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ABSTRACT
A fast algorithm for elastic-plastic contact simulation is overviewed in this
paper. Betti’s reciprocal theorem is employed to assess surface normal
displacement and stress state in an elastic half-space in the presence of plastic
strains. Resulting equations suggest problem decomposition in an elastic and a
residual part, which cannot be solved independently. While solution of the former is
available from Polonsky and Keer’s algorithm for elastic contact with arbitrarily
shaped geometry, the latter requires assessment of plastic zone. Plastic strain
increment is derived employing a universal algorithm for integration of
elastoplasticity equations. Elastic-plastic contact problem is solved iteratively based
on the reciprocal adjustment between pressure and plastic strain, until convergence
is reached.
plastic contact modeling to assess surface normal plastic strains. As shown in the following section,
displacement and stress state in an elastic half-space knowledge of stress state and of hardening state of the
in the presence of plastic strains. The basis of Betti’s elastic-plastic material allows for computation of
theorem is the equality between the work done by the plastic strain increment, when a new loading
virtual force through the displacements produced by increment is applied leading to further yielding.
the real force and the work done by the real force Again, two independent loads are considered, leading
through the displacements produced by the virtual to two independent states ( u,ε ,σ ) and
force.
According to this formulation, if two ( u∗∗ ,ε ∗∗ ,σ ∗∗ ) , the latter corresponding to a unit load
r
independent loads are applied to an elastic body of applied along the direction of xk , in a point B inside
volume Ω and of boundary Γ , generating two the half-space:
independent states ( u,ε ,σ ) and ( u∗ ,ε ∗ ,σ ∗ ) with ⎧⎪ 0, M ≠ B;
vanishing body forces, and the latter corresponds to a pk∗ ( M ) = ⎨ −1
r ⎪⎩( dx1dx2 dx3 ) , M = B. (4)
unit load applied along the direction of x3 , in a point
A of the boundary (a unit impulse): The following equation yields from the general
form of Betti’s reciprocal theorem:
⎪⎧ 0, M ≠ A;
p3∗ ( M ) = ⎨ −1 (1) uk ( B ) = 2 μ ∫
∗∗
ε ijp ( M )ε kij ( M ,B )d Ω +
⎪⎩( dx1dx2 ) , M = A, Ωp
the following equation holds: (5)
∗∗
∗
( M , p3∗ ( A )) p3 ( M )d Γ +
∫ u3k ( M ,B ) p3 ( M )d Γ.
u3 ( A ) = ∫ u33 ΓC
ΓC
(2) ∗∗ ∗∗
∗ Here, u3k ( M ,B ) and ε kij ( M ,B ) are the
2μ ∫ ε ijp ( M )ε 3ij ( M , p3∗ ( A ))d Ω. r
Ωp displacements along direction of x3 and the ij strain
tensor component respectively, induced at point M in
Here, ΓC is the boundary subdomain with
the half-space by the unit load applied at point B
normal tractions p3 defined, and Ω p the volume r
along the direction of xk . Varying the position of B in
subdomain with existing plastic strains ε p , both Ω and applying superposition principle with respect to
corresponding to state ( u,ε ,σ ) , μ Lamé's constant integration point M, displacements in every point of
the body can be assessed.
and M the integration point. This point is located Eq. (5) suggests that stresses have an “elastic”
within ΓC in the first term of Eq. (2) and within Ω p
part, σ pr , related to contact pressure p3 , which is
∗
in the second. Consequently, u33 ( M , p3∗ ( A )) is the expressed as a surface integral over ΓC , and a
r
displacement in the direction of x3 , and
residual part, σ r , expressed as a volume integral over
∗
ε 3ij ( M , p3∗ ( A )) is the strain tensor induced at point plastic region Ω p . The term “elastic” in the previous
M by the loading described in Eq. (1). Varying the statement can be misleading, as all stresses are elastic,
position of A on Γ and applying the superposition but σ pr denotes the part of stresses that would vanish
principle with respect to integration point M , normal
if an elastic unloading occured. This stresses are
displacement in every point of the boundary can be
related to contact pressure, as opposed to residual
assessed.
