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International Journal of Solids and Structures 47 (2010) 330–353
Contents lists available at ScienceDirect
International Journal of Solids and Structures
journal homepage: www.elsevier .com/locate / i jsolst r
A 3D FEM–BEM rolling contact formulation for unstructured meshes
L. Rodríguez-Tembleque, R. Abascal *
Escuela Técnica Superior de Ingenieros, Camino de los descubrimientos s/n, 41092 Sevilla, Spain
a r t i c l e i n f o
Article history:Received 20 June 2009Received in revised form 4 September 2009Available online 13 October 2009
Keywords:Rolling contact mechanicsUnstructured meshesBoundary element methodFinite element method
0020-7683/$ - see front matter � 2009 Elsevier Ltd. Adoi:10.1016/j.ijsolstr.2009.10.008
* Corresponding author. Tel.: +34 954 487486; fax:E-mail address: [email protected] (R. Abascal).
a b s t r a c t
This work presents a new formulation for solving 3D steady-state rolling contact problems. The convec-tive terms for computing the tangential slip velocities involved in the rolling problem, are evaluatedusing a new approximation inspired in numerical fluid dynamics techniques for unstructured meshes.Moreover, the elastic influence coefficients of the surface points in contact are approached by meansof the finite element method (FEM) and/or the boundary element method (BEM). The contact problemis based on an Augmented Lagrangian Formulation and the use of projection functions to establish the con-tact restrictions. Finally, the resulting nonlinear equations set is solved using the generalized Newtonmethod with line search (GNMls), presenting some acceleration strategies as: a new and more simplifiedprojection operator, which makes it possible to obtain a quasi-complementarity of the contact variables,reducing the number of contact problem unknowns, and using iterative solvers. The presented method-ology is validated solving some rolling contact problems and analyzed for some unstructured meshexamples.
� 2009 Elsevier Ltd. All rights reserved.
1. Introduction
The necessity of having (analytical and numerical) designingtools for mechanical elements under rotation, such as rotary ma-chine components, bearings and rollers, as well as wheels, rollingpaths for cars or railways, makes the rolling contact problems havean important place in the technical literature relative to mechani-cal engineering and computational mechanics.
The earliest rolling contact problems were related to the rail-way. The pioneering work in this direction was developed by Car-ter (1926) and later by Bentall and Johnson (1967, 1968) andNowell and Hills (1987a,b). Also it has to be mentioned the ap-proaches, formulations and algorithms developed by Kalker(1967, 1971, 1975, 1982, 1986, 1988). Two essential books in roll-ing contact mechanics are: Kalker’s book (Kalker, 1990), where hesummarized all his work, and Johnson’s book (Johnson, 1985),which collects most of the analytical developments in contactand rolling contact mechanic together with his works in rollingcontact.
In the numerical area of rolling contact mechanics, besides theKalker’s contributions, it has to be mentioned the works based onfinite element method (FEM) of Singh and Paul (1974), Batra(1981), Zeid and Padovan (1981), Padovan and Zeid (1984) andBass (1987), as well as Oden and his collaborators in the field thevariational inequalities and FEM, collected in the book of Kikuchiand Oden (1988). Also it has to be cited the works of Panagiotopo-
ll rights reserved.
+34 954 487295.
ulos (1985), Klarbring (1986, 1987, 1993) and Klarbring and Björk-man (1988) in mathematical programming.
More recently it has to be mentioned the works of Hu and Wrig-gers (2002), Nackenhorst (2004) and Ziefle and Nackenhorst(2008), who present an Arbitrary Lagrangian Eulerian (ALE) formu-lation of the problem, and Strömberg (2005), who suggests a for-mulation for contact and impact problems including rolling.
Between the rolling contact works related with the boundaryelement method (BEM), we emphasize the ones of Anderson(1982), París and Garrido (1989), Man et al. (1993a,b), Martínand Aliabadi (1993), González and Abascal (1998, 2000a,b, 2002)and Abascal et al. (2007).
The methodology suggested in this work is based on an Aug-mented Lagrangian Formulation whose precursors are Landersand Taylor (1985), Wriggers et al. (1985), Simo et al. (1985), Alartand Curnier (1991) and Simo and Laursen (1992), and it was ex-tended by Strömberg (1997) and Christensen et al. (1998). Thebooks of Laursen (2002) and Wriggers (2002) compile all this for-mulations together with the main strategies for numerical contactproblems.
The present work proposes a new methodology based on Kal-ker’s Eulerian formulation (Kalker, 1990) for solving 3D frictionalrolling contact problems, using structured or unstructured mesheson the solids interface contact zone. There are some difficultieswhen it has to be evaluated the convective terms which arise fromthe state of strain at the surface. When the contact meshes are reg-ular and the nodes positions are equidistant at the contact surfaces,the derivative associates to the convective terms can be evaluatedusing a finite difference forward technique, like (González and
Fig. 1. Contact pair I of points Pa 2 Xa ða ¼ 1;2Þ.
Fig. 2. Eulerian description for a wheel-road rolling contact problem.
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 331
Abascal, 1998, 2000a,b). In case the solid meshes are unstructured,it is necessary to resort to more complex approximations. The ex-tended Godunov scheme (Godunov, 1959; Hirsch, 1990) or least-squares gradient approximation, in numerical fluid dynamics usingfinite volume method (FVM) on structures and unstructuredmeshes (Blazek, 2001) are redefined in this work for computingthe convective terms in the rolling contact Kalker’s formulation.
A resolution framework for 3D frictional contact problems ispresented in this work, which is valid for both FEM and/or BEM sol-ids modeling, based on the generalized Newton method (GNM)proposed by Pang (1990). The contact problem is formulated bymeans of the Augmented Lagrangian similarly to Alart and Curnier(1991), and imposes the contact restrictions with projection func-tions. The contact operators approximation carried out in this workin the Newton process, allows for a reduction in the number of un-knowns in the contact zone, as well as a simplification in theexpressions of the Jacobian matrices associated to the contactrestrictions, while maintaining a good convergence ratio. Further-more, the line search calculation in the Newton’s method is carriedout by means of direct resolution strategies, such as factorization,and iterative ones, such as generalized minimum residual(GMRES), thus allowing for a CPU time comparative analysis. A ser-ies of numeric examples will be presented to validate the formula-tion and the algorithm proposed.
