Evaluation of the reliability of contact characteristic simulation results by the experimental-computational method

The reliability of contact coupling simulation results was evaluated. Deformations were simulated using FEM and non-contact rough surface scanning. Milled aluminium specimens were loaded normally to their base with a flat steel stamp deforming only a few single microasperities. In such cases there is no guarantee that the microasperity shapes used in 3D modelling will correspond to those in the place of stamp action. The density of points describing the shapes is important. A scatter of the values of the parameters describing the contact characteristics can occur depending on the specimen’s area selected for loading with the stamp. Using the experimental-computational method it was determined how much the contact characteristic simulation results can differ from the experimental results. [Display omitted] •3D model for the rough surface contact deformation under normal load analysis.•The surface substitute was designed with reverse engineering.•The model takes into account the rough surface and the subsurface of the sample.•3D model was verified by single asperities perpendicular loading with high precision.•Estimating the reliability of the calculation results of the contact deformation characteristics.