The second term in Eq. (2), which is expressed stresses σ r , which are linked to the plastic region
as a volume integral, represents the residual part of Ω p , and would persist after elastic unloading. If
displacement, namely the deflection that would persist M ijk l is the stiffness tensor from Hooke’s law, the
after unloading elastically the considered body:
∗ following equations hold:
u3r ( A ) = 2 μ ∫ ε ijp ( M )ε 3ij ( M , A )d Ω (3)
⎛1 ⎞
Ωp σ ijpr = M ijk l ⎜ ( ukpr,l + ulpr,k )⎟ , (6)
⎝2 ⎠
Knowledge of normal residual displacement
with
allows solving the elastic-plastic contact problem as a
purely elastic problem with modified initial contact ukpr ( B ) = ∫ uk∗∗3 ( M ,B )p3 ( M )d Γ , (7)
geometry. A level of iteration, corresponding to ΓC
solution of elastic contact, is therefore required for the and
mutual adjustment between contact pressure and ⎛1 ⎞
surface normal displacement. σ ijr = M ijk l ⎜ ( ukr ,l + ulr,k ) − ε kpl ⎟ , (8)
Betti’s reciprocal theorem is also applied to ⎝2 ⎠
assess stress state in the half-space, in the presence of with
15
THE ANNALS OF “DUNĂREA DE JOS“ UNIVERSITY OF GALAŢI
FASCICLE VIII, 2010 (XVI), ISSN 1221-4590, Issue 1
TRIBOLOGY
ukr ( B ) = 2 μ ∗∗
ε ijp ( M )ε kij dividing the region of plastic strains Ω p in a set of
∫ ( M ,B )d Ω . (9)
Ωp N cuboids of elementary volume Ωc , having
Resulting equations (2) and (5) suggest elastic- uniform plastic strains in each elementary cuboid.
plastic contact problem split in an “elastic” and a Consequently, the continuous distribution of ε p in
residual part. The elastic part comprises the static force
Ω p is assumed as piece-wise constant and Ω p is
equilibrium, interference equation, and complement-
tarity conditions, while the residual part expresses the substituted by a reunion of elementary cuboids Ω pn .
plastic strain increment and plastic zone contribution to With this formulation, the residual displacement can
surface normal displacement and to stress state in the be expressed as the sum of contributions of all
elastic-plastic body. However, the two subproblems elementary cuboids:
cannot be solved independently, as residual displace- N
∗
ment, computed in the residual part, enters interference u3r ( A ) = 2 μ ∑ ε ijp ( k ) ∫ ε 3ij ( k,A), (10)
equation in the elastic part, while contact stress, k =1 Ωc
assessed in the elastic subproblem, is needed to find the
or, by indexing the cuboids with a set of three
plastic strain increment in the residual part.
integers, and by denoting the cuboid sides with
Analytical resolution of resulting equations is
Δ1 , Δ 2 and Δ 3 , the equation (11) is obtained.
available for neither the elastic, nor the residual part,
as integration domains, namely boundary region with The tensor ε 3∗ , representing strains due to a unit
tractions and plastic strain volume respectively, not concentrated force applied on surface boundary, is
known a priori, are arbitrarily shaped. Therefore, known from Boussinesq fundamental solutions, [14],
numerical approach is preferred. The principle of which represent, in terms of spectral methods, the
numerical approach consists in considering corresponding Green functions. In order to compute
continuous distributions as piece-wise constant on the the influence coefficients, functions dii are defined as
cells of a three-dimensional grid imposed in a volume
∗ ∗ ∗
enveloping integration domains. Continuous primitives of functions 2 με 3ii = μ ( u3i,i + u3i,i ) with
integration in the analytical model of the elastic- r r r
respect to directions of x1 ,x2 and of x3 , and
plastic contact model is replaced by multi-summation
of elementary cells individual contributions, known functions dij , i< j, as primitives of
from the influence coefficients or Green’s functions.
