Modeling of repeated rolling contact of rigid ball on rough surface: residual stress and plastic strain analysis

In this paper, a three-dimensional finite element model of rigid hemisphere repeatedly rolling over a rough flat surface under constant normal load is discussed. The aim of this research is to study the von Mises residual stress and plastic strain distribution and to determine the steady-state phase of the repeated rolling contacts. The results show that the change of residual stress distribution takes place in the first-two rolling cycles and there is no significant change for the residual stress from the second to third rolling cycle, i.e. the surface is run-in after a few cycles. The increase of the contact load affects the area of the von Mises residual stress at the surface and subsurface and also the number of the deforming asperities. The residual stress distribution is getting wider as the normal force increases. The plastic strain is captured after the third cycle of rolling. Small area of plastic strain is found for the rough surface for the low forces applied which indicates the surface deformed mainly elastically. The rough surface is predicted to be plastically deformed for the highest force applie