A variational approach with embedded roughness for adhesive contact problems

TL;DR

This paper introduces a novel variational finite element method that incorporates surface roughness as a correction to the gap function, enabling accurate and efficient analysis of adhesive contact problems with complex rough profiles.

Contribution

It proposes the MPJR interface finite element that embeds roughness effects without explicit discretization, improving accuracy in contact simulations involving rough surfaces.

Findings

Validated against Hertzian contact problems with high accuracy.

Demonstrated effectiveness in modeling rough surface contact with the Weierstrass-Mandelbrot function.

Shown to be computationally efficient for complex roughness profiles.

Abstract

A new variational formulation is herein proposed for the solution of adhesive contact problems for non-planar profiles of arbitrary shape indenting a deformable half-plane. The method exploits the original idea of accounting for the shape of roughness as a correction to the normal gap function, rather than explicitly discretizing roughness with higher-order numerical interpolation schemes. The resulting interface finite element with eMbedded Profile for Joint Roughness (MPJR interface finite element) is derived and its implementation as a user-defined element is comprehensively described. The method is validated against Hertzian contact problems between a cylinder and a half-plane, also in the presence of adhesion, showing a remarkable accuracy in spite of the low-order interpolation used. The capability and efficiency of the method are subsequently illustrated in relation to the challenging frictionless normal contact problems between deformable substrates and rough profiles analytically described by the Weierstrass-Mandelbrot function. This method opens new perspectives for the solution of contact problems with roughness using the finite element method that, so far, were strongly limited by the issue of providing an accurate representation of roughness.