Modeling of large deformation frictional contact in powder compaction processes

In this paper, the computational aspects of large deformation frictional contact are presented in powder forming processes. The influence of powder–tool friction on the mechanical properties of the final product is investigated in pressing metal powders. A general formulation of continuum model is developed for frictional contact and the computational algorithm is presented for analyzing the phenomena. It is particularly concerned with the numerical modeling of frictional contact between a rigid tool and a deformable material. The finite element approach adopted is characterized by the use of penalty approach in which a plasticity theory of friction is incorporated to simulate sliding resistance at the powder–tool interface. The constitutive relations for friction are derived from a Coulomb friction law. The frictional contact formulation is performed within the framework of large FE deformation in order to predict the non-uniform relative density distribution during large deformation of powder die pressing. A double-surface cap plasticity model is employed together with the nonlinear contact friction behavior in numerical simulation of powder material. Finally, the numerical schemes are examined for efficiency and accuracy in modeling of several powder compaction processes.     

Development of generalized Iwan model to simulate frictional contacts with variable normal loads

Most friction models are originally proposed to predict restoring forces in mechanical contacts with constant normal load. In practice the contact interface kinematics may involve normal motion in addition to the tangential displacements, leading to variation of the contact normal load. This phenomenon is observed most strongly in contacts with high lateral vibration amplitudes and is known as slap. The current study establishes a general friction model to account for variation in the normal load and enables one to predict the behavior of a contact more precisely. Iwan model (1966) [5] is a suitable candidate for contact interface modeling and is able to represent the stick-micro/macro slip behavior involved in a friction contact. This physical based model is employed in the current work and its physical parameters are generalized to include the normal load variation effects. The model is characterized by a slippage distribution density function and a linear stiffness at stick state. Both these parameters, defined in presence of constant normal load in the original model, are derived considering normal load variation leading to generalization of the contact model. Conventional models with constant normal loads produce symmetric contact interface hysteresis loops, but the developed generalized Iwan model is capable of generating asymmetric hysteresis loops similar to those frequently seen in experiments. The generalized contact model is employed to simulate the measured behavior of a beam with frictional support observed in an experimental test set-up. The contact slippage distribution function is first identified in a constant normal load condition. Next in low levels of contact preloads where variation of the normal load is significant, the identified distribution function in generalized form is employed to predict the experimental observations.     

Experimental and theoretical investigation of creep groan of brakes through minimal models

Creep groan of brake systems is a low frequency vibration phenomenon occurring at low speeds which can make passengers feel uncomfortable. This phenomenon is caused by the stick-slip-effect resulting in limit cycle oscillations with frequencies lower than 200 Hz. For the experimental investigation of this problem, an idealized brake test rig is designed concentrating on the investigation of the frictional contact by realizing low damping and small disturbances in the system. Different sensors are utilized in the test rig. Limit cycles and bifurcation effects can be observed in the experimental results. With respect to modeling, a one degree-of-freedom (DOF) model using Coulomb's friction law and a two DOF model using the bristle friction law are considered. In a comparative study of experimental and simulation results, the parameters of both friction laws can be identified from the dynamic experimental results, such as the static and dynamic friction coefficients, contact stiffness and Stribeck velocity. Experimental and theoretical results show a very good concordance. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Viscoplasticity with frictional contact and rapid growth

We consider a problem in the inelastic deformation theory with a quasistatic deformation process of the gradient‐monotone type. We assume that the body has contact with a rigid foundation: the body moves on the foundation with friction. The frictional contact is modelled by a velocity‐dependent dissipation functional. This makes an evolution problem with two nonlinear monotone operators. We consider the gradient‐monotone inelastic constitutive function with a rapid growth at infinity. This leads us to a nonreflexive Orlicz space as an operational base. The frictional dissipation potential brings about a minimalization problem in this nonreflexive Orlicz space. Copyright © 2016 John Wiley & Sons, Ltd.     

Analysis of a general dynamic history-dependent variational–hemivariational inequality

This paper is devoted to the study of a general dynamic variational–hemivariational inequality with history-dependent operators. These operators appear in a convex potential and in a locally Lipschitz superpotential. The existence and uniqueness of a solution to the inequality problem is explored through a result on a class of nonlinear evolutionary abstract inclusions involving a nonmonotone multivalued term described by the Clarke generalized gradient. The result presented in this paper is new and general. It can be applied to study various dynamic contact problems. As an illustrative example, we apply the theory on a dynamic frictional viscoelastic contact problem in which the contact is modeled by a nonmonotone Clarke subdifferential boundary condition and the friction is described by a version of the Coulomb law of dry friction with the friction bound depending on the total slip.     

