A High Precision Modeling Technology of Material Surface Microtopography and Its Influence on Interface Mechanical...

Area of Science:

• Materials Science
• Mechanical Engineering
• Computational Mechanics

Background:

• Accurate prediction of mating surface contact performance is essential for material and product design.
• Real surface topography significantly influences contact mechanics.
• Existing models often simplify surface characteristics, limiting predictive accuracy.

Purpose of the Study:

• To develop a numerical simulation method for rough surfaces incorporating real topography.
• To create a multi-scale hierarchical algorithm for calculating contact performance.
• To validate the proposed methods using aeroengine rotor mating surfaces.

Main Methods:

• Surface topography acquisition and characterization using measuring equipment.
• Development of a non-Gaussian surface model using Johnson transform, considering kurtosis and skewness.
• Implementation of a multi-scale hierarchical algorithm for contact performance calculation.
• Simulation of aeroengine rotor mating surfaces with varying topographies.

Main Results:

• The non-Gaussian simulation method effectively captures real surface topography.
• The multi-scale hierarchical algorithm accurately calculates contact performance.
• Significant differences in normal contact stiffness and elastic-plastic contact area were observed between different mating surfaces.
• The method's feasibility was verified through aeroengine rotor simulations.

Conclusions:

• The developed numerical simulation and multi-scale algorithm enable fast and effective calculation of mating surface mechanical properties.
• This approach provides a basis for optimizing surface micro-topography characteristics and enhancing product performance.
• The study highlights the importance of considering non-Gaussian surface features for accurate contact analysis.