Frictional energy dissipation in contact of nominally flat rough surfaces under harmonically varying loads

If the nominal contact tractions at an interface are everywhere below the Coulomb friction limit throughout a cycle of oscillatory loading, the introduction of surface roughness will generally cause local microslip between the contacting asperities and hence some frictional dissipation. This dissipation is important both as a source of structural damping and as an indicator of potential fretting damage. Here we use a strategy based on the Ciavarella-Jäger superposition and a recent solution of the general problem of the contact of two half spaces under oscillatory loading to derive expressions for the dissipation per cycle which depend only on the normal incremental stiffness of the contact, the external forces and the local coefficient of friction. The results show that the dissipation depends significantly on the relative phase between the oscillations in normal and tangential load—a factor which has been largely ignored in previous investigations. In particular, for given load amplitudes, the dissipation is significantly larger when the loads are out of phase. We also establish that for small amplitudes the dissipation varies with the cube of the load amplitude and is linearly proportional to the second derivative of the elastic compliance function for all contact geometries, including those involving surface roughness. It follows that experimental observations of less than cubic dependence on load amplitude cannot be explained by reference to roughness alone, or by any other geometric effect in the contact of half spaces.     

化学跑合剂对跑合效果的影响

在ＢＪ５２Ａ胶合试验机、ＪＰ－ＢＤ１５００型接触疲劳试验机和ＣＬ－１００齿轮试验机上考察了化学跑合剂的作用，并就其机理进行了探讨。结果表明：采用化学跑合剂跑合后，表面粗糙度明显降低；表面接触面积增大，可以实现１次满载快速跑合；与采用含磨料的跑合方法比较，化学跑合剂可以明显提高表面接触精度，减少裂纹源的发生和发展，使表面承载能力明显提高。当齿轮加工精度较低或高速、重载齿轮的硬齿面精加工存在困难时，可     

Effective macroscopic adhesive contact behavior induced by small surface roughness

In this paper we study a model contact problem involving adhesive elastic frictionless contact between rough surfaces. The problem's most notable feature is that it captures the phenomenon of depth-dependent-hysteresis (DDH) (e.g., see Kesari et al., 2010), which refers to the observation of different contact forces during the loading and unloading stages of a contact experiment. We specifically study contact between a rigid axi-symmetric punch and an elastic half-space. The roughness is represented as arbitrary periodic undulations in the punch's radial profile. These undulations induce multiple equilibrium contact regions between the bodies at each indentation-depth. Assuming that the system evolves so as to minimize its potential energy, we show that different equilibrium contact regions are selected during the loading and unloading stages at each indentation-depth, giving rise to DDH. When the period and amplitude of our model's roughness is reduced, we show that the evolution of the contact force and radius with the indentation-depth can be approximated with simpler curves, the effective macroscopic behavior, which we compute. Remarkably, the effective behavior depends solely on the amplitude and period of the model's roughness. The effective behavior is useful for estimating material properties from contact experiments displaying DDH. We show one such example here. Using the effective behavior for a particular roughness model (sinusoidal) we analyze the energy loss during a loading/unloading cycle, finding that roughness can toughen the interface. We also estimate the energy barriers between the different equilibrium contact regions at a fixed indentation-depth, which can be used to assess the importance of ambient energy fluctuations on DDH.     

碱性腐蚀环境下接触载荷对钢丝微动疲劳行为的影响

以矿用钢丝为研究对象,在自制的钢丝微动疲劳试验机上开展钢丝在碱性腐蚀环境下的微动疲劳试验,考察钢丝在应变比为0.8时不同接触载荷下钢丝的微动运行特性,并用光学显微镜和扫描电子显微镜观察钢丝的磨痕和断口形貌,分析其微动磨损和疲劳断裂机理.结果表明:不同接触载荷下钢丝的摩擦系数具有相同的变化趋势,均可以分为4个阶段:跑合期、上升期、下降期和稳定期;4种不同接触载荷下钢丝摩擦副均运行于滑移状态,磨损机制以腐蚀磨损、磨粒磨损、疲劳磨损和塑性变形为主;钢丝疲劳寿命与磨损量成反比,疲劳断口可分为3个区:疲劳源区、扩展区和瞬断区.     

Experimental investigation of frictional noise and surface-roughness characteristics

An experimental investigation into the nature of the noise generated when a stylus travels over a frictional surface has been carried out using several engineering materials. The relation between the sound pressure level (SPL) and surface roughness under various contact loads was established. An acoustic device was designed and constructed to be used as a reliable tool for measuring roughness. For each tested material, it has been found that the filtered noise signal within a certain spectrum bandwidth contains a specified frequency at which the amplitude is maximum. This frequency was named the dominating frequency and was found to be a material constant independent of surface roughness and contact load. It was also found that the dominating frequency for a given material is proportional to the sonic speed in that material.     

