Elastic-Plastic Contact Analysis of Single Layer Solid Rough Surface Model using FEM

Evaluation of contact pressure, surface and subsurface contact stresses are essential to know the functional response of surface coatings and the contact behavior mainly depends on surface roughness, material property, thickness of layer and the manner of loading. Contact parameter evaluation of real rough surface contacts mostly relies on statistical single asperity contact approaches. In this work, a three dimensional layered solid rough surface in contact with a rigid flat is modeled and analyzed using finite element method. The rough surface of layered solid is generated by FFT approach. The generated rough surface is exported to a finite element method based ANSYS package through which the bottom up solid modeling is employed to create a deformable solid model with a layered solid rough surface on top. The discretization and contact analysis are carried by using the same ANSYS package. The elastic, elastoplastic and plastic deformations are continuous in the present finite element method unlike many other contact models. The Young-s modulus to yield strength ratio of layer is varied in the present work to observe the contact parameters effect while keeping the surface roughness and substrate material properties as constant. The contacting asperities attain elastic, elastoplastic and plastic states with their continuity and asperity interaction phenomena is inherently included. The resultant contact parameters show that neighboring asperity interaction and the Young-s modulus to yield strength ratio of layer influence the bulk deformation consequently affect the interface strength