Finite element simulation for dynamic large elastoplastic deformation in metal powder forming

In this paper, a transient dynamic analysis of the powder compaction process is simulated by a large displacement finite element method based on a total and updated Lagrangian formulation. A combination of the Mohr–Coulomb and elliptical yield cap model, which reflects the stress state and degree of densification, is applied to describe the constitutive model of powder materials. A Coulomb friction law and a plasticity theory of friction in the context of an interface element formulation are employed in the constitutive modelling of the frictional behaviour between the die and powder. Finally, the powder behaviour during the compaction of a plain bush, a rotational flanged and a shaped tip component are analysed numerically. It is shown that the updated Lagrangian formulation, using a combination of the Mohr–Coulomb and elliptical cap model, can be effective in simulating metal powder compaction.     

The calculation of the energy losses in a sliding elastic contact with friction and wear (the plane problem)

The plane problem of the sliding contact of a punch with an elastic foundation when there is friction and wear is considered. Assuming the existence of a steady solution in a moving system of coordinates, relations are derived between the sliding velocity, the wear, the contact stresses and the displacements for an arbitrary dependence of the wear rate on the contact pressure. Taking into account the presence of a deformation component of the friction force, an equation is written for the balance of the mechanical energy for the punch - elastic base system considered. It is shown that the equality of the work of the external force in displacing the punch to the losses due to friction and the change in the shape of the foundation due to wear is satisfied when the work done by the contact stresses on the increments of the boundary displacements is equal to zero, and the frictional losses must be determined taking into account the non-uniformity of the distributions of the shear contact stresses and the sliding velocity in the contact area. Two special cases of the foundation in the form of a wide and narrow strip are considered, for which the total coefficient of friction is calculated, taking into account the deformation component of the friction force.     

T-splines discretizations for large deformation contact problems

A T-spline-based isogeometric analysis is applied to frictional contact problems between deformable bodies in the context of large deformations. The continuum is discretized with cubic T-splines and cubic NURBS (Non-Uniform Rational B-Splines) for comparison purposes. A Gauss-point-to-surface (GPTS) formulation is combined with the penalty method to treat the normal and friction contact constraints in the discretized setting. It is demonstrated that the proposed formulation combined with analysis-suitable T-spline interpolations, is a computationally accurate and efficient technology for local and global solutions of contact problems. T-spline analysis models are generated using commercially available T-spline modeling software without intermediate mesh generation or geometry clean-up steps. (© 2015 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Modeling frictional contact in shell structures using variational inequalities

A new variational inequality-based formulation is presented for the large deformation analysis of frictional contact in shell structures. This formulation is based on a seven-parameter continuum shell model which accounts for the normal stress and strain through the shell thickness and accommodates double-sided shell contact. The kinematic contact conditions are expressed accurately in terms of the physical contacting surfaces of the shell. Furthermore, Lagrange multipliers are used to ensure that the kinematic contact constraints are accurately satisfied and that the solution is free from user-defined parameters. Large deformations and rotations are accounted for by invoking the Piola–Kirchhoff stress and the Green–Lagrange strain measures. Three examples involving a strip friction test, ring contact and sheet compression tests are used to verify the developed formulations and algorithms, and test various aspects of the solution technique. Photoelastic analysis of the ring compression example is performed for experimental verification.     

Electro-mechanical sliding frictional contact of a piezoelectric half-plane under a rigid conducting punch

This paper investigates the two-dimensional sliding frictional contact of a piezoelectric half-plane in the plane strain state under the action of a rigid flat or a triangular punch. It is assumed that the punch is a perfect electrical conductor with a constant electric potential. By using the Fourier integral transform technique and the superposition theorem, the problem is reduced to a pair of coupled Cauchy singular integral equations and then is numerically solved to determine the unknown contact pressure and surface electric charge distribution. The effects of the friction coefficient and electro-mechanical loads on the normal contact stress, normal electric displacement, in-plane stress and in-plane electric displacement are discussed in detail. It is found that the friction coefficient has a significant effect on the electro-mechanical sliding frictional contact behaviors of the piezoelectric materials.     