AP1000屏蔽厂房在接触爆炸荷载作用下的非线性动力分析

屏蔽厂房是AP1000核岛厂房的第一层外部防线,确保屏蔽厂房在服役期间遭受爆炸冲击荷载作用下的安全性和完整性,十分重要。本文中,采用欧拉-拉格朗日算法(coupled Euler-Lagrange, CEL),对炸药在屏蔽厂房20种不同起爆部位作用下的动态破坏特征进行了研究,以结构贯穿破坏的损伤质量作为损伤程度的判别依据,着重探讨在不同起爆位置作用下结构的压力和损伤演化特性。研究表明:在接触爆炸荷载作用下,厂房在起爆点附近发生局部破坏;在相同高度下,环向不同角度起爆所引起的损伤程度差异较小,不同高度起爆的损伤程度差异较大。通过压力和损伤的演化分析,确定了屏蔽厂房最不利抗爆部位,对厂房不同部位的配筋策略提出建议。结论可为制定屏蔽厂房在爆炸冲击荷载作用下的安全防护措施提供参考依据。     

化学跑合对表面接触疲劳寿命的影响

化学跑合剂加速跑合过程已有一些文献报道，但在化学跑合对表面接触疲劳寿命的影响方面却还未见有关工作公开发表。因此，在总结齿轮跑合技术的基础上，借助于ＪＰ－ＢＤ１５００型接触疲劳试验机，对用化学跑合剂跑合后的试件表面接触疲劳寿命进行了试验研究。并就化学跑合提高表面抗疲劳磨损能力的原因作了考察、分析与探讨，进而提出了试件表面的接触模型，在给定的试验条件下，较软试件表面用化学跑合剂跑合后的接触疲劳寿命比用     

磁电弹复合材料和刚性导电导磁圆柱压头的二维微动接触分析

本文求解平面应变状态下磁电弹复合材料半平面和刚性导电导磁圆柱压头的二维微动接触问题。假设压头具有良好的导电导磁性,且表面电势和磁势是常数。微动接触依赖载荷的加载历史,所以首先求解单独的法向加载问题,然后在法向加载问题的基础上求解循环变化的切向加载问题。整个接触区可以分为内部的中心粘着区和两个外部的滑移区,其中滑移区满足Coulomb摩擦法则。利用Fourier积分变换,磁电弹半平面的微动接触问题将简化为耦合的Cauchy奇异积分方程组,然后数值离散为线性代数方程组,利用迭代法求解未知的粘着/滑移区尺寸、电荷分布、磁感应强度、法向接触压力和切向接触力。数值算例给出了摩擦系数、总电荷和总磁感应强度对各加载阶段的表面接触应力、电位移和磁感应强度的影响。     

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从结构损伤识别的需要出发研究能够准确反映钢构件承载过程中发生的塑性变形 和损伤过程的量化测试方法. 用漫反射法测量了钢构件在变形和损伤过程中表面粗糙度变化 的图像,依据记录下来的表面图像进一步处理得到构件表面粗糙度的平均灰度值的变化,据 此寻找对构件塑性变形和损伤状态相关并且敏感的参数指标. 研究结果表明,基于漫反射法 和图像处理得到的钢构件承载过程中表面粗糙度的平均灰度值的变化可以判断金属试样是否 发生了塑性变形,并可定量描述试样在塑性变形后期的损伤程度.     

基于共轭梯度法和快速傅立叶变换的粗糙表面微动接触数值研究

实际工程表面多为粗糙表面,研究粗糙表面的表面形貌对微动接触中压力和应力的影响具有重要意义。本文研究接触过程中法向载荷保持不变,切向载荷为周期性的交变载荷。首先,建立接触算法和模型,算法核心是利用共轭梯度法CGM(Conjugate gradient method)计算微动接触中的表面压力及切向应力并利用快速傅里叶变换FFT(Fast Fourier transform)加快计算速度。然后,对单峰表面、正弦表面和随机粗糙表面的接触进行数值研究。结果表明,表面幅值对切向载荷-位移曲线以及接触过程中的能量耗散有影响,表面幅值越大,相同切向载荷作用下产生的切向位移越大,能量耗散也越大。     

