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2920609
2920609
Temperature-Displacement Finite
S. M. Kulkarni
Element Analysis of Two-
Graduate Student.
Dimensional Rolling-Sliding
C. A. Rubin
Professor. Contact With a Translating Heat
G. T. Hahn Source
Professor.
The present paper, describes a transient translating elasto-plastic thermo-mechanical
Center for Materials Tribology, finite element model to study 2-D frictional rolling contact. Frictional two-
Vanderbilt University, dimensional contact is simulated by repeatedly translating a non-uniform thermo-
Nashville, TN 37235 mechanical distribution across the surface of an elasto-plastic half space. The half
space is represented by a two dimensional finite element mesh with appropriate
boundaries. Calculations are for an elastic-perfectly plastic material and the selected
thermo-physical properties are assumed to be temperature independent. The paper
presents temperature variations, stress and plastic strain distributions and deforma-
tions. Residual tensile stresses are observed. The magnitude and depth of these
stresses depends on 1) the temperature gradients and 2) the magnitudes of the nor-
mal and tangential tractions.
Introduction
The mechanics of elasto-plastic rolling-plus-sliding contact investigated. Except for Newman (1986), who has developed
with friction, but in the absence of heating, has been examined as elasto-plastic finite element model to study the stress fields
by Johnson and Jefferies (1963) and Ham et al. (1988). In in welded plates, all the investigations discussing the subsur-
reality, the heating that accompanies friction will introduce face effects of thermo-mechanical contact, are elastic (Ken-
thermal stresses and locally alter the elastic and plastic proper- nedy and Karpe, 1982; Ling and Mow, 1965; Mow and Cheng,
ties of the material. Existing literature predominantly deals 1967, and Tseng and Burton, 1982). Premature failure due to
with surface limited analyses (Barber, 1971a, 1972, 1973a, overheating of HPOTP bearings used in the Space Shuttle
1976, 1980a, b, 1982; Comninou and Dundurs, 1979; Com- Main Engine (Maurer and Pallini 1985; Bhat and Dolan,
ninou et al., 1981; Hills and Barber, 1986; Korovchinski, 1983), warrant the development of an elasto-plastic thermo-
1965; Mikic, 1974; Panek and Dundurs, 1979), and the con- mechanical finite element model to simulate frictional rolling
tact of rough surfaces, such as, flash temperatures, the local- contact more realistically. A preliminary step in that direction,
ized transient temperatures due to asperity contact (Archard, a stationary thermo-mechanical analysis (Kulkarni et al.,
1959; Blok, 1937, 1963; Holm, 1948; Kuhlmann-Wilsdor, 1988), consists of a conductive half plane with a convective
1985; Nagaraj et al., 1979; Winer and Cheng, 1980; and surface subjected to the combination of mechanical pressure
Zumgahr, 1987). Many studies have examined the competing and different thermal loads (representing the heat generated
processes of: (a) frictional heating at the contact interface and due to friction). Although, the mechanical effect of the sur-
the resulting thermal expansion with (b) heat transfer and face tractions and the cyclic nature of the applied loads was
wear. The unstable increase in the contact stress, known as not considered, the study established the existence of varying
thermoelastic instability (TEI) (Barber 1967, 1968, 1969, levels of residual tensions proportional to the attending
1971b, 1973b; Burton et al., 1973; Dow, 1972; Dow and Bur- temperature gradients. The present paper describes a tran-
ton 1972, 1973; Dow and Stockwell, 1977; and Johnson et al., sient, translating, elasto-plastic, thermo-mechanical finite ele-
1988) and its manifestation as scuffing (Durkee, 1978; Durkee ment model of 2-D frictional rolling contact. The temperature
and Cheng, 1979; and Sovak and Cheng, 1982) have also been variations, stress-plastic strain distributions, and deforma-
tions are calculated for specific contact conditions.