2. Kinematic equations
2.1. Contact kinematic equations
We are going to consider the contact between two solidsXa ða ¼ 1;2Þ, with boundaries Ca, and defined with respect to aCartesian reference system: xi � fx1; x2; x3g in R3. In order to knowthe relative position between both bodies at all times (s), a gap var-iable is defined for the pair I � fP1; P2g of points ðPa 2 Xa; a ¼ 1;2Þ,as
g ¼ BTðx2 � x1Þ ð1Þ
where xa is the position of Pa at every instant, defined as:xa ¼ Xa þ ua
o þ ua (Xa: global position; uao : rigid body global dis-
placement; ua: elastic displacement expressed in the global sys-tem). Matrix B ¼ t1jt2jn½ �, is a base change matrix expressing thepair I gap in relation to the local orthonormal base ft1; t2;ng associ-ated to every I pair. The unitary vector n is normal to the contactsurfaces with the same direction as the normal to C1 and expressedin the global system. Vectors ft1; t2g are the tangential unitarianvectors (see Fig. 1).
The expression (1) can be written as
g ¼ BTðX2 � X1Þ þ BTðu2o � u1
oÞ þ BTðu2 � u1Þ ð2Þ
being BTðX2 � X1Þ the geometric gap between two solids in the ref-erence configuration ðggÞ, and BTðu2
o � u1oÞ the gap originated due
to the rigid body movements ðgoÞ. Therefore, the gap of the I pair re-mains as follows:
g ¼ ggo þ BTðu2 � u1Þ ð3Þ
where ggo ¼ gg þ go. In this work, the reference configuration foreach solid ðXaÞ that will be considered is the initial configuration(before applying load). Consequently, gg may also be termed initialgeometric gap.
In the expression (3) two components can be identified: thenormal gap gn and the tangential gap or slip, gt ,
gn ¼ ggo;n þ u2n � u1
n gt ¼ ggo;t þ u2t � u1
t ð4Þ
being uan and ua
t the normal and tangential components of the dis-placements ua : ua
t uan
� �T ¼ BT ua.
2.2. Rolling kinematic equations
In a rolling contact problem the solid particles are travelingthrough the contact zone because of the solids rotations. Therefore,the contact of a pair I � fP1; P2g has to consider as kinematic vari-ables the normal gap, gn, and the tangential slip velocity, _gt .
Kalker (1990) formulates the tangential kinematical variable ofthe rolling contact problem from an Eulerian point of view (seeFig. 2). Consequently, it is defined the contact pairs relative tangen-tial slip velocities with respect to a system of reference which trav-els with the contact zone. Thus the tangential slip velocity can beexpressed as
_gt ¼dgt
ds¼ _ggo;t þ ð _u2
t � _u1t Þ ð5Þ
where _ggo;t is the creep or rigid bodies tangential velocities ðvat Þ slip:
_ggo;t ¼ v2t � v1
t ð6Þ
and _uat ða ¼ 1;2Þ is the displacement field ðua
t Þ material derivative:
_uat ¼
ouat
osþ va
t � ruat ð7Þ
332 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
Therefore, the tangential slip velocity can be written as:
_gt ¼ v2t � v1
t þoðu2
t � u1t Þ
osþ v2
t � ru2t � v1
t � ru1t ð8Þ
According to the rolling situation, the expression (8) could besimplified:
� Rolling with partial slip between the two surfaces. In this situa-tion the relative velocities are similar, so ðv2
t ’ v1t Þ. Therefore,
kv2t � v1
t k � kv2t þ v1
t k (being k � k the Euclid’s norm), and theexpression (7) could be approximated as:
_uat ¼
ouat
osþ vt � rua
t ð9Þ
being vt the mean rolling velocity: vt ¼ ðv2t þ v1
t Þ=2, so the tangentialslip velocity (8) can be expressed as:
_gt ¼ v2t � v1
t þoðu2
t � u1t Þ
osþ vt � rðu2
t � u1t Þ ð10Þ
� Rolling with total slip between the two surfaces: In this situationthe relative velocities are not similar, and kv2
t � v1t k � k _u2
t�_u1
t k, so the tangential slip velocity is,
_gt ¼ v2t � v1
t ð11Þ
However, for technical applications the case of partial slip is ofmost importance, so Eq. (10) will be considered in this formulationand it will be written in a compact form as
_gt ¼ cþ Drðu2t � u1
t Þ ð12Þ
In the expression below c is the rigid body tangential slip velocity orcreep:
c ¼ _ggo;t ¼ kvtknt ð13Þ
being nt the non-dimensional creep: nt ¼ ðv2t � v1
t Þ=kvtk. The opera-tor Drð�Þ is defined as:
Drð�Þ ¼oð�Þosþ v t1
oð�Þoxt1
þ v t2
oð�Þoxt2
ð14Þ
and for a steady state rolling contact situation, as:
Drð�Þ ¼ v t1
oð�Þoxt1
þ v t2
oð�Þoxt2
ð15Þ
3. Rolling contact laws
3.1. Unilateral contact law
� No interpenetration of the bodies of domain Xa and boundaryCa ða ¼ 1;2Þ: X1 \X2 ¼£. Therefore, the surface of each bodycan be divided in three regions depending on whether it is incontact Ca
c
� �, with tractions imposed Ca
�t
� �or with displacements
imposed Ca�u
� �, so that: Ca ¼ Ca
c [ Ca�u [ Ca
�t and Cac \ Ca
�u \ Ca�t ¼£,
with a ¼ 1;2. Moreover, it is possible to denote the Contact Zoneas Cc , since: Cc ¼ C1
c ¼ C2c .
� The solids are in contact without cohesion, they can be separated,therefore for each pair I � fP1; P2g 2 Cc : gn P 0 and tn 6 0. Thevariable gn is the pair I normal gap, and tn is the normal contacttraction defined as: tn ¼ BT
nt1 ¼ �BTnt2, where ta is the traction
of point Pa 2 Cac expressed in the global system of reference,
and Bn ¼ ½n� is the third column in the change of base matrix:
B ¼ ½Bt jBn� ¼ ½t1jt2jn�, as defined in Section 2. The normal trac-tions acting upon the pair I points are of the same value andopposite signs, in accordance with Newton’s third law.
� The variables gn and tn are complementary: gntn ¼ 0.