Analysis of a dynamic contact problem for electro-viscoelastic cylinders

We consider a mathematical model which describes the antiplane shear deformations of a piezoelectric cylinder in frictional contact with a foundation. The process is mechanically dynamic and electrically static, the material behavior is described with a linearly electro-viscoelastic constitutive law, the contact is frictional and the foundation is assumed to be electrically conductive. Both the friction and the electrical conductivity condition on the contact surface are described with subdifferential boundary conditions. We derive a variational formulation of the problem which is of the form of a system coupling a second order hemivariational inequality for the displacement field with a time-dependent hemivariational inequality for the electric potential field. Then we prove the existence of a unique weak solution to the model. The proof is based on abstract results for second order evolutionary inclusions in Banach spaces. Finally, we present concrete examples of friction laws and electrical conductivity conditions for which our result is valid.     

橡皮环大变形接触问题

本文借助于子结构技术解决了大变形橡皮环和弹性薄极具有摩擦的接触问题,研究了摩擦系数、极厚对橡皮环变形的影响。     

The solution of three-dimensional friction contact problems

A variational method is developed for solving friction contact problems, in which the friction obeys Coulomb's of friction law in velocities, and numerical solutions of three-dimensional problems of the contact of a sphere, a cylinder of finite length and a cube with an elastic half-space are constructed. It is established that the maximum frictional forces correspond to a boundary point of the regions of adhesion and slippage. When the number of steps,increase this maximum decreases, and the distribution of the frictional forces becomes smoother. Certain undesirable effects that can arise during numerical implementation of the method – numerical artefacts – are described. These effects can occur in the numerical solution of problems with a different physical content, the mathematical structure of which is similar to the structure of the contact problems investigated, as the artefacts are caused by the presence of unilateral constraints and by the dependence on external effects of the region in which unilateral constraints with an equally sign occur. This problem is solved by an appropriate choice of the load-step zero approximations.     

A dynamic viscoelastic contact problem with normal compliance,finite penetration and nonmonotone slip rate dependent friction

We consider a mathematical model which describes the dynamic evolution of a viscoelastic body in frictional contact with an obstacle. The contact is modelled with normal compliance and unilateral constraint, associated to a rate slip-dependent version of Coulomb’s law of dry friction. In order to approximate the contact conditions, we consider a regularized problem wherein the contact is modelled by a standard normal compliance condition without finite penetrations. For each problem, we derive a variational formulation and an existence result of the weak solution of the regularized problem is obtained. Next, we prove the convergence of the weak solution of the regularized problem to the weak solution of the initial nonregularized problem. Then, we introduce a fully discrete approximation of the variational problem based on a finite element method and on a second order time integration scheme. The solution of the resulting nonsmooth and nonconvex frictional contact problems is presented, based on approximation by a sequence of nonsmooth convex programming problems. Finally, some numerical simulations are provided in order to illustrate both the behaviour of the solution related to the frictional contact conditions and the convergence result.     

Nature and mechanism of friction of rubberlike polymers in different physical states

We have investigated the frictional properties of crosslinked butadiene-nitrile and butadiene-styrene copolymers and natural rubber in friction against polished steel under vacuum conditions in the temperature interval from –200 to +150° C, which embraces the glassy and high-elastic states, as well as the transition region between them. The temperature dependence of polymer friction is characterized by two maxima, a principal and a low-temperature maximum. The principal maximum, observed in the glass transition region, is not associated with the mechanical loss maximum observed in the polymers themselves. The temperature dependence of the force of friction is composed of three parts. In the high-elastic region there is an increase in the force of friction with fall in temperature, in accordance with the molecular-kinetic theory of friction of rubberlike polymers. In this region the nature of friction is associated with mechanical losses in the surface layer of polymer. The mechanical losses inside the polymer itself are unimportant. The deviation from the theoretical curve and the fall in the force of friction below a certain temperature in the transition region are chiefly associated with a decrease in the actual area of contact as the polymer passes into the glassy state. In the glassy region the friction is significantly determined by the mechanical losses in the polymer itself associated with the repeated elastic and forced-elastic deformation of the asperities in the layer of polymer in contact with the rigid surface. Therefore the low-temperature maximum is closely related to the mechanical loss maximum observed in the same temperature region in dynamic tests. Apart from this, the friction maximum is also associated with the increase in the forces of adhesion and the reduction of the actual area of contact at temperatures at which a forced-elastic mechanism of compression of the polymer asperities is not realized.Mekhanika Polimerov, Vol. 3, No. 1, pp. 123–135, 1967     

