ME 383S

Bryant

February 17, 2006 1

CONTACT
Mechanical interaction of bodies via surfaces Surfaces must touch Forces press bodies together Size (area) of contact dependent on forces, materials, geometry, temperature, etc. Contact mechanics

ME 383S

Bryant

February 17, 2006 2

NATURE OF CONTACT
Rough surfaces contact Highest peaks on highest peaks Contact area = discrete islands Real contact area small fraction of apparent area Consequence contact stresses higher heating (friction) more intense electrical contacts: local constriction resistance

ME 383S

Bryant

February 17, 2006 3

CONTINENTAL ANALOGY OF CONTACT

Earth's surface rough: mountains & valleys

Place South America on North America

Contact: highest peaks against highest peaks - Andes/Appalachia - Highlands/Rockies Apparent contact area large, real contact area small Contact between bodies similar

ME 383S

Bryant

February 17, 2006 4

CONTACT MECHANICS FUNDAMENTALS

Fundamental Solutions: Boussinesq: 3D Elastic deformations from point force normal to semi-infinite space Flamant: 2D Elastic deformations from point force normal to semi-infinite space

Contact between spheres elastic: Hertzian contact plastic: Indentation (Meyer) hardness overall quirks

ME 383S

Bryant

February 17, 2006 5

FLAMANT SOLUTION (2D)

Point force P, normal to semi-infinite elastic space 2D: plane strain or plain stress
P x u y v

(x, y)

Elastic deformations: (u, v) along (x, y) P & 2 xy ) P % 2y 2 ( u=" '($ " 1)% " 2 * , v = " &($ + 1)log r " 2 ) 4 # ' r * 4 # ( r + Stresses:

2P % y y 3 ( 2P % y 3 ( 2 P % xy 2 ( " xx = # & 2 # 4 ) " yy = # & 4 ) " xy = # & 4 ) $ 'r r *! $ 'r * $ 'r *

: elastic shear modulus, !: Poisson's ratio Elastic modulus: E = 2(1 + !) ! Dundars constant: ! = 3! 4!, plane strain, = (3 !)/(1 + !), plane stress

r = x 2 + y , tan " = x/y

ME 383S

Bryant

February 17, 2006 6

SOLUTION (2D)
Point force P, tangential to semi-infinite elastic space 2D: plane strain or plain stress P
(x, y) y v u x

Elastic deformations: (u, v) along (x, y)

P % 2y 2 ( P & 2 xy ) u=" &($ + 1)log r + 2 ) , v = '(# $ 1)% + 2 * , 4 # ' r * 4 " ( r +

Stresses: 2 P % x xy 2 ( 2P % y y3 ( 2 P % xy 2 ( " xx = &$ + ) " = # & 4 ) " xy = &$ + ) # ' r 2 r 4 * ! yy # ' r2 r4 * $ 'r * : elastic shear modulus, !: Poisson's ratio !: Dundars constant ! strain; = (3 ! = 3 4!, plane !)/(1 + !), plane stress

r = x 2 + y , tan " = x/y

ME 383S

Bryant

February 17, 2006 7

BOUSSINESQ SOLUTION (3D)

Point force P on semi-infinite elastic space P
y z w x u

(x, y, z)

Elastic deformations: (u, v, w) along (x, y, z) P u = 4! P v = 4! P w = 4! xz { r3 yz { r3 z2 { r3 x - (1 - 2 ") r (r + z) y - (1 - 2 ") r (r + z)

+

} }

2(1 - ") r

: elastic shear modulus, ": Poisson's ratio r = x 2+ y 2 + z 2

ME 383S

Bryant

February 17, 2006 8

HERTZIAN CONTACT THEORY

Contact between elastic curved bodies Initial Contact
E1 !1 R1 Z o (x, y) R2 E2 !2 initial contact x

bodies (spheres) touch at origin curvatures R1, R2 elastic parameters (E1,"1) (E2,"2) initial separation (parabolas) Zo(x, y)=
x2 + y2 2

{R +R }
1 2

ME 383S

Bryant

February 17, 2006

HERTZIAN CONTACT THEORY Compressive normal load P Induces contact pressures p = p(x, y) normal surface deformations w1, w2 wi = wi[p(x, y); Ej, "j, Rj] (from Boussinesq) final separation
x 2a

p(x,y)
Z f (x, y)

Zf(x, y) = Zo(x, y) - # + w1 + w2 contact diameter 2a, defines contact area normal approach #, amount centers of bodies come together

