An FFT Deterministic Simulation of Elastic Rough Surfaces in Three-Dimensional Contact and Model Analysis

2009 ◽  
Author(s):  
Robert L. Jackson ◽  
Itzhak Green
Keyword(s):  
Contact Area ◽  
Thermal Contact Resistance ◽  
Thermal Contact ◽  
Three Dimensional ◽  
Real Contact Area ◽  
Real Contact ◽  
Contact Models ◽  
Surface Profiles ◽  
Rough Surface Contact ◽  
Mathematical Foundations

For practicing engineers in industry it is important to have closed-form, easy to use equations that can be used to predict the real contact area, and relate it to friction, wear, adhesion, and electrical and thermal contact resistance. There are quite a few such models in the literature, but their agreement or their effectiveness has not been determined. This work will use several measured surface profiles to make predictions of contact area and contact force from many elastic contact models and compare them to a deterministic FFT based rough surface contact model. The results show that several of the models show good quantitative and qualitative agreement despite having very different mathematical foundations.

Thermal Contact Resistance at a Metal Foam-Solid Surface Interface

2011 ◽  
Author(s):  
Ehsan Sadeghi ◽  
Scott Hsieh ◽  
Majid Bahrami
Keyword(s):  
Thermal Conductivity ◽  
Contact Resistance ◽  
Effective Thermal Conductivity ◽  
Contact Area ◽  
Thermal Contact Resistance ◽  
Thermal Contact ◽  
Metal Foams ◽  
Real Contact Area ◽  
The Real ◽  
Real Contact

Accurate information on heat transfer and temperature distribution in metal foams is necessary for design and modeling of thermal-hydraulic systems incorporating metal foams. The analysis of this process requires determination of the effective thermal conductivity as well as the thermal contact resistance (TCR) associated with the interface between the metal foams and adjacent surfaces/layers. In the present study, a test bed that allows the separation of effective thermal conductivity and thermal contact resistance in metal foams is described. Measurements are performed in a vacuum under varying compressive loads using ERG Duocel aluminum foam samples with different porosities and pore densities. Also, a graphical method associated with a computer code is developed to demonstrate the distribution of contact spots and estimate the real contact area at the interface. Our results show that the porosity and the effective thermal conductivity remain unchanged with the variation of compression in the range of 0 to 2 MPa; but TCR decreases significantly with pressure due to an increase in the real contact area at the interface. Moreover, the ratio of real to nominal contact area varies between 0 to 0.013, depending upon the compressive force, porosity, and surface characteristics.

scholarly journals A Condition for Complete Flattening of Asperities in a Rough Contact

2018 ◽  
Vol 220 ◽  
pp. 01007
Author(s):  
Mikhail V. Murashov
Keyword(s):  
Contact Area ◽  
Contact Process ◽  
Real Contact Area ◽  
Confined Compression ◽  
Real Contact ◽  
Decisive Importance ◽  
Roughness Elements ◽  
Contact Models ◽  
Surface Profiles ◽  
Low Pressures

Considering rough surface profiles in a contact model is of decisive importance. In the up-to-date rough contact models there remained underexplored the opportunity of complete flattening of smaller asperities and therefore the need of using the multilevel roughness models, including fractal ones. If higher level asperities are not flattened completely when pressed, then they will be able to impact on the contact process. This paper considers model problems of elastic-plastic contact with hardening for a body with protrusions and two pyramids as the objects similar to asperities. Modeling results show that asperities are completely flattened only on condition of confined compression. For real contacting rough surfaces under low pressures, complete flattening of asperities will not occur. It is shown that roughness elements on the surface of the asperities do not disappear even at severe deformation of the latter. The reason is a combination of the asperity form and hardening of material, while the consequence is a reduction of the real contact area.

A model of thermal contact conductance at high real contact area fractions

Wear ◽  
2010 ◽  
Vol 268 (1-2) ◽  
pp. 77-85 ◽  
Author(s):  
Przemysław Sadowski ◽  
Stanisław Stupkiewicz
Keyword(s):  
Contact Area ◽  
Thermal Contact ◽  
Thermal Contact Conductance ◽  
Real Contact Area ◽  
Contact Conductance ◽  
Real Contact

Unloading Process in Elastic-Plastic Contact of a Rough Surface With a Flat

2008 ◽  
Author(s):  
A. Sepehri ◽  
K. Farhang
Keyword(s):  
Finite Element ◽  
Rough Surface ◽  
Contact Force ◽  
Contact Area ◽  
Three Dimensional ◽  
Integral Form ◽  
Real Contact Area ◽  
Elastic Plastic ◽  
Real Contact ◽  
Approximate Equations

Three dimensional elastic-plastic contact of a nominally flat rough surface and a flat is considered. The asperity level Finite Element based constitutive equations relating contact force and real contact area to the interference is used. The statistical summation of asperity interaction during unloading phase is derived in integral form. Approximate equations are found that describe in closed form contact load as a function of mean plane separation during unloading. The approximate equations provide accuracy to within 6 percent for the unload phase of the contact force.

