principle of the method is a line contact is introduced instead of a point contact between two teeth in mesh with each other. The tooth surface of the helical gear is designed and cut by a modified tool. Higher normal pressure angles like 25° and 35° are used. The modified involute is accomplished to eliminate interference between the teeth. Engineering software packages have been applied to generate all crossed helical gears gear profiles. The modification is compounding curves consisting of an epicycloid-involute-hypocycloid gear teeth profile generated by the cutter modified. Findings The stresses in the crossed helical gear teeth profile were reduced by increasing the normal pressure angle values. Using a 35° pressure angle the enhancement percentage in contact stress and teeth fillet region will be about 29.345% and 15.421%, respectively. The best enhancement in a gear’s resistance is the epicycloid-involute-hypocycloid gear teeth profile. The enhancement was 32.610% and 18.588%. The skew in line of action in skewed helical gear will be sensitive when the crossing angles are small. Their teeth surface tends to be easily worn out; however, the wearing process will be reduced by using a proposed gear teeth profile. Practical implications The gear teeth to be modified are cut by a shaper process. The modifying rack cutter of this study can be used as a reference for creating a different helical gears sample. The helical teeth surface is modified to become an envelope of the other. This makes an original point contact change into a line contact. The epicycloid-involute-hypocycloid gear teeth profile is preferred for a higher contact ratio and a large load capacity. This work explicitly introduces a new method of kinematic consideration to improve the load capacity of crossed helical gear. Originality/value This paper showed some novel results by the unique shape of the rack-cutter designed to generate different helical angles and different gear positions. In the future, it will make valuable contributions to the further development of the dynamic performance of a crossed helical gear system through the study in the field of using asymmetric teeth profiles of helical gears with tip relief as the manner to enhance the crossed helical gear performance. Investigation of crossed helical gear by applying a predesigned parabolic function of transmission error enables the absorption of linear discontinuous functions caused by misalignment.

Experimental study on tribological behavior of a binderless cemented carbide at high contact stress

Knowledge of frictional evolution and associated damage mechanism during sliding wear conditions using binderless WC-based cemented carbide is lacking. In this study, the frictional evolution and corresponding transformation of microstructure, and wear mechanisms of Al2O3/WC-based cemented carbide due to the effect of different contact pressure, especially high pressure have been explored using a reciprocating ball-on-flat sliding wear tester, which was experimentally simulated following the ASTM G133–02 standard. The dynamic curves in friction coefficient with the sliding time were described. The microscopic 3D topography of contact surface was obtained by the MFP-3D atomic force microscope. The material removal and the wear rate were discussed. Worn surface morphologies at different moments, cross-sectional images of wear tracks at different loads, and wear debris were taken by field emission scanning electron microscope. The results suggested that the pressure plays a decisive role in frictional evolution and wear characteristics. Two models of frictional evolution were declared. A novel “surge” phenomena in friction coefficient was found and explained at high contact pressure. Wear transition from mild wear to severe wear was confirmed. More than one wear mechanism was observed, including micro-cutting (polishing), generation and propagation of cracks, cracking-induced spalling, plastic deformation, and the formation of tribolayer.

Experimental study on the influence of particle morphology on compression characteristics of coral sand in South China Sea

Particle morphology is an important physical parameter that influences the engineering properties of coral sand, especially its compressibility. According to the quantitative analysis of particle morphology via the dynamic image analysis technology, a series of one-dimensional compression tests on coral sand and quartz sand with different particle morphology and densities were performed to reveal the effect of particle morphology on the compressibility of coral sand. The results demonstrated that the morphology of particles can be quantified using the shape-angularity group indicator (SAGI), whereas the SAGI of coral sand was greater than that of quartz sand. Coral sand exhibited a yield stress ranging from 1 to 2.5 MPa, and compressive deformations in both coral sand and quartz sand were dominated by irreversible plastic deformation. As the SAGI and densification increased, the number of particle coordination increased while the contact stress between grains decreased, which caused the yield stress of coral sand specimens to increase as well as the compression index and particle crushing rate to decrease. The SAGI of quartz sand particles remained relatively unchanged while that of coral sand particles gradually decreased after crushing, i.e., the coral sand particles developed a more regular shape after crushing.