As these multi-summation operations are in fact (
∗
2 μ ε 3ij )
+ ε 3∗ ji = 2 μ ( u3i,
∗ ∗
j + u3 j,i ) with respect to the
convolution and/or correlation products, spectral same directions. The influence coefficients can then
methods are applied to speed up the computation. be computed according to the formulas given in
The numerical model of the elastic part is Appendix.
obtained from that corresponding to a normal elastic Eq. (13) written with respect to indices of
contact problem completed with the residual term, elementary cells takes the following form:
namely the residual displacement, which is u3r ( i, j,0 ) =
superimposed into the interference equation.
Consequently, the elastic subproblem can be treated ∑ p
εζξ ( l ,m,n )Dζξ ( l − i ,m − j,n ) , (11)
as an elastic contact problem with modified initial ( l ,m,n )∈Ω pn
contact geometry. The most efficient solver is based with summation over ζ ,ξ = 1,2,3 , ζ ≤ ξ . If
on the conjugate gradient algorithm advanced by
Polonsky and Keer [12], tweaked with the Discrete expression Dζξ ( i − l , j − m,n ) is used in relation (11)
Convolution Fast Fourier (DCFFT) technique instead of Dζξ ( l − i ,m − j,n ) , namely the point of
advanced by Liu, Wang and Liu [13], for efficient
evaluation of convolutions. integration and the point of observation are
In the same manner, the residual part is interchanged, Eq. (11) takes the following form:
reformulated numerically, by imposing digitized u3r ( i, j,0 ) =
plastic strain distribution and finite load increments.
As the region of plastic strains Ω p can be arbitrarily ∑ Dζξ ( i − l , j − m,n ) ε ζξ
p
( l ,m,n ), (12)
( l ,m,n )∈Ω pn
shaped, the integral in Eq. (3) can only be computed
numerically. The numerical formulation is based on
u3r ( i, j,0 ) = 2 μ ∑
( l ,m,n )∈Ω pn
{εζξ ( l,m,n ) ×
p
which represents a discrete cyclic convolution with complete history of loading. In this level, the load is
r r
respect to directions of x1 and of x2 . Efficient applied in finite increments, starting from an intensity
computation for this product is available through corresponding to elastic domain, until the imposed
DCFFT [13]. value is reached.
An additional reduction of necessary The algorithm for solving one loading step in
computational resources is performed if complex the elastic-plastic normal contact problem is
summarized in Figure 1.
influence coefficients Dij are defined as:
Dij = Dij + i ⋅ Di +1 j , (14)
and complex plastic strains:
ε ijp = ε ijp − i ⋅ ε ip+1 j . (15)
Convolution of terms in Eqs. (14) and (15)
yields:
Dij ⊗ ε ijp = Dij ⊗ ε ijp + Di +1 j ⊗ ε ip+1 j +
(16)
(
i ⋅ Di +1 j ⊗ ε ijp − Dij ⊗ ε ip+1 j )
which returns, on the real part, the contribution of two
members of the tensor, computed in one complex
convolution operation only. The complex part of the
right member in Eq. (16) is discarded. With this
approach, the number of fast Fourier transforms
(FFT) required to assess contribution of two terms of
the plastic strain tensor is reduced considerably: one
direct FFT and one inverse FFT (IFFT), instead of Fig. 1. Elastic - plastic algorithm
four FFTs and two IFFTs needed if the two
contributions had been assessed independently. Firstly, the elastic problem with modified
In the same manner, continuous integral in Eq. contact geometry hi is solved, yielding contact area
(9), assessing residual stresses, is reduced to multi- and pressure distribution p . The latter is used to
summation over a finite set of cuboids of uniform assess elastic displacement field u pr and stress field
plastic strains:
r σ pr . These terms represent the “elastic” part of
σ ξζ ( i, j,k ) = displacement and of stress, namely that part that is
(17) recovered once loading is removed (after contact
∑ Aξζςγ ( i − l , j − m,k − n )εςγp ( l ,m,n ),
opening). The stresses induced by pressure are used,
( l ,m,n )∈Ω pn
together with hardening state parameters, in the
where A is a fourth order tensor whose derivation is residual subproblem, to assess plastic strain increment
detailed in [15]. Residual stresses are computed using
the hybrid convolution-correlation three-dimensional and to update the achieved plastic zone ε p . Residual
spectral algorithm advanced by Spinu and Diaconescu parts of displacement, u r , and of stresses, σ r , can
[15], resulting in a dramatic decrease in then be computed. As opposed to their elastic
computational effort.