10

HERTZIAN CONTACT THEORY Problem Statement

P
p(x,y)

Unknowns a, # (eigenvalues) Contact pressures p(x, y) (eigenfunction) Physics: static equilibrium

x

Z f(x, y) 2a

Boundary Conditions over contact (x2+ y2 < a2) Zf(x, y) = 0, p(x, y) " 0 outside (x2+ y2 " a2) p=0 P=
% $p(x, contact area

y) dx dy

11

HERTZIAN CONTACT THEORY Solution Sphere on Sphere (point contact):

P
p(x,y)
x2 y 2 " a 2 a2

p(x, y) = po 3P po = 2! a2
x 2a

1"

Z f (x, y)

a=

3"P( k1 + k2 )R1 R2 4(R1 + R2 )

1 3

1- "i2 ki = !E i #=

9" P ( R1 + R2 ) ( k1 + k2 ) 16R1 R2

1 3

12

Cylinder on Cylinder (line contact):

x2 p( x ) = po 1 " a 2 ,
" 4 P ( k1 + k 2 ) R1R2 % ' , a =$ l ( R + R ) # & 1 2 !
1/ 2

po =

2P "al

1- "i2 ki = !E i

/ ) 4 l3 #1 P 1 &,2 " = ( k1 + k 2 )11 + ln* % + (-4 l 1 + ( k1 + k 2 ) P $ R1 R2 '.4 0 3

l: length of contact along axis of cylinders

13

PLASTIC CONTACT THEORY

Indentation (Meyer) hardness

P p !A P

Contact pressures p(x, y) approximately uniform Hardness pressure (indentation hardness) P $ % p ! &A H # 3 x Yield stress

Bodies in contact Load P > elastic limit & plastic deformations

Use: estimate contact area, given H and P

14

OVERALL CONTACT MODEL

P

P p(x,y)

!
P

2a P

Spheres Increasing normal load P 0 $ P < Pe ; # = #1+#2 = P " Pe ; # = #1+#2 > Elastic (Hertzian) contact model
1 3

{ {

9!2P2(k1+k2)2(R1+R2) 16R1R2

Elastic-Plastic contact model 9!2Pe2(k1+k2)2(R1+R2) 16R1R2

1 3

Similar formulations, tangential loads & deformations P >> Pe, Meyer Hardness problem

15

Hardness (Indentation) Test

Brinell hardness H B
Hard steel ball (diameter D, load F) indent for 30 sec. measure permanent (pla stic) set
F
Hard St eel Ball (d ia mete r D)

HB = F/( ! D t) [N/m 2 ] (units of

stress) t " {D - (D 2 - d 2 )1/2 }/2
t

s pecim en

Other hardness tests

Vickers: Diamond point indentation Rockwell: measured like or Vickers scratch test Brinell

16

Brinell Hardness
For steels S = S(H) Ultimate strength
Su = KB HB

Yield Strength
Sy ! 1.05S u - 30ksi

17

Micro Hardness Measurements

Micro hardness tester: Indents specimen Use on thin films, e.g. hard drive coatings

18

CONTACT QUIRKS
Nonlinear contact stiffness P = P(#) P=C#
3/2

4 , C = 3!(k +k ) 1 2

R1R2 R1+R2

& nonlinear contact vibrations Tangential motions: slip/stick with friction high pitched "squeal" / fingernail on blackboard

19

ROUGH CONTACT MODELS

Greenwood & Williamson
P

Rough surfaces contact: current separation = d

P
Asperities contact interference # = (z1 + z2) - d

z1 , z2 surface heights, upper & lower

20

Model asperities as spheres

r1

do

z1 z2 r2

Relate contact quantities to surface heights z = z1 + z2 (random variable) Expected values & Macroscopic Contact Parameters
"

E[H(z)] = N

# H (z)F ( z)dz
d

N: total number asperities H(z): physical quantity, dependent on heights z Lower limit: heights z " d for asperities to touch Microscopic understanding & Important practical engineering parameters

21

Contact force (elastic) on ith asperity Asperity force: Pi(z) = C # Total force: H(z) = Pi(z)
"

3/2

= C (z - d)

3/2

(Hertz)

P = E[Pi(z)] = N

# P (z)F( z)dz
i d

Real contact area

Asperity area: H(z) = Ai(z) = ! a2 From Hertz: a = C1

"

1/ 2

= C1

(z " d )1/ 2

Contact conductance
Asperity conductance: Gi(z) = '/2a (Holm)