谐振载荷作用下工程结构振动疲劳寿命预估的损伤力学-有限元法

建立了预估谐振载荷作用下结构振动疲劳寿命的损伤力学-有限元方法。首先根据损伤热力学原理,构建了损伤演化方程,建立光滑试件在恒幅应变交变载荷作用下寿命预估方法;进一步由损伤力学守恒积分原理,得到恒幅重复载荷作用下应力与寿命的关系式;然后根据标准件疲劳试验结果,拟合得到损伤演化方程中的材质参数;最后利用APDL语言编程对ANSYS软件进行了二次开发,借助ANSYS软件对谐振载荷作用下结构振动疲劳裂纹萌生寿命进行预估。作为算例,本文利用该方法预估了LC9CgS1铝合金梁谐振载荷作用下疲劳裂纹萌生寿命。     

A friction contact stiffness model of fractal geometry in forced response analysis of a shrouded blade

To investigate the nonlinear vibration behavior of a shrouded blade with friction dynamic contact interface, a friction contact stiffness model is proposed to describe the friction force at different rough interfaces and different normal loads. In the proposed model, the friction contact interface is discretized to a series of friction contact pairs and each of them can experience stick, slip, or separate states. Fractal geometry is used to simulate the topography of contact surfaces. The contact stiffness is calculated using the Hertz contact theory and fractal geometry, which is related to contact interfaces parameters including normal load, roughness, Young??s modulus, and Poisson??s ratio. The trajectory tracking method is used to predict the friction force and it is not necessary to judge the transition condition among stick, slip, and separate states. It is suitable for complicated periodic motion of the contact interfaces. The forced response of a real shrouded blade is predicted using the proposed model and the multi-harmonic balance method. The effect of surface roughness, initial normal load, and contact area on the forced response of a shrouded blade is studied. It is shown that contact stiffness increases with normal load and fractal dimension. The resonant amplitude is sensitive to the initial normal load and contact surface roughness. The response can be influenced by the contact area, which is an important parameter for blade designers.     

Transition from elastohydrodynamic to mixed lubrication in highly loaded squeeze contacts

We analyze the highly loaded strongly non-stationary squeeze process of an oil film sandwiched between an elastic spherical ball and a rigid rough substrate. We show that the coupling between the elastic properties of the contacting solids, the oil rheology, the surface roughness and the applied load determines a wide range of lubrication conditions from fully elastohydrodynamic to mixed and even boundary lubrication. In particular we find that increasing (decreasing) the surface roughness (the applied normal load) speeds up the squeeze process, anticipates and shrinks the time interval during which the transition to mixed lubrication conditions occurs. On the contrary, the initial separation between the approaching bodies only marginally affects the transition time. We also observe that, in mixed lubrication conditions, the highest asperity-asperity contact pressure occurs in the annular region where the separation between solids takes its minimum value. One then concludes that surface damage and wear should nucleate in the outer region of the contact.     

Thermal stresses and shakedown in wheel/rail contact

Summary  Sliding friction between railway wheels and rails results in considerable contact temperatures and gives rise to severe thermal stresses at the surfaces of the wheels and rails. An approximate analytical solution is presented for a line contact model. The increased bulk temperature of the wheel after a long period of constant operating conditions is also taken into account. The thermal stresses have to be superimposed on the mechanical contact stresses. They reduce the elastic limit of the wheel and rail, and yielding begins at lower mechanical loads. When residual stresses build up during the initial cycles of plastic deformation, the structure can carry higher loads with a purely elastic response in subsequent load cycles. This phenomenon is referred to as shakedown. Due to the distribution of temperature, the rail surface is generally subjected to higher stresses than the wheel surface. This can cause structural changes in the rail material and hence rail damage. Received 7 May 2002; accepted for publication 3 September 2002     

含冲击损伤复合材料层压板压缩破坏机制的声发射特性研究

复合材料层压板在压缩破坏过程中包含了丰富的声发射信息.为了研究含冲击损伤的复合材料层压板的压缩破坏机制,采用声发射观察层压板的压缩破坏过程,通过分析声发射信号的特征规律,表征了在压缩载荷下材料损伤的形式及其演化过程.结果表明:通过对声发射参数(撞击计数、能量、幅值、事件位置)和载荷曲线进行综合分析,发现损伤的发展过程经过了初始阶段、平稳扩展期和断裂阶段,冲击造成的分层区域最先出现屈曲并最早破坏;在损伤初始阶段和平稳扩展期间,损伤是一种渐进式的增长,层压板具有一定的承载能力;在断裂阶段损伤快速扩展,层压板的承载能力迅速下降,在出现纤维密集断裂的现象后整体破坏.     