counterparts, the terms u r and σ r express a potential
Finally, the algorithm proposed for simulation
state, that would remain after contact unloading, if no
of elastic-plastic contact with isotropic hardening is
plastic flow occurs during load relief. The total
based on three levels of iteration:
1. The innermost level, corresponding to the displacement can then be computed, u pr + u r , thus
residual part, assesses plastic strain increment, based imposing a new interference equation in the elastic
on an algorithm described in detail in the following subproblem. These sequences are looped until
section, and the contribution of plastic zone to stress convergence is reached.
state and surface displacement.
2. The intermediate level adjusts contact 3. PLASTIC STRAIN INCREMENT
pressure and residual displacement in an iterative
approach specific to elastic contact problems with According to general theory of plasticity, plastic
arbitrarily shaped contact geometry. flow occurrence can be described mathematically with
3. The outermost level is related to the fact that, the aid of a yield function, assessing the yield locus in
unlike elastic solids, in which the state of strain the multidimensional space of stress tensor
depends on the achieved state of stress only, components. If von Mises criterion is used to assess
deformation in a plastic body depends on the stress intensity, this function can be expressed as:
THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS“ OF GALAŢI 17
FASCICLE VIII, 2010 (XVI), ISSN 1221-4590, Issue 1
TRIBOLOGY
8. Chen W.W., Wang Q.J., Wang F., Keer L.M., Cao J., 2008, Summation and Conjugate Gradient Techniques, Wear, Vol.
Three-Dimensional Repeated Elasto-Plastic Point Contacts, 231(2), pp. 206–219.
Rolling, and Sliding, J. Tribology (Trans. ASME), vol. 75, pp. 13. Liu S. B., Wang Q., Liu G., 2000, A Versatile Method of
021021-1-12. Discrete Convolution and FFT (DC-FFT) for Contact Analyses,
9. Cretu S. Sp., Benchea M., 2008, An Improved Incremental Wear, Vol. 243 (1–2), pp. 101–111.
Model to Analyse Elastic-Plastic Concentrated Contacts, Proc. of 14. Boussinesq J., 1969, Application des potentiels á l'etude de
16th International Colloquium Tribology, Esslingen, Germany, l'equilibre et du mouvement des solides élastiques, Reed. A.
pp.33 (on CD also). Blanchard, Paris.
10. Benchea M., Cretu S., 2008, An Improved Incremental Model 15. Spinu S., Diaconescu E., 2009, A Fast Numerical Method to
to Analyse Elastic - Plastic Concentrated Contacts – The Finite Predict Elastic Fields Due to Eigenstrains in an Isotropic Half-
Element Analysis and Validation, Acta Tribologica, Vol. 16, ISSN Space - Part I. Algorithm Overview, The Annals of University
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11. Cretu S., Hatmanu V., 1985, A Numerical Analysis of 4590, Issue 2, Tribology, pp. 191-196.
Permanent Deformation in Elastic-Plastic Line Contact, Bul. Inst. 16. El Ghazal H., 1999, Etude des proprietes microstructurales et
Polit. Iasi, XXXI, (1-4), pp. 19-25. mecaniques des aciers 16NiCrMo13 cemente et 32CrMoV13
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Solving Rough Contact Problems Based on the Multi-Level Multi- fatigue de roulement, PhD Thesis, INSA Lyon, France.