Contributed by the Tribology Division for publication in the JOURNAL OF Description of the Model
TRIBOLOGY. Manuscript received by the Tribology Division January 3, 1990;
revised manuscript received July 9, 1990. Associate Editor: H. S. Cheng. A two dimensional finite element mesh (see Fig. 1) with ap-
a = coefficient of thermal
X = circumferential or in- expansion, m/m-°C
3
plane coordinate, m P = mass density, kg/m G = shear modulus, MPa
y = radial or depth coor- C
P = specific heat, EPP = Elastic-Perfectly-
dinate, m KJ/kg-°C Plastic
z = axial or out-of-plane p(x) = pressure at any point, = parameter / for the
coordinate, m
= peak pressure, MPa
MPa r residual state
Po w = half contact width, m Vxx = circumferential stress,
k = o0/l.Ti = von Mises shear yield t{x) = tangential traction at MPa
strength, MPa any point, MPa a
zz = axial stress, MPa
p0/k,p0/kk = relative peak pressure p = coefficient of friction = shear stress, MPa
K = thermal conductivity, q(x) = heat flux at any e" = equivalent plastic
W/m-°C point, MPa strain
E = Young's modulus, V = slip velocity, m/s a = K/pc = thermal diffusivity,
MPa h = film coefficient, m 2 /s
V = Poisson's ratio W/m 2 -°C T = temperature, °C
bient value. For nodes along the sides of the mesh, AD and
BC, the temperatures are not fixed but temperature gradients
in the circumferential or X-direction are set equal to zero. -2 -t5 -1 -0.5 0 0.5 1 15 2
X/ W
To make the mesh behave as a semi-infinite body, the
boundaries are displaced elastically. Equations for the elastic Fig. 5 Surface temperatures just under the translating load, during six
displacements due to a concentrated force acting 1) normal consecutive passes, PASS1 through PASS6, for CAL1 or CAL2 (see
Table 1) as a function of normalized surface coordinate, x/w
and 2) tangential, to the surface have been derived using the
appropriate Airy Stress Function (see Appendix). The applied
nonuniform distribution of tractions, p and t, are discretized boundary conditions, explained above, are applied during
into numerous concentrated forces, each acting on an in- each translational step. Earlier 2-D rolling contact studies
finitesimal area. The elastic displacements at the nonsurface (Bhargava et al., 1985a,b) show that the half-space subjected
boundary nodes due to each concentrated load are then to cyclic mechanical loads attains a steady stress state after
calculated and superposed. For nodes along the bottom sur- two contacts. Hence, in the interest of reducing computer
face, DC, both X- and F-directions are prescribed, while for time, the thermomechanical calculations (CAL1 and CAL3)
those on the sides AD and BC, only displacements in the X- consist of (1) initial thermal cycling (the surface of the half-
direction are calculated using the elastic solution. space subjected to the transient translating heat flux, q) to
A frictionless 2-D rolling calculation was performed at establish appropriate temperature gradients, followed by (2)
p0/k = 5.0, and residual stresses, 1) circumferential, a^/k thermomechanical passes (in addition to q, the mechanical
(Fig. 2), and 2) axial, CT^ (Fig. 3), were compared with the components, p and / are applied) to determine the combined
work of Bhargava et al. (1985a, b). The peak values of the effect (Table 1). However, this does not imply that a thermal
residual stresses are within 15-20 percent. A rolling-sliding steady state has been reached. Analyses CAL2 and CAL4
calculation was also performed atp0/k= 5.0, and a coefficient (Table 1) describe the effect of pure thermal cycling. CAL3
of friction ^ = 0.1; the residual stresses, 1) circumferential, and CAL4 were performed using a higher thermal input i.e.,
o^/k, and 2) axial, orzz, were compared with the work of Ham the same heat rate was allowed a larger time of contact. CAL3
et al. (1987) (Fig. 4). The study by Ham et al. (1987) is for a and CAL4 are approximate representations of CAL1 and
p0/k of 4.5 and /i = 0.2; the residual stress distributions are CAL2, respectively, at a much later time period.
similar to those obtained using the present model. The calculations were performed using the finite element
The HPOTP (Cryogenic Turbopump) bearings in the Space package ABAQUS 4.7 on the CRAY X-MP/48 at the San
Shuttle Main Engine were used as a reference for the thermal Diego Supercompouter Center. Typical CPU time re-
and thermo-mechanical calculations. The coefficient of fric- quirements were, 12 minutes/contact for the thermal calcula-
tion is assumed to be /x = 0.1 and using the diameter of the in- tions and 20 minutes/contact for the thermo-mechanical
ner race, the revolutions/minute and 1 percent slip, the veloci- calculations.