Study on the wear characteristics of cylindrical needle bearings on the crankshaft of RV decelerator

PurposeThe purpose of this study is to systematically analyze the wear of cylindrical needle bearings in rotary vector reducers under temperature rise and identify the influencing factors.Design/methodology/approachBased on the dynamic characteristics of the RV-20E reducer, the time-varying contact force of the cylindrical needle bearing and the entrainment speed of the inner and outer raceways were calculated. A mixed elastohydrodynamic lubrication model of the needle bearing, considering friction and temperature rise, was established using a dynamic rough tooth surface model. The model solved for the oil film thickness, contact stress and wear conditions of the bearing raceway contact area. The effects of the number of rolling needles, the diameter of rolling needles and surface strength on the wear characteristics were analyzed.FindingsThe results of this study show that the oil film thickness, oil film pressure and surface scratches of cylindrical needle bearings exhibit an uneven, patchy distribution under the combined effects of friction and temperature rise. When the radius of the rolling needle is less than 1.44 mm, inner ring wear is less than outer ring wear. Conversely, when the radius exceeds 1.44 mm, inner ring wear is greater. The optimal rolling needle radius is 1.6 mm. Increasing the number of rolling needles and enhancing the yield strength of the contact surface significantly extend bearing life.Originality/valueThis study provides valuable recommendations for optimizing bearing structural parameters and material characteristics in the design of rotary vector reducers.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2024-0242/

Experimental and numerical study on mounting force and withdrawal strength of self-threaded dowels in particleboard

Traditional and alternative joining techniques have been used for many years at the connection points of structural bearing systems. Especially, glued doweled and screwed type mechanical connections are widely used in wooden structures and furniture constructions. Although there are many studies related to the strength of dowel and screw joints, limited papers describe the practical use of self-threaded dowels (STDs) in the joints. In this study, thread geometry effect of the STDs in particleboard (PB) was investigated by determining the mounting force and withdrawal strength values. For this purpose, STDs including three different thread width (0,2 - 0,3 - 0,4 mm) and two different thread length (1 - 2 mm) were designed, produced and tested under static compressive and tensile forces. All STDs were produced with polylactic acid (PLA) by using Layer Plastic Deposition (LPD) method in 3D printing technology. Uniaxial compression tests were performed in order to determine the minimum mounting force while the tension tests were performed for determining the maximum withdrawal force required to put the STDs into the hole and pull out them, respectively. Numerical analysis (FEM) were used to analyze the contact pressures and stresses of the STD joints. Abaqus v6.13-1 software was utilized for the numerical analyses. In addition, multiple regression analysis was carried out to predict the mounting force and withdrawal strength of the STDs. Results showed that the predictive expressions developed provided reasonable estimates for mounting force and withdrawal strength of STDs. According to the statistical analyses; thread width, thread length and their interaction have significantly affected both mounting force and withdrawal strength of STDs. At the end of the experimental and numerical tests, STDs with 0,2 mm width and 2 mm length threads gave the lowest mounting force values, stresses and contact forces. However, the highest withdrawal strength values were obtained from the STDs with 0,3 mm width and 1 mm length threads. According to the results of the study, the optimum STD was the one with 0,3 mm thread width and 2 mm thread length. In conclusion, the STDs can be utilized as an alternative fastener to the conventional glued dowel type joints in PB. However, corner joints constructed of different kinds of wood-based composites and connected with the STDs should be investigated in the future studies.

Tribological behavior and lubrication mechanism of polyalphaolefin with added Cu-Ni bimetallic nanoparticles on a TiN coating

In this study, the tribological behavior of TiN coatings lubricated with a polyalphaolefin (PAO)-based oil containing Cu-Ni bimetallic nanoparticles was investigated under a maximum contact pressure of 0.9 GPa in reciprocating ball-on-disk mode. The addition of 0.1 wt% Cu-Ni nanoparticles to PAO6 reduced the friction coefficient to 0.018 and also decreased the wear rate of TiN coatings to 4.23 × 10-7 mm3/Nm. X-ray photoelectron spectroscopy (XPS) and Raman spectroscopy revealed the deposition of Cu-Ni nanoparticles and carbon-based tribofilms on the contact region of the tribopairs. These originated from the tribo-induced degradation of the polyalphaolefin molecule in PAO6 + 0.1 %Cu-Ni nanoparticles, which helped decrease the COF and wear. Moreover, a comparative analysis suggested that the presence of nickel in the Cu-Ni nanoparticles had a catalytic effect during sliding. They facilitated the in situ formation of carbon-based film due to the degradation of polyalphaolefins under the combined effects of frictional heat and contact stress, demonstrating a self-repair capability.