APPENDIX
The influence coefficients for the residual part of normal displacement can be computed using the
following relation:
⎛ Δ1 Δ Δ Δ Δ Δ ⎞
⎜ dζξ ( x1 ( i ) + 2 ,x2 ( j ) + 2 ,x3 ( k ) + 3 ) + dζξ ( x1 ( i ) + 1 ,x2 ( j ) − 2 ,x3 ( k ) − 3 )+⎟
⎜ 2 2 2 2 2 ⎟
⎜ Δ1 Δ2 Δ3 Δ1 Δ2 Δ3 ⎟
⎜ dζξ ( x1 ( i ) − 2 ,x2 ( j )+
2
,x3 ( k ) −
2
) + dζξ ( x1 ( i ) −
2
,x2 ( j )−
2
,x3 ( k ) +
2
)− ⎟
Dζξ ( i, j,k ) = ⎜ ⎟ , (34)
⎜ d ( x ( i ) + Δ1 ,x ( Δ2 Δ3 Δ Δ2 Δ3
j )+ ,x3 ( k ) − ) − dζξ ( x1 ( i ) + 1 , x2 ( j )− ,x3 ( k ) + )−⎟
⎜ ζξ 1 2
2
2 2 2 2 2 ⎟
⎜ ⎟
⎜⎜ d ( x ( i ) − Δ1 ,x ( Δ2 Δ3 Δ1 Δ2 Δ3
ζξ 1 2 j )+ ,x3 ( k ) + ) − dζξ ( x1 ( i ) − ,x2 ( j )− ,x3 ( k ) − ) ⎟⎟
⎝ 2 2 2 2 2 2 ⎠
with functions dij as following:
1 ⎛ ⎛ ⎛x x ⎞ ⎛x ⎞⎞ ⎞
d11 ( x1 ,x2 ,x3 ) = ⎜ ( 1 − 2ν )x3 ⎜⎜ tan −1 ⎜ 2 3 ⎟ − tan −1 ⎜ 2 ⎟ ⎟⎟ − 2ν x1 ln( x2 + r ) ⎟⎟ ; (35)
2π ⎜ ⎝ x1r ⎠ ⎝ x1 ⎠⎠
⎝ ⎝ ⎠
d 22 ( x1 ,x2 ,x3 ) = d11 ( x2 ,x1 ,x3 ) . (36)
⎛ ⎛ ⎛x ⎞ ⎞ ⎞
⎜ 2( 1 −ν ) ⎜⎜ x3 tan −1 ⎜ 1 ⎟ + x2 ln( x1 + r ) + x1 ln( x2 + r ) ⎟⎟ + ⎟
1 ⎜ ⎝ ⎝ x3 ⎠ ⎠ ⎟
d33 ( x1 ,x2 ,x3 ) = ⎜ ⎟; (37)
2π ⎜ −1 ⎛ x x ⎞ ⎟
1 2
⎜ +( 2ν − 1 )x3 tan ⎜ x r ⎟ ⎟
⎝ ⎝ 3 ⎠ ⎠
2
d12 ( x1 ,x2 ,x3 ) = ( −2ν r − ( 1 − 2ν )x3 ln ( x3 + r ) ) ; (38)
π
1⎛ −1 ⎛ r ⎞ −1 ⎛ x1 x3 ⎞⎞
d 23 ( x1 ,x2 ,x3 ) = ⎜ x1 tanh ⎜ ⎟ − x2 tan ⎜ ⎟ ⎟⎟ ; (39)
π ⎜⎝ x
⎝ 3⎠ ⎝ x2 r ⎠⎠
d13 ( x1 ,x2 ,x3 ) = d 23 ( x2 ,x1 ,x3 ) . (40)