Delamination of an elastic film from an elastic–plastic substrate during adhesive contact loading and unloading

Adhesive contact between a rigid sphere and an elastic film on an elastic–perfectly plastic substrate was examined in the context of finite element simulation results. Surface adhesion was modeled by nonlinear springs obeying a force-displacement relationship governed by the Lennard–Jones potential. A bilinear cohesive zone law with prescribed cohesive strength and work of adhesion was used to simulate crack initiation and growth at the film/substrate interface. It is shown that the unloading response consists of five sequential stages: elastic recovery, interface damage (crack) initiation, damage evolution (delamination), film elastic bending, and abrupt surface separation (jump-out), with plastic deformation in the substrate occurring only during damage initiation. Substrate plasticity produces partial closure of the cohesive zone upon full unloading (jump-out), residual tensile stresses at the front of the crack tip, and irreversible downward bending of the elastic film. Finite element simulations illustrate the effects of minimum surface separation (i.e., maximum compressive surface force), work of adhesion and cohesive strength of the film/substrate interface, substrate yield strength, and initial crack size on the evolution of the surface force, residual deflection of the elastic film, film-substrate separation (debonding), crack-tip opening displacement, and contact instabilities (jump-in and jump-out) during a full load–unload cycle. The results of this study provide insight into the interdependence of contact instabilities and interfacial damage (cracking) encountered in layered media during adhesive contact loading and unloading.     

Nonlinear Acoustic Interaction of Contact Interfaces

Nonlinear acoustic interactions at contact interfaces can be used to characterize defects or imperfect bonds at these interfaces. Most methods used to characterize nonlinear interactions consider only a portion of the nonlinear signature, such as nonlinearities caused by high-order harmonics or sidebands. We describe a signal processing algorithm that can extract three nonlinear indicators related to amplitude attenuation, phase shift, and harmonics. Two aluminum blocks were mounted together to form a contact interface and subjected to normal compressive loading. Experiments were conducted to investigate the nonlinear interactions between the ultrasonic waves and interfaces, with a focus on the influence of excitation levels, applied pressure, and surface roughness. The ultrasonic signals were then processed using the nonlinear feature extraction algorithm. We show that the nonlinear indicators can characterize the contact condition of interfaces, and that their sensitivities to pressure differ for interfaces of different roughness and over different pressure ranges.     

磨合过程中液体润滑实现超低摩擦的混合模型研究

针对球-盘滑动试验,在磨合过程中获得超低摩擦的液体润滑状态,建立耦合流体润滑、粗糙接触力学、Archard磨损方程和相关物理参数(液体黏度、表面粗糙度和磨损系数)时变函数的混合模型,研究磨合过程中液体润滑的摩擦系数演化.通过数值模拟结果可知：在磨合过程中,润滑介质等效黏度增大,形成流体动压润滑薄膜,有效隔开粗糙表面;其次在磨合过程中,新生成的表面粗糙度降低,减少粗糙峰承载比,实现超低摩擦润滑状态;最后在适当的液体黏度和提高表界面效应减少边界摩擦系数,可进一步实现液体超低摩擦润滑状态.为磨合过程宏观液体润滑性能演化所建立的混合数值模型对提高液体润滑超低摩擦设计效率具有重要价值意义.     

动力损伤后的脆性岩石静力蠕变断裂模型研究

应力波动力扰动下脆性岩石的静力蠕变特性,对深部地下工程围岩变形的评价有重要的实践意义.动力载荷作用导致的局部细观裂纹损伤严重影响脆性岩石蠕变力学行为.基于细观裂纹扩展与应力关系模型、动力扰动损伤演化函数、静动力载荷演化路径函数与黏弹性本构模型,提出一种应力波动力扰动下脆性岩石蠕变断裂特性的宏细观力学模型.其中动力损伤通过控制岩石内部细观裂纹数量变化实现.模型描述了应力波动力扰动下岩石的应变时间演化曲线,解释了岩石动力扰动下蠕变失效特性.研究了不同应力波幅值及周期影响下的脆性岩石应变-时间关系曲线,并通过试验结果验证了模型的合理性.讨论了动力损伤变化形式,突变发生时刻,突变量的大小对岩石蠕变失效特性的影响.分析了应力波幅值、周期对岩石动态动力损伤效应以及蠕变失效特性的影响.主要研究结果:动力损伤的变化值越大,岩石蠕变失效发生时间越短.冲击载荷扰动期间,动力损伤发生的时刻及增加的形式,对动力扰动后的岩石应变及蠕变破坏时间影响很小.动力损伤变化量随应力波幅值增加、周期减小而加速增大.应力波幅值越大、周期越小,岩石发生蠕变失效时间越短.