3.2. Friction law
The law of friction is defined for the tangential contact vari-ables: tangential slip velocity, _gt , and tangential traction, tt:tt ¼ BT
t t1 ¼ �BTt t2, where ta is the traction of point Pa 2 Cc ex-
pressed in the global axes, and Bt ¼ ½t1jt2�.Thus, the law of friction for each pair I � fP1; P2g 2 Cc , is ex-
pressed as follows:
� Tangential contact tractions module fulfills the law of friction:kttk 6 ljtnj, being l the friction coefficient, and j � j the absolutevalue.
� The tangential slip velocity and the tangential traction comply withthe maximum energy dissipation principle: _gt ¼ �kttðk P 0Þ,where k is a real positive number.
� There is a complementarity in the variables: tangential slipvelocity module, k _gtk, and ðkttk � ljtnjÞ : k _gtkðkttk � ljtnjÞ ¼ 0.
3.3. Rolling contact laws
To sum up, the unilateral contact condition and the law of frictiondefined for any I pair of points in contact can be compiled as fol-lows, according to their contact status:
Contact-adhesion : tn 6 0; gn ¼ 0; _gt ¼ 0
Contact-Slip :tn 6 0; gn ¼ 0kttk ¼ ljtnj; _gt � tt ¼ �k _gtkkttk
�No contact : tn ¼ 0; gn P 0; tt ¼ 0
ð16Þ
4. Rolling contact constraints
For the rolling contact tractions of any I pair of points in contact,the contact laws (16) define an admissible convex region in R3;Cf ,called Contact Cone or Friction Cone. In order to guarantee that con-tact traction values remain in Cf , and that (16) is fulfilled, a refor-mulation of the restrictions is carried out by means of thefollowing contact operators:
4.1. Normal operator
Unilateral contact constrains can be shortened as
Unðtn; gnÞ ¼ tn � PR� ðtnÞ ¼ 0 ð17Þ
The normal contact operator or normal projection function:PR� ð�Þ : R! R�,
PR� ðxÞ ¼minðx; 0Þ ð18Þ
projects the variable x in R�, the admissible region of the contactnormal tractions. The mixed variable or augmented normal tractiontn is defined as,
tn ¼ tn þ rgn ð19Þ
where the parameter r is a dimensional positive penalizationparameter ðr 2 RþÞ.
4.2. Tangential operator
Similarly to the normal case, the tangential contact restrictionsmay also be summarized as
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 333
Ut tt ; _gtð Þ ¼ tt � PCg ðtt Þ ¼ 0 ð20Þ
The tangential contact operator, or tangential projection function,PCg ð�Þ : R2 ! R2,
PCg ðxÞ ¼x; if kxk < g
get ; if kxkP g
�ð21Þ
(where et ¼ x=kxk is the projection direction) ensures that the valueof the variable x 2 R2 remains within the Coulomb disk, Cg , of ra-dium gðg ¼ jltnjÞ. In the plane tt1 —tt2 , Cg represents the tangentialtractions admissible region for a given normal traction value ðtnÞ.
In this case, the augmented tangential traction is defined as,
tt ¼ tt � r _gt ð22Þ
where the parameter r is a dimensional positive penalizationparameter ðr 2 RþÞ, whose value may differ from that of the aug-mented normal variable (19). The negative sign in (22) is due tothe fact that tt and _gt present opposite directions.
4.3. Normal-tangential operator
The constraints of the combined normal-tangential contactproblem can be formulated as
Uðt; gn; _gtÞ ¼ t� PCfðtÞ ¼ 0 ð23Þ
The contact operator PCfis defined as
PCfðtÞ ¼
PCg tt� �
PR� tn� �( )
ð24Þ
PR� being the normal projection function defined in (18), and PCg atangential projection function similar to (21), where the region Cg
radium is jlPR� ðtnÞj. The Augmented Lagrangian of the contact trac-
tions is: ðtÞT ¼ tt� �T tnh i
.
Eq. (23) compiles the law of unilateral contact and the law offriction, taking the following values depending on the contact sta-tus of the I pair of points:
� ðtnÞI > 0 (No contact): ðtÞI ¼ 0� tn� �
I 6 0 (Contact) and:– kðtt ÞIk < jlPR� tn
� �I
� �j (Adhesion):
_gt
gn
� �I¼ 0
– kðtt ÞIkP jlPR� ððtnÞIÞj (Slip): tt þ ltnxt
gn
� �I
¼ 0
5. Variational formulation
Let us consider the contact between two rolling solids Xa ða ¼1;2Þ. The total virtual work for the problem can be expressed as thesum of the virtual over each solid Xa ðdPa; a ¼ 1;2Þ, plus the inter-face contact virtual work, dPc , so
dPtotal ¼ dP1 þ dP2 þ dPc ð25Þ
The contact virtual work, dPc , can be expressed as
dPcðu1;u2; tc;gÞ ¼Z
Cc
dtc BTðu1 � u2Þ � ggo þ gn o
dC
þZ
Cc
ðdu1 � du2ÞT Btc dC
þZ
Cc
dgT tc � PCfðtcÞ
n odC ð26Þ
being ðtcÞT ¼ ðtt Þ
T tnh i
the augmented contact tractions (19) and(22). The first term in (26), on the right-hand side, is the weak form
of the contact kinematic equation (3), the second one representsthe work of the tractions over each solid’s contact interface,and the third term expresses, in a weak form, the contact con-straints (23).
6. Discrete equations
6.1. FEM equations
To formulate the virtual work of a three-dimensional domain X,this one is divided in a set of elemental sub-domains Xe 2 X, so:X ¼
SNee¼1X
e andTNe
e¼1Xe ¼ Ø, being Ne the number of elements of
X.The total work of the solid can be expressed as
dP ¼XNe
e¼1
dPeðuÞ ð27Þ
where the variation of potential energy of element Xe can bewritten as
dPeðuÞ ¼Z
XedeTrdX�
ZXe
duT bdX�Z
CeduT�tdC ð28Þ
Solid X has null contact boundary conditions on (27), so the contactvirtual work is considered on (26).
Using iso-parametric elements and the classical FEM formula-tion (Zienkiewicz, 1977), the displacement field is approximated,on Xe, using its nodal values ðdeÞ in the following way: u ’ u ¼Nde. N is the shape function approximation matrix, whose dimen-sion is 3 3ne (ne: number of nodes per element).