Research on Strength of Bilateral Support Bearing of PDC–Cone Hybrid Bit

The existing PDC (polycrystalline diamond compact)–cone hybrid bit bearing adopts a unilateral support structure, which is prone to stress concentration in the journal area, resulting in fracture and wear failure of the bearing, thus reducing the service life of the hybrid bit. In this paper, a new type of double supported bearing hybrid bit is proposed. The static strength analysis of unilateral and bilateral support bearing structures is carried out by finite element simulation, and the stress and strain distribution of the two structures under loads of 20–100 kN is obtained. Experimental devices for unilateral and bilateral support bearing structures are designed and manufactured to complete 50–100 kN static pressure loading experiments. The results show that the stress and strain of unilateral and bilateral support bearing increased linearly with the increase of load. Compared with unilateral bearing, when the load was 100 kN, the maximum Mises stress of bilateral bearing decreased from 358.80 MPa to 211.10 MPa, with a decrease of 41.16%. The maximum contact stress decreased from 415.20 MPa to 378.10 MPa, a decreased of 8.94%, and the maximum principal strain decreased from 1.101 × 10−3 to 9.71 × 10−4, a decrease of 11.81%. The axial strain in the danger zone was reduced by 14.68% and 17.35%, respectively. It is found that the contact stress of the simulation data is highly correlated with the bearing life, and the service life of the bilateral bearing bit is increased by 8.94%. The simulation data and experimental results provide data support for the production of hybrid bits with bilateral bearing support.

Mechanochromic Suction Cups for Local Stress Detection in Soft Robotics

Advancements in smart soft materials are enhancing the capabilities of robotic manipulators in object interactions and complex tasks. Mechanochromic materials, acting as lightweight sensors, offer easily interpretable visual feedback for localized stress detection, structural health monitoring, and energy‐efficient robotic skins. Herein, an innovative mechanochromic soft end‐effector capable of discerning local contact stresses during mechanical interactions with objects is presented and their relative position is ascertained. This system utilizes a reversible force‐induced color switch in a thin layer of spiropyran‐functionalized polydimethylsiloxane, which coats a silicone‐made suction cup. The mechanochromic suction cup is integrated with a 3D‐printed compact load‐transferring system and electronic color‐changing detection elements. The assembly may serve as a synthetic receptor for robotic actuators, discerning localized interaction forces down to 3 N. The system's resilience to varying environmental factors, including illumination, tilting, and interaction with objects of various shapes is verified. The results indicate potential for exteroceptive solutions in reconfigurable manipulation tasks without compromising the overall softness of the manipulator.

Finite element analysis of distraction osteogenesis with a new extramedullary internal distractor

Distraction osteogenesis (DO) is a bone regenerative maneuver, which is conventionally done with external fixators and, more recently, with telescopic intramedullary nails. Despite the proven effectiveness, external approaches are intrusive to the patient’s life while intramedullary nailing damages the growth plates, making them unsuitable for pediatric patients. An internal DO plate fixator (IDOPF) was developed for pediatric patients to address these limitations. The objective of this study was to test the hypothesis that the IDOPF can withstand a partial weight bearing scenario and create a favorable mechanical microenvironment at the osteotomy gap for bone regeneration as the device elongates. A finite element model of a surrogated long bone diaphysis osteotomy fixation by means of the IDOPF was created and subjected to axial compression, bending and torsion. As the osteotomy gap increased from 2 mm to 20 mm, under compression, The average axial interfragmentary strains decreased from 2.33% to 0.35%. Stress increased from 179 MPa to 281 MPa at the contact interfaces of the telescopic compartments, which exceeded the endurance limit of stainless steel (270 MPa) but was below its yield limit (415 MPa). These results demonstrate, that the IDOPF can withstand a partial load bearing scenario and provide a stable biomechanical environment conductive to bone healing. However, high contact stresses at the telescopic interfaces of the device are likely to cause wear, as is frequently reported in telescopic fixators. This study is a step towards refining the IDOPF design for clinical use.

Fractal contact and asperities coalescence of rock joints under normal loading: Insights from pressure-sensitive film measurement

Direct measurement of the real contact area of rock joints under normal loading is crucial for comprehending the subsurface geological processes. However, measuring this phenomenon quantitatively at site-scale or laboratory-scale is challenging. Here, we investigate the evolution mechanism of the real contact area in rock joints by conducting closure tests on artificial and saw-cut sandstone joints under normal stresses up to 50 MPa. Geometrical shapes of contact patches are quantified by the pressure-sensitive film using the adaptive threshold method. An extensive range of contact stress within contact patches is innovatively measured by integrating the results from multi-type pressure-sensitive films. Experimental results demonstrate that the real contact area increases with the increasing normal stress hyperbolically. Such a nonlinear contact evolution behavior can be attributed to the coalescence of adjacent contact patches. The fractal dimension of composite surface governs the geometrical shapes of contact patches and the distribution of contact stress. The relationship between patch areas and bearing loads follows the Hertzian theory when the patches are small, while it gradually becomes linear with the increasing patch size. A power model with exponential cut-off is proposed to predict the size distribution of contact patches. This work can provide new insights for estimating the patch-dependent seismic nucleation length and slip stability of subsurface joints.