Modeling of Repeated Rolling Contact on Rough Surface: Surface Topographical Change

An finite element analysis (FEA) of a repeated rolling contact over an elastic-plastic deforming rough surface is performed. The surface topographical change is calculated to determine the running-in phase to the steady-state rolling contact situation. A rigid hemisphere is repeatedly rolled over a rough flat aluminum surface and the effect of the contact load and the number of overrollings is studied. It is found that the change in surface topography due to the repeated rolling contact results in smoothening of the rough surface due to the flattening of the highest asperities. The result shows that the running-in of the repeated rolling contact takes place within the first few overrollings.