The strain pseudo-vector approximation can be written as:e ¼ Du ’ Bue, being B the resulting matrix after applying the sym-metric gradient operator, D, to N. The stress pseudo-vector is ob-tained as: r ¼ Ee, where E is the constitutive matrix. Substitutingthese interpolations into (28) produces the variation of the discretefunctional for a finite element
dPeðdeÞ ¼ ðddeÞTfKede � feg ð29Þ
where Ke is the element stiffness matrix and fe is the consistentelement nodal force vector. Considering (27), the total virtual workof the system can be expressed as
dP ¼ ðddÞTfKd� Fg ð30Þ
where K and F are constructed from the assembly of Ke and fe,respectively. Eq. (30) express the virtual work of the solid X.
In contact problems, the nodal displacement vector (d) can be
rearranged as: ðdÞT ¼ ðdqÞTðdcÞTh i
, where dc compiles the displace-
ments of the nodes belonging to Cc , and dq the exterior nodaldisplacements. In the same way, the stiffness matrix (K) is orga-nized in columns: K ¼ KqKc
� �.
6.2. Contact virtual work equations
The contact interface virtual work (26), can be approximateddiscretizing the contact tractions ðtcÞ, the gap (g), the tangentialslip velocity ð _gtÞ, and the solids displacements ðua; a ¼ 1;2Þ, over
the contact interface ðCcÞ. To that end, Cc is divided into Nfe ele-
mental surfaces ðCecÞ, thus: Cc ¼
SNfe
e¼1Cec and
TNfe
e¼1Cec ¼£. These
elements ðCecÞ constitute a contact frame.
Considering the discretization on the contact frame, the contactvirtual work discrete expression can be written as:
334 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
dPc u1; u2; tc; g� �
¼XNf
e
e¼1
ZCe
c
dtTc BT u1 � u2� �
� ggo þ gn o
dC
þXNf
e
e¼1
ZCe
c
ðdu1 � du2ÞT Btc dC
þXNf
e
e¼1
ZCe
c
dgT tc � PCftc� �n o
dC ð31Þ
being ua ða ¼ 1;2Þ the displacement approximation of Xa over Cc; tc
the discrete contact tractions over the frame, and g the discrete gap.The contact tractions are discretized over the contact frame as:
tc ’ tc ¼XNf
i¼1
dPiki ð32Þ
where dPiis the Dirac’s delta on each contact frame node i, and ki is
the Lagrange multiplier on the node ði ¼ 1; . . . ;Nf Þ.The gap (g) is approximated in the same way:
g ’ g ¼XNf
i¼1
dPiki ð33Þ
where ki is the nodal value. The tangential slip velocity approxima-tion will be described in details in the next section: _g ’ st .
The contact is node-to-node, therefore the solids’ interfacemeshes and the contact frame mesh are node coincident, so Eq.(31) can be expressed as:
dPc ¼XNp
I¼1
dkTI BT
I d1I � d2
I � kgoI þ kI
n o
þXNp
I¼1
dd1I � dd2
I
� TBIkI þ
XNp
I¼1
dkTI kI � P kI
� �� �ð34Þ
being I the index for the Np contact pairs in the potential contactzone, BT
I the change of base matrix, dI nodal displacements, kgoI
the geometric gap of solids’ rigid body displacements, kI the I paircontact gap, and kI the contact Lagrange multipliers on the local sys-tem of reference, and kI , the augmented contact traction:kI� �T ¼ kt
� �Tkn
h iI, with
kt ¼ kt � rtst ; kn ¼ kn þ rnkn ð35Þ
To manage the interface discrete variables of each solid ðXaÞand the frame Lagrange multipliers, we introduce the assembling
Boolean operators: Lai and Lf
i . Lai allows to extract the node i
displacement ðdai Þ, from vector da ðda
i ¼Lai daÞ, and Lf
i extractsfrom the multipliers vector (K), the variable associated to node
i ðkiÞ; ðki ¼Lfi KÞ. According to the organization of the displace-
ment vector: ðdaÞT ¼ daq
� Tðda
c ÞT
�, the assembling matrix has the
following distribution: Lai ¼ La
iqLaic
h i.
Defining the matrices:
Ca ¼XNa
i¼1
XNf
j¼1ði;jÞ�I
ðLai Þ
T BjLfj Cg ¼
XNf
i¼1
XNf
j¼1ði;jÞ�I
ðLfi Þ
TLf
j ð36Þ
where Ca has the following structure: ðCaÞT ¼ 0 eCa� T
�, the expres-
sion (34) can be written as:
dPc ¼ ðdKÞT ðC1ÞT d1 � ðC2ÞT d2 � Cgkgo þ Cgkn o
þ dd1� T
C1K� ðdd2ÞT C2K
þ ðdkÞTðCgÞT K� PCfðKÞ
n oð37Þ
being k the nodal gap vector and K the Lagrange multipliers vector.The normal-tangential contact operator, PCf
, is defined for the aug-mented nodal multipliers ðKÞ, and eCa establishes the relation be-tween the contact degrees of freedom relation of each solid Xa
and the Lagrange multipliers. The matrix Cg is equal to the identitymatrix: Cg ¼ I.
7. Slip velocity approximation
Considering a node to node resolution scheme for the contactproblem, the tangential slip velocity equation (12) could be dis-cretized and expressed as:
st ¼ �cþ Drkt ð38Þ
where st is a vector which stores the slip velocity of every contactpair, �c is a vector which stores the creep velocities, kt is a vectorwhich stores the tangential gap (or slip) of every contact pair:
st ¼
ðstÞ1...
ðstÞI...
ðstÞNp
2666666664
3777777775; �c ¼
�c1
..
.
�cI
..
.
�cNp
2666666664
3777777775; kt ¼
ðktÞ1...
ðktÞI...
ðktÞNp
2666666664
3777777775ð39Þ
and finally, Dr is a matrix operator which approximate the convec-tive term in (12), for the steady-state case.
The tangential slip vector ðktÞ is computed as: k ¼ ðC2ÞT d2
�ðC1ÞT d1 þ kgo, compiling the normal and tangential componentsof every I pair:
kI ¼kt
kn
�I
¼d2
t
d2n
" #I
�d1
t
d1n
" #I
þ0
kgo;n
�I
ð40Þ
The convective term in (12) could be approximated, Drkt , usingtwo numerical schemes: Godunov approximation technique or Least-squares technique. The first scheme is based on Godunov methodol-ogy (Godunov, 1959; Hirsch, 1990), and the second scheme, on thedisplacement gradient reconstruction by Least-squares. Both tech-niques are inspired on fluid-dynamic numerical methodologies(see Blazek, 2001) using the finite difference method (FDM) orthe finite volume method (FVM), for structured or unstructuredmeshes (Fig. 3). The formulation presented is valid for any methodused for solid modeling: FEM or BEM, and for lineal or quadraticcontact frame elements.