ty, Kis calculated to be 0.9 m/s. The Peclet number is taken as
30, and the half contact width, vv = 0.0005 m. Table 1 presents Results
a brief description of the four different calculations per- The present model represents frictional rolling contact be-
formed. Each computation includes a certain number of ther- tween two components rotating about the Z-axis and the
mal/thermomechanical contact cycles, followed by cooling to results describe the temperature distributions, the stress
the ambient temperature. A contact cycle consists of 43 distributions, the equivalent plastic strain contours and the
spatially unequal thermal/thermomechanical translations distortions.
through a distance of 24w, from point A to point B (Fig. 1). Figure 5 shows surface temperatures for CAL1 or CAL2 .
The time steps used are also nonuniform to maintain a con- [The temperatures are within 1 percent (also for CAL3 and
stant sliding velocity. The first step of a new cycle immediately CAL4) and the thermo-mechanical coupling was used to
follows the last step of the previous cycle. This physically simplify the computations.] The transient thermal load is sym-
models 16 balls/rollers in the bearing race. Appropriate metric about x/w = 0.0 while the temperature distribution is
X-»-
y/w Fig. 9 Displaced mesh, halfway through PASS1 (only thermal load) for
CAL3 (see Table 1). Solid lines-displaced mesh, dashed lines-original
Fig. 7 Comparison of the normalized residual circumferential, a'xxlk, mesh. Mag. factor = 75.
axial, a'^/k, stress as a function of normalized depth, y/w, for CAL2 (ther-
mal contact load), after six passes followed by cooling to the ambient X-»-
temperature
asymmetric and the peak value occurs at —0.5 x/w (in the
direction opposite to that of the translation). It is seen that
with successive passes there is a decrease in the temperature in-
crements per pass. The highest value of the temperature after 6
consecutive passes is observed to be 280°C. Figure 6 shows
normalized residual stresses (after the semi-infinite body has
been cooled back to the ambient temperature) as a function of
the normalized depth, y/w. Both, the axial (orzz/k) and cir-
cumferential {a^/k) components are tensile and significant
values extend to a depth of about 1.2w. The axial component
is observed to be about 4 times that of the circumferential
component. Results for pure thermal cycling [CAL2] are
presented in Fig. 7. Both stresses, orxx/k and arzz/k, attain high Fig. 10 Displaced mesh, halfway through PASS3 (Ihermomechanical
values but taper off to small values at a depth of only 0.7w. load) for CAL3 (see Table 1). Solid lines-displacement mesh, dashed
From Figs. 6 and 7 we can see that the translating mechanical lines-original mesh Mag. factor = 23.
load serves to decrease the peak residual tensions but increases
the depth of plastic activity (From 0.7w to 1.2w). For CAL1 the distortion halfway through the third contact (thermo-
this is described in Fig. 8 by way of residual equivalent plastic mechanical load) is seen in Fig. 10. The temperature distribu-
strain contours. The peak activity occurs at a depth of 0.5w. tions in the half-space halfway through the third contact are
Results for a longer time of contact (CAL3 and CAL4) are presented in Fig. 11 while Fig. 12 gives the surface
also presented. Figure 9 shows the displaced mesh for CAL3, temperatures for CAL3 or CAL4 (similar to Fig. 5). The
halfway through the first contact (only thermal load) whereas temperatures, which are asymmetrically distributed, show a
1 •7.00E-05 a •4.90C*Q2
2 +7.00E*01 9 •>S.SOE*02
3 *1.40E*02 ID *6.3DE*<B
11 «7.a£»02
<
5
*2.10E*02
•>2.80E»02 -LIDE-OS
g *3.S0£»O2 -I.0QE«<8
7 •>4.20E»02 •-s.ocE'oa
-l.SSE»08
Fig. 11 Temperature contours, halfway through PASS3 (ther- *i.ooE><a
momechanical load) for CAL3(see Table 1) H.0CE»O8
2w
2 •S.DOE-03
3 •I.20E-O2
1 ••l.BCE-02
Fig. 12 Surface temperatures just under the translating load, during 5 '5.40E-02
three consecutive passes, PASS1 through PASS3, for CAL3 or CAL4 ~ W s •3.00E-O2
(thermal contact only) as a function of normalized surface coordinate, 7 •>3.KE-02
x/iv a •4.20E-02
9 •H.80E-02
10 *S.«E-02
ii •6.SK-02
peak value of 740°C after the third pass. It is interesting to Fig. 14 Residual equivalent plastic strain contours, for a section of the
mesh, for CAL3 (thermo-mechanical load), after three passes followed
note that tensile stresses are observed ahead of and behind the by cooling
translating transient thermo-mechanical load in the vicinty of
the surface, (azz shown in Fig. 13) in addition to the high com-
pressive stresses present in the vicinity of the load. Figure 14,
shown for a section of the mesh, for the case when the mesh stress distribution, however the high heat case (Figs. 15 and
has been cooled to the ambient temperature after three con- 16), does not have this effect.
