Plastic deformation in rough surface line contacts—a finite element study

The paper describes an elastic–plastic finite element (EPFE) analysis of line contact between a cylinder and rigid plane using commercial software. The range of loading demonstrates the transition from purely elastic to fully plastic contact behaviour, revealing the residual deformations and stress fields upon unloading. A multiple contact configuration was analysed in the form of sinusoidal roughness. Results obtained under elastic conditions were validated by comparison with theoretical solutions. This model was extended by replacing the sinusoidal surface with a real roughness profile. Modelling multiple contacts indicates the influence of adjacent surface “asperities” on contact pressure and residual stress distributions. ► FE contact analysis shows good agreement with Hertz and Westergaard elastic theory. ► Zones liable to cracks identified from residual stresses in cylinder/plane contact. ► Multiple contact analysis shows importance of interaction between adjacent contacts. ► Residual stresses relevant to understanding of rough surface fatigue performance.