scholarly journals Elastic Rough Surface Contact and the Root Mean Square Slope of Measured Surfaces over Multiple Scales

2021 ◽  
Vol 5 (2) ◽  
pp. 44
Author(s):  
Robert Jackson ◽  
Yang Xu ◽  
Swarna Saha ◽  
Kyle Schulze
Keyword(s):  
Rough Surface ◽  
Root Mean Square ◽  
Contact Area ◽  
Multiple Scales ◽  
Real Contact Area ◽  
Mean Square ◽  
The Real ◽  
Real Contact ◽  
Surface Contact ◽  
Rough Surface Contact

This study investigates the predictions of the real contact area for perfectly elastic rough surfaces using a boundary element method (BEM). Sample surface measurements were used in the BEM to predict the real contact area as a function of load. The surfaces were normalized by the root-mean-square (RMS) slope to evaluate if contact area measurements would collapse onto one master curve. If so, this would confirm that the contact areas of manufactured, real measured surfaces are directly proportional to the root mean square slope and the applied load, which is predicted by fractal diffusion-based rough surface contact theory. The data predicts a complex response that deviates from this behavior. The variation in the RMS slope and the spectrum of the system related to the features in contact are further evaluated to illuminate why this property is seen in some types of surfaces and not others.

A Multiscale Model of Thermal Contact Resistance Between Rough Surfaces

2008 ◽  
Vol 130 (8) ◽  
Author(s):  
Robert L. Jackson ◽  
Sushil H. Bhavnani ◽  
Timothy P. Ferguson
Keyword(s):  
Contact Resistance ◽  
Thermal Contact Resistance ◽  
Multiple Scales ◽  
Rough Surfaces ◽  
Thermal Contact ◽  
Multiscale Model ◽  
New Model ◽  
Surface Features ◽  
Contact Models ◽  
Rough Surface Contact

A new multiscale model of thermal contact resistance (TCR) between real rough surfaces is presented, which builds on Archard’s multiscale description of surface roughness. The objective of this work is to construct the new model and use it to evaluate the effects of scale dependent surface features and properties on TCR. The model includes many details affecting TCR and is also fairly easy to implement. Multiscale fractal based models often oversimplify the contact mechanics by assuming that the surfaces are self-affine, the contact area is simply a geometrical truncation of the surfaces, and the pressure is a constant value independent of geometry and material properties. Concern has grown over the effectiveness of frequently used statistical rough surface contact models due to the inadequacies in capturing the true multiscale nature of surfaces (i.e., surfaces have multiple scales of surface features). The model developed in this paper incorporates several variables, including scale dependent yield strength and scale dependent spreading resistance to develop a new model that can be used to evaluate TCR. The results suggest that scale dependent mechanical properties are more influential than scale dependent thermal properties. When compared to an existing TCR model, this very inclusive model shows the same qualitative trend. Results also show the significance of capturing multiscale roughness when addressing the thermal contact resistance problem.

An analytical model of thermal contact resistance based on the Weierstrass—Mandelbrot fractal function

2010 ◽  
Vol 224 (4) ◽  
pp. 959-967 ◽  
Author(s):  
S Jiang ◽  
Y Zheng
Keyword(s):  
Contact Resistance ◽  
Surface Topography ◽  
Contact Area ◽  
Thermal Contact Resistance ◽  
Thermal Contact ◽  
Fractal Model ◽  
Design Guidelines ◽  
Real Contact Area ◽  
Fractal Function ◽  
Conduction Theory

A fractal model for analysing the thermal contact resistance (TCR) of rough surfaces is presented; it is based on the classical heat conduction theory and fractal geometry for the surface topography description, elastic—plastic deformation of contacting asperities, and size-dependent constriction resistance. Relations for the TCR in terms of contact load are obtained for heat conductive surfaces with known material properties and surface topography. With the real contact area being approximately 1 per cent of the apparent contact area or less, the microcontact area distribution has a dominant influence on the TCR. Useful design guidelines for heat contacts are extracted from the numerical results. The analytical results agree well with previous experiments.

On the Mechanism of Contact Between Metal Surfaces: Part 2—The Real Area and the Number of the Contact Points

1968 ◽  
Vol 90 (1) ◽  
pp. 81-88 ◽  
Author(s):  
T. Tsukizoe ◽  
T. Hisakado
Keyword(s):  
Contact Area ◽  
Three Dimensional ◽  
Real Contact Area ◽  
Load Range ◽  
The Real ◽  
Real Contact ◽  
Contact Points ◽  
Theoretical Analyses ◽  
Total Contact Area ◽  
Real Area

Assuming that the distribution curve obtained from the profile curve of the surface has a normal distribution, the relation between the real contact area and the separation is obtained theoretically in the case of ideal plastic flow of the microcontacts. If the asperities are cones of the same angle which depends on the surface roughness, the three-dimensional number and the distribution of the radii of contact points are also deduced theoretically. The results of the theoretical analyses are compared with the experimental results for the real contact areas and the numbers of the contact points. Results show that over the wide load range the average radii of contact points are almost constant; consequently, the total contact area is increased mainly owing to the increase in the number of the contact points.

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