tacts (CAL3), indicates that high values of the equivalent
plastic strain extend beyond a depth of 2w. This is confirmed Discussion
in Fig. 15 describing the normalized residual stresses, orxx/k The complex nature of the cyclic stresses and strains at-
and arzz/k, as functions of normalized depth, y/w. Significant tending frictionless 3-D contact has been described elsewhere
tensile values extend all the way to a depth of 4.5w. In contrast (Kulkarni et al., 1990a,b and c). This might result in surface
with Fig. 15, Fig. 16 describes the residual state due to a purely (due to the translating tensile stresses close to the surface) or
thermal cycling (CAL4). The mechanical load produces very subsurface (due to the rotating principal directions) crack in-
small differences in the values of the residual tension in the itiation and propagation by a suitable mechanism. The
vicinity of the surface and no effect is seen on the depth of the presence of friction and possible pressure peaks closer to the
plastic activity. surface (due to asperity contact) may also move crack initia-
Considering Figs. 6, 7, 15, and 16, it may be noted that the tion sites closer to the surface. But in cryogenic turbopump
effect of the mechanical load on the residual stress state of a bearings of the Space Shuttle Main Engine, where evidence of
thermo-mechanical contact depends on its magnitude relative high temperatures has been found and whose life is found to
to the thermal influx. For the case of low heat input (Figs. 6 be limited (Bhat and Dolan, 1983), crack initiation, propaga-
and 7) the mechanical load significantly changes the residual tion and the eventual failure might have thermal origins. The
A P P E N D I X
Boundary Conditions for Nonsurface Nodes
Describing the boundary conditions at the nonsurface
boundary nodes, consists of
1. Prescribing the boundary temperatures due to the
translating thermal load and Fig. A2 A concentrated vertical force, Pv, acting on the surface of a
half plane
2. Prescribing the boundary displacements due to the
translating thermo-mechanical load.
Boundary Displacements
The First Boundary Value Problem of Elasticity, with polar
Boundary Temperatures coordinates, is used to obtain the solution for these
In this section the work of Carslaw and Jaeger has been ex- displacements. The stresses must satisfy the equilibrium equa-
tended to predict temperatures in a half space due to a tions as well as the boundary conditions, the strains must
translating non-uniform heat source. satisfy the compatibility equations and the stresses must be
Using their solution, for the temperature distribution in an related to the strains, by Hooke's law. A suitable Airy Stress
infinite solid due to a line heat source, inserting a nonuniform Function can be found to satisfy the equilibrium equations,
heat source, distributed over a width 2w, given by the boundary conditions and the compatibility equations.
From the Airy Stress Function, the stresses are calculated,
then strains are found using Hooke's law and the
9W = «P.K(l--J-) displacements are obtained from the strain-displacement rela-
tions and the boundary conditions.
and considering that this heat source has been moving infinite- (a) Vertical or Normal line load at the surface of a half-
ly long at a velocity ' V across the half-space (see Fig. Al) and plane:
finally integrating with respect to time from 0 to oo, with the The appropriate Airy Stress Function is
present time being oo,
£/= rdsin 0
V(x-x')
K0{- -[(x-x')2+y2 1/2
2-KK J-M.' 2K The displacements for plane strain are found to be
P(l + v)
:
(--£-) dx' Ur=-
2irE
-[4(y-l)cos 01n r + 2(l-2^)(cos 0-0sin 0)]