Painlevé’s paradox and dynamic jamming in simple models of passive dynamic walking

Painlevé’s paradox occurs in the rigid-body dynamics of mechanical systems with frictional contacts at configurations where the instantaneous solution is either indeterminate or inconsistent. Dynamic jamming is a scenario where the solution starts with consistent slippage and then converges in finite time to a configuration of inconsistency, while the contact force grows unbounded. The goal of this paper is to demonstrate that these two phenomena are also relevant to the field of robotic walking, and can occur in two classical theoretical models of passive dynamic walking — the rimless wheel and the compass biped. These models typically assume sticking contact and ignore the possibility of foot slippage, an assumption which requires sufficiently large ground friction. Nevertheless, even for large friction, a perturbation that involves foot slippage can be kinematically enforced due to external forces, vibrations, or loose gravel on the surface. In this work, the rimless wheel and compass biped models are revisited, and it is shown that the periodic solutions under sticking contact can suffer from both Painlevé’s paradox and dynamic jamming when given a perturbation of foot slippage. Thus, avoidance of these phenomena and analysis of orbital stability with respect to perturbations that include slippage are of crucial importance for robotic legged locomotion.     

Boundary optimal control for nonlinear antiplane problems

We consider a nonlinear antiplane problem which models the deformation of an elastic cylindrical body in frictional contact with a rigid foundation. The contact is modelled with Tresca’s law of dry friction in which the friction bound is slip dependent.The aim of this article is to study an optimal control problem which consists of leading the stress tensor as close as possible to a given target, by acting with a control on the boundary of the body. The existence of at least one optimal control is proved. Next we introduce a regularized problem, depending on a small parameter ρ, and we study the convergence of the optimal controls when ρ tends to zero. An optimality condition is delivered for the regularized problem.     

A general FE computer program for 3D incremental analysis of frictional contact problems of elastoplasticity

The paper presents an original computer program PLAST for incremental analysis of 3D geometrically (unknown geometry of contact) and physically (frictional) non-linear contact problems of elasticity (thermoelasticity) or elastoplasticity (thermoelastoplasticity ) with or without strain hardening. Linearized contact problems of elastoplasticity and elasticity can also be analyzed. The program is based on the general algorithm combining different procedures for Coulomb and elasto-Coulombian friction models with or without hardening. All the friction terms for both the models are consistently defined as global (on the level of structure nodes). The program is assigned for large moving or stationary technological structures consisting of two bodies in contact with or without manufacturing or assemblage deviations. The capabilities of the program include strain and stress, stress concentration and contact analyses. The program can cooperate with commercial pre- and postprocessors. Verification of the program is based on calculations of test examples that can be easily checked analytically. Usefulness of the program for technological problems is supported with real turbomachinery blade attachment calculations.     

Resolución numérica de las ecuaciones del movimiento de edificios de varias plantas con no linealidades severas

This paper presents a new algorithm for solving the equations of motion of multi-storey buildings that incorporate frictional energy dissipators as seismic protection. The behavior of the dissipators is represented by Coulomb dry friction models; they introduce severe nonlinearities in the dynamic behavior of the structure every time that the contact conditions (stick or slip) change in the dissipators. These nonlinearities complicate the resolution of the equations of motion as it usually is described by lumped masses models whose degrees of freedom are the displacements of the floors and, as the stick or slip conditions change, the degrees of freedom must be modified: for blocking conditions they are only the displacements of the storeys while under sliding conditions the displacements of the dissipators have to be also considered. In previous articles the accuracy of the proposed algorithm has been verified by comparison with experimental results; as well, the computational efficiency of the algorithm has been confirmed by comparing the required resources (in terms of computation time and of memory allocation) with those of other algorithms. The objectives of this paper are to describe in detail the numerical solution of the equations of motion and present representative examples confirming the ability of the algorithm to reproduce the dynamic behavior of buildings with friction dissipators and reporting preliminarily about the usefulness of such devices to reduce the oscillations of the structure to be protected.