The control volumes for lineal elements are computed followinga median-dual cell-vertex scheme associated with the grid nodes(see Fig. 4). Median-dual control volumes are formed by connect-ing the elements centroid and edge-midpoints of all elements shar-ing the particular node I. If the contact frame mesh is discretizedusing quadratic elements, they have to be subdivided in triangles,as Fig. 5 shows. Therefore, we have a like linear-triangles mesh,and the median-dual mesh is formed the ‘‘new” elements centroid.
7.1. Godunov approximation
This scheme defines a control cell which surrounds each contactpair I. It is assumed a piece-constant distribution of the tangentialslip velocity, uniform on every control volume or cell (this is equiv-alent a one-point quadrature integration). The perimeter of eachcell or control volume is formed by straight segments, joining theelements centroid with the edge-midpoints of all elements (seeFig. 4), so each frame node is encapsulated by a control cell consti-tuting a dual grid.
The flux of solid particles which cross the contact zone is com-puted on each edge as a function of the tangential slip, to avoid
Fig. 5. Triangular and quadrilateral quadratic elements subdivision.
Fig. 3. Flux of solid particles traveling through an unstructured contact zone mesh.
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 335
having a multi-valued numerical solution on each control cell edge.Therefore, for each cell centered on pair I, the material derivative isapproximated as
ðDrktÞI ¼XNJ
J¼1
ðdrÞIJðktÞJ ¼1XI
XNJ
J¼1
X2
k¼1
fkð1� signðfkÞÞ
2½ðktÞJ � ðktÞI�
ð41Þ
where XI is the area of the control volume, NJ is the number of con-tact pairs J sharing a cell edge with I, and k is the index for the num-ber of common edges between the pairs I and J. The mean flux fk isdefined as:
fk ¼ ðvtÞTk nkLk ð42Þ
being Lk; ðvtÞk and nk: the edge k length, the mean rolling velocity,and the unitary vector normal to the edge k. ðktÞI and ðktÞJ are thetangential slip values of contact pairs I and J, respectively. Eq. (41)considers only the upwind flux using the term: ð1� signðfkÞÞ=2,which is null for the downwind flux, and equal to one, for an up-wind one (see Fig. 6(a)).
7.2. Least-squares approximation
The evaluation of gradients at pair I by the least-squares ap-proach is based upon the use of a first-order Taylor series expan-sion for each element edge that is incident to the pair. The
Fig. 4. Cell-vertex median-dual m
approach of the gradient is obtained as a weighted sum of all thisvalues:
ðDrktÞI ¼XNJ
J¼1
ðdrÞIJðktÞJ ¼XNJ
J¼1
ðvtÞTI wI;J½ðktÞJ � ðktÞI� ð43Þ
where wI;J are the weights for the element edge lIJ defined by thepairs I and J, NJ is the number of element edges that containsI, and ðvtÞI is the mean rolling velocity on I.
The weights wI;J are computed using the least-squares method,obtaining the expressions presented in Blazek’s book (Blazek,2001):
ðwt1ÞI;J ¼ ðDðxt1ÞIJÞ=r211 � r12 r11Dðxt2ÞIJ � r12Dðxt1ÞIJ
� r2
11r222
� ��ðwt2ÞI;J ¼ r11Dðxt2ÞIJ � r12Dðxt1ÞIJ
� r11r2
22
� ��ð44Þ
being Dðxt1ÞIJ and Dðxt2ÞIJ : DðxtÞIJ ¼ ðxtÞJ � ðxtÞI , and the expressionsfor r11; r12 and r22:
r11 ¼XNJ
J¼1
ðDðxt1ÞIJÞ2
!1=2
r12 ¼XNJ
J¼1
Dðxt1ÞIJDðxt2ÞIJ
!,r11
r22 ¼XNJ
J¼1
ðDðxt2ÞIJÞ2 � r2
12
!1=2
ð45Þ
In the expressions above, NJ is the number of upwind J pairs. Thusthe approximation follows an upwind scheme computing the tan-
esh for linear approximation.
Fig. 6. Upwind approximation using: (a) median-dual cell vertex Godunov scheme and (b) least squares.
336 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
gential slip gradient. In Fig. 6(b) we can see that the number upwindJ pairs is three.
7.3. Tangential slip velocity approximation
Eq. (38) can be written in a compact form as:
st ¼ �cþ eDrk ð46Þ
being eDr a square 2Np 3Np matrix, as:
eDr ¼
ðdrÞ11½I 0� � � � ðdrÞ1Np½I 0�
..
. . .. ..
.
ðdrÞNp1½I 0� � � � ðdrÞNpNp½I 0�
266664377775 ð47Þ
where I is a 2 2 unitary matrix, and 0 is a 2 1 null vector. Thecoefficients ðdrÞIJ computed on (41) or (43).
8. FEM–FEM rolling contact equations system
Making null the total potential variation (25), considering (30)and (37), and including Eq. (46) for computing the tangential slipvelocity, the following nonlinear equations set is obtained:
HðzÞ ¼ RðzÞ þ F ¼ 0
RðzÞ ¼
K1 0 C1 0 0
0 K2 �C2 0 0
ðC1ÞT �ðC2ÞT 0 Cg 0
0 0 0 eDr �I
0 0 Pk PgnPst
266666666664
377777777775
d1
d2
K
k
st
8>>>>>>>>><>>>>>>>>>:
9>>>>>>>>>=>>>>>>>>>;
z ¼
d1
d2
K
k
st
8>>>>>>>>><>>>>>>>>>:
9>>>>>>>>>=>>>>>>>>>;F ¼
�F1
�F2
�Cgkgo
�c
0
8>>>>>>>>><>>>>>>>>>:
9>>>>>>>>>=>>>>>>>>>;
ð48Þ
Matrix eDr was defined in (47). Matrices Pk;Pgnand Pst are the non-
linear rolling contact terms, obtained assembling: ðPkÞI; ðPgnÞI
and ðPst ÞI , whose values depend on the rolling contact state of pairI:
Pk ¼XNf
i¼1
Xj¼1
ði;jÞ�INf
Lfi
� TðPkÞIL
fj ;
Pgn¼XNf
i¼1
XNf
j¼1ði;jÞ�I
Lfi
� TðPgnÞIL
fj ;
Pst ¼XNf
i¼1
XNf
j¼1ði;jÞ�I
Lfi
� TðPst ÞIL
fj ð49Þ
� No-contact: ðk Þ P 0
n IðPkÞI ¼
1 0 0
0 1 0
0 0 1
26643775
I
; ðPgnÞI ¼
0 0 0
0 0 0
0 0 0
26643775
I
; ðPst ÞI ¼
0 0 0
0 0 0
0 0 0
26643775
I
ð50Þ
� Contact-adhesion: kn� �
I < 0 and kt� �
I
< l kn� �
I
�� ��
ðPkÞI ¼
0 0 0
0 0 0
0 0 0
26643775
I
; ðPgnÞI ¼
0 0 0
0 0 0
0 0 �rn
26643775
I
; ðPst ÞI ¼
rt 0 0
0 rt 0
0 0 0
26643775
I
ð51Þ
� Contact-slip: kn� �
I < 0 and kt� �
I
P l kn� �
I
�� ��
ðPkÞI ¼
1 0 lxt1
0 1 lxt2
0 0 0
26643775
I
; ðPgnÞI ¼
0 0 0
0 0 0
0 0 �rn
26643775
I
;
ðPst ÞI ¼
0 0 0
0 0 0
0 0 0
26643775
I
ð52Þ
being ðxtÞI ¼ kt� �
I
�kt� �
I
.
9. BEM–BEM rolling contact equations system
9.1. BEM equations
The BEM formulation for elastic continua X with boundary C iswell known and can be found in many classical texts such as Breb-bia and Domínguez (1992).
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 337
For a boundary point ðP 2 CÞ, the Somigliana identity can bewritten as:
CuðPÞ þ CPVZ
CtudC
� �¼Z
XubdXþ
ZC
utdC ð53Þ
where u, t and b are, respectively, the displacements, the boundary
tractions and the body forces of X. u ¼ uijðP;QÞn o
is the funda-
mental solution tensor for displacement, and t ¼ tijðP;QÞn o
for
tractions. Both are solution of Navier’s equation at point Q inthe ith direction due to a unit load applied at point P in the jthdirection. The matrix C is equal to 1
2 I for a smooth boundaryC, and CPVfIg is called the Cauchy Principal Value of the inte-gral I.
Dividing the boundary C, into Ne elements, Ce 2 C, so:C ¼
SNee¼1C
e andTNe
e¼1Ce ¼ Ø, the integral equation (53) can be
written as follows:
CuðPÞ þXNe
e¼1
ZCe
tudC� �
¼XNe
e¼1
ZCe
utdC� �
ð54Þ
in case of absence of body loads (b=0).The fields u and t are approximated over each element Ce using
shape functions, as a function of the nodal values ðde and peÞ:u ’ u ¼ Nde and t ’ t ¼ Npe, being N the shape function approxi-mation matrix.
After the discretization, Eq. (54) can be written as
Ciui þXN
j¼1
Hei de ¼
XN
j¼1
Gei pe ð55Þ
being Hei ¼
RCe tNdC; Ge
i ¼R
Ce uNdC, the integrals over the ele-ment e when the collocation point is the node i. Finally, the contri-bution for all i nodes can be written together in matrix form to givethe global system of equations,
Hd ¼ Gp ð56Þ
where d and p are the displacements and tractions nodal vectors,respectively. Matrices G and H are constructed collecting the termsof matrices He
i and Gei .
Assuming that the displacement or the traction is known oneach node and direction, the boundary conditions can be imposedrearranging the columns in H and G, and passing all the unknownsto vector x on the left-hand side. This gives the final system ofequations:
Ax ¼ F ð57Þ
9.2. BEM–BEM formulation
In case of modeling the solids Xa ða ¼ 1;2Þ using the BEM (57),matrix Aa is organized for contact problems as: Aa ¼½Aa
xAap � Aa
x ¼ AaqAa
c
h i� , being Aa
p the columns of Aa which affect
the nodal contact tractions, Aac the columns which affect the con-
tact nodes displacements, and Aaq the columns which affect the
exterior nodes unknowns. Therefore, the terms of (48) for aBEM–BEM formulation are:
RðzÞ ¼
A1x 0 A1
peC1 0 0
0 A2x �A2
pfPC2 0 0
ðC1ÞT �ðC2ÞT 0 Cg 0
0 0 0 eDr I
0 0 Pk PgnPst
266666666666664
377777777777775
x1
x2
K
k
st
8>>>>>>>>>>>><>>>>>>>>>>>>:
9>>>>>>>>>>>>=>>>>>>>>>>>>;
z ¼
x1
x2
K
k
st
8>>>>>>>>>>>><>>>>>>>>>>>>:
9>>>>>>>>>>>>=>>>>>>>>>>>>;F ¼
�F1
�F2
�Cgkgo
�c
0
8>>>>>>>>>>>><>>>>>>>>>>>>:
9>>>>>>>>>>>>=>>>>>>>>>>>>;
ð58Þ
being vector K the nodal contact tractions, so that: p1c ¼ eC1K
and p2c ¼ �eC2K.
10. FEM–BEM rolling contact equations system
Contact problems simulation using different numericalmethods (FEM and BEM) for solids modeling has to consider theFEM–BEM coupling techniques. These methodologies follow twostrategies which were started by the works (Zienkiewicz et al.,1977; Brebbia and Georgiou, 1979). The FE variables are: displace-ments and forces, and BE variables are: displacements andtractions. Because of that it is necessary for one of the formula-tions to make it compatible with the other one. In this sense,the work of Zienkiewicz et al. (1977) formulate the problemconsidering the BE region as a FE region. On the other hand,Brebbia and Georgiou (1979) formulate the FE region as a BEone.
Following the second strategy, if solid X1 is modeled using theFEM, the term of dPc corresponding to the tractions virtual workis computed as:
XNfe
e¼1
ZCe
c
ðdu1ÞT Btc dC ¼XNf
e
e¼1
XN1c
i¼1
XNf
j¼1
dd1i
� TZ
Cec
NiNj dC
( )BT
j kj ð59Þ
where the index e represents the frame elements, i the contactnodes of X1, and j the contact frame nodes. Ni and Nj are the shapefunctions associated to these nodes.
Eq. (59) can be written as
XNfe
e¼1
ZCe
c
ðdu1ÞT Btc dC ¼ ðdd1ÞT M1K ð60Þ
defining:
d1 ¼XN1
i¼1
L1i
� �Td1
i K ¼XNf
i¼1
Lfi
� Tki
M1 ¼XN1
i¼1
XNf
j¼1
ðL1i Þ
T MijBjLfj Mij ¼
ZCe
c
NiNj dC
ð61Þ
Therefore, considering (48) and (62), in case of modeling one solidby the FEM and the other one by the BEM, we have:
338 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
RðzÞ ¼
K1 0 M1 0 00 A2
x �A2peC2 0 0
ðC1ÞT �ðC2ÞT 0 Cg 0
0 0 0 eDr I0 0 Pk Pgn
Pst
266666664
377777775
d1
x2
K
kst
8>>>>>><>>>>>>:
9>>>>>>=>>>>>>;
z ¼
d1
x2
K
kst
8>>>>>><>>>>>>:
9>>>>>>=>>>>>>;F ¼
�F1
�F2
�Cgkgo
�c0
8>>>>>><>>>>>>:
9>>>>>>=>>>>>>;
ð62Þ
11. Solution procedure
The non-liner equations set (48) is going to be solved using thegeneralized Newton method with line search (GNMls).
11.1. Generalized Newton method
The GNMls is an effective extension of the Newton’s method forB-differentiable functions proposed by Pang (1990). This methodis based on the computation of the non-linear directional deriva-tive of the objective function.
Fig. 7. (a) Two rings rolling. (b) Meshes details. (c) Nondi
The application of the GNMls to solve the non-linear system,HðzÞ ¼ 0, being HðzÞ a B-differentiable function, can be summa-rized in the following steps:
(I) Let zð0Þ be an arbitrary initial vector, and let q; b; r and e bepositive scalars: q > 0; b 2 ð0;1Þ; r 2 ð0;1=2Þ; and e > 0.
(II) Given zðnÞ with H zðnÞ� �
–0, the direction DzðnÞ is obtainedsolving:� � � �
mension
H zðnÞ þBH zðnÞ;DzðnÞ ¼ 0 ð63Þ
where BH zðnÞ;DzðnÞ� �
is the function B-derivative.ðnÞ
(III) Let aðnÞ ¼ bm q, mðnÞ be obtained as the first non-negativeinteger so: W zðnÞ þ aðnÞDzðnÞ
� �6 1� 2raðnÞ� �
W zðnÞ� �
, beingW zðnÞ� �
¼ 12 kH zðnÞ
� �k2 an error function, whose minimum is
zðnÞ þ aðnÞDzðnÞ� �
.(IV) Set the new solution vector: zðnþ1Þ ¼ zðnÞ þ aðnÞDzðnÞ.(V) Finish if W zðnþ1Þ� �
6 e1; otherwise return to (II) and iterateuntil convergence is reached.
The main difficulty is to compute BH zðnÞ;DzðnÞ� �
. The system ofequations H zðnÞ
� �is divided in two parts:
H zðnÞ� �
¼ HLD zðnÞ� �
þHNLD zðnÞ� �
ð64Þ
where HNLDðzÞ is the part whose directional derivative is non-linearin some points, and HLDðzÞ is the rest, having directional derivativeat all its points. Thus, the B-derivative can be expressed as:
al rolling contact magnitudes on x ¼ 0 plane.
Fig. 8. (a) Rolling contact tractions surfaces. (b) Tangential slip velocity vectors, st , (top panel) and tangential traction vectors, kt , over the normal contact pressure, kn , contour(bottom panel).
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 339
BH zðnÞ;DzðnÞ� �
¼ rHLD zðnÞ� �
þ oHNLD zðnÞ� �� �
DzðnÞ ð65Þ
being rHLD zðnÞ� �
the linear part of the Jacobian matrix, andoHNLD zðnÞ
� �is the non-linear one:
rHLD zðnÞ� �
¼
K1 0 M1 0 00 A2
x �A2peC2 0 0
ðC1ÞT �ðC2ÞT 0 Cg 0
0 0 0 eDr �I0 0 0 0 0
266666664
377777775 ð66Þ
and
oHNLD zðnÞ� �
¼
0 0 0 0 00 0 0 0 00 0 0 0 00 0 0 0 00 0 Jk Jgn
Jst
26666664
37777775
ðnÞ
ð67Þ
The matrices JðnÞk ; JðnÞgnand JðnÞst
are constructed from the assembly of
the matrices: JðnÞk
� I; JðnÞgn
� I
and JðnÞst
� I, which are associated to each
I pair, like (49). The value of these matrices depends on the I pair
augmented contact variable KðnÞn
� �I ¼ KðnÞn
� �I þ rn kðnÞn
� I
and�
KðnÞt
� I¼ KðnÞt
� I� rt sðnÞt
� IÞ states:
– No-contact: KðnÞn
� �I P 0
JðnÞk
� I¼
1 0 0
0 1 0
0 0 1
2666437775
I
; JðnÞgn
� I¼
0 0 0
0 0 0
0 0 0
2666437775
I
; JðnÞst
� I¼
0 0 0
0 0 0
0 0 0
2666437775
I
ð68Þ
– Contact-adhesion: KðnÞn
� �I < 0 and KðnÞt
� I
< l KðnÞn
� �I
�� ��
JðnÞk
� I¼
0 0 0
0 0 0
0 0 0
2666437775
I
; JðnÞgn
� I¼
0 0 0
0 0 0
0 0 �rn
2666437775
I
; JðnÞst
� I¼
rt 0 0
0 rt 0
0 0 0
2666437775
I
ð69Þ
– Contact-slip: KðnÞn
� �I < 0 and KðnÞt
� I
P l KðnÞn
� �I
�� ��
340 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
Jkð ÞðnÞI ¼
W11 W12 lxt1
W21 W22 lxt2
0 0 0
264375ðnÞ
I
; JðnÞgn
� I¼
0 0 00 0 00 0 �rn
264375
I
;
JðnÞst
� I¼�rt
eW11 �rteW12 0
�rteW21 �rt
eW22 00 0 0
264375ðnÞ
I
ð70Þ
being W ¼ ð1þ aÞI� bR, eW ¼ W� I, xðnÞt ¼ KðnÞt
� I
.KðnÞt
� I
,
R ¼ KðnÞt
� I� KðnÞt
� I, a ¼ l KðnÞn
� �I
�KðnÞt
� I
, and
b ¼ l KðnÞn
� �I
�KðnÞt
� 3.
11.2. Computing DzðnÞ direction
To compute the direction DzðnÞ, the system of linear equations(SLEs) (63) has to be solved. For this purpose, three different meth-ods are going to be used in this work: direct resolution by factoriza-tion, iterative resolution by means of GMRES (Saad and Shultz,1986), and iterative resolution using GMRES with adaptative error(Kelley, 1995).
The GMRES iterative process finishes when:
BH zðnÞ;DzðnÞ� �
�H zðnÞ� � 6 g2 H zðnÞ
� � ð71Þ
being g2 the tolerance of the process.
Fig. 9. (a) Wheel rolling over a half-space. (b) FE and BE Meshes. (c) BE mesh
Usually, the value of g2 is constant and proportional to the New-ton’s tolerance. Kelley (1995) suggests choosing an appropriate tol-erance according to the problem we are solving. If g2 is too small,too much computational effort can be spent during the startingNewton iterations, because each step is solved to a precision far be-yond what is needed to correct the non-linear iteration. To avoidover-solving of the SLE, an appropriate tolerance is used for eachiteration n gðnÞ2
� , as a function of the ‘‘proximity” between zðnÞ
and the solution.A measurement of the proximity to the real solution, is:
gðnÞ1 ¼ cH zðnÞ� � 2
Hðzðn�1ÞÞk k2 ð72Þ
where c 2 ð0;1�. Thus, Kelley (1995) suggests the following criteriafor g2:
gðnÞ2 ¼g2;max n ¼ 0
min g2;max;gðnÞ1
� n > 0
8<: ð73Þ
being g2;max a limit superior of gðnÞ2 . For practical reasons, we canconsider gðn�1Þ
1 , consequently (73) is expressed as:
gðnÞ2 ¼g2;max n ¼ 0
min g2;max;gðn�1Þ1
� n > 0
8<: ð74Þ
details. (d) Nondimensional rolling contact magnitudes on x ¼ 0 plane.
Fig. 10. (a) Rolling contact tractions surfaces. (b) Tangential slip velocity vectors, st , (top panel) and tangential traction vectors, kt , over the normal contact pressure, kn ,contour (bottom panel).
Table 1Meshes data.
Mesh type Number of nodes Number of elements
Linear quadrilateral elements 673 640Quadratic quadrilateral elements 1985 640Linear triangular elements 703 1340Quadratic triangular elements 2745 1340
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 341
In case zðnÞ were far from the solution and gðnÞ2 were too small during
some consecutive iterations, gðnÞ2 cannot be allowed to reduce its va-
lue, thus: gðnÞ2 ¼min g2;max;max gðn�1Þ1 ; c gðn�1Þ
2
� 2� �� �
.
Therefore, (74) is written:
– gðnÞ2 ¼ g2;max if n ¼ 0,
– gðnÞ2 ¼min g2;max;gðn�1Þ1
� if n > 0 and c gðn�1Þ
2
� 26 0:1,
– gðnÞ2 ¼minðg2;maxÞ;max gðn�1Þ1 ; c gðn�1Þ
2
� 2� �
if
n > 0 and cðgðn�1Þ2 Þ2 P 0:1, with c ¼ 0:1.
The choice of adaptative error for GMRES resolution allows toreduce the CPU times (CPUT) in contact problems resolution.
11.3. Projection function
The main computational effort on the Newton’s Method is dueto the SLE resolution (63), in obtaining the direction DzðnÞ
� �for
every iteration (n). One strategy for effort decreasing is to reduce
the number of equations and unknowns. Applying the contactoperators (18) and (21), it is possible to know the value ofsome variables ðzcÞ at instant ðnþ 1Þ. Therefore, for the I pair incontact:
� If KðnÞn
� �I > 0) Kðnþ1Þ
n
� �I ¼ 0 and Kðnþ1Þ
t
� I¼ 0.
� If KðnÞn
� �I 6 0) kðnþ1Þ
n
� I¼ 0 and:
– If KðnÞt
� I
< �l KðnÞn
� �I ) kðnþ1Þ
t
� I¼ 0.
– If KðnÞt
� I
P �l KðnÞn
� �I ) Kðnþ1Þ
t
� I¼ �l Kðnþ1Þ
n
� �I eðnþ1Þ
t
� I,
being eðnþ1Þt ¼ x
ðnþ1Þt
� .
Fig. 11. (a) Rolling sphere over a rigid flat. (b) Halfspace triangular mesh details. (c) Halfspace quadrilateral mesh details. (d) Nondimensional rolling contact magnitudes onx ¼ 0 plane.
342 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
In most cases the value is null, thus we can say that a quasi-com-plementarity exists between the contact variables. This fact can beapplied to reduce the size of the equations system, decreasing thenumber of rolling contact unknowns, and consequently accelerat-ing the GNMls.
To approximate the direction et , we can observe the contactprojection function behavior (21) during the Newton iteration.Expanding the tangential component of this operator in Taylor
series, in the contact-slip case, KðnÞt
� I
P �l KðnÞn
� �I ,
PCg Kðnþ1Þt
� I
� ¼ PCg KðnÞt
� I
� þ
oPCg
ozc
�ðnÞI
DzðnÞc
� �I þ � � � ð75Þ
being g ¼ l KðnÞn
� �I
�� ��,PCg Kðnþ1Þ
t
� I
� ¼ �l Kðnþ1Þ
n
� �I x
ðnÞt
� I� l
KðnÞn
� �I
KðnÞt
� I
�xt2
xt1
� �ðnÞI
�xt2xt1f gðnÞI DKðnÞt
� Iþ � � � ð76Þ
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 343
Taking into account that the second term on the right-hand sidegoes to zero when zðnÞ is converging, the projection function canbe expressed as:
PCg Kðnþ1Þt
� I
� ¼ �l Kðnþ1Þ
n
� �I x
ðnÞt
� I
ð77Þ
Consequently, the direction et for the tangential operator at instantðnþ 1Þ is equal to the previous one,
eðnþ1Þt
� I¼ x
ðnÞt
� I
ð78Þ
Fig. 12. (a) Rolling contact tractions distribution. (b) Tangential slip velocity vectors, s(bottom panel).
This fact allows us to know a half of the rolling contact unknowns inthe step ðnþ 1Þ.
11.4. Matrices for the n-iteration
The system (63) can be expressed for the n-iteration as,
H zðnÞ� �
¼ RðnÞzðnÞ � F ¼ 0 ð79Þ
being
t . (c) Tangential traction vectors, kt , over the normal contact pressure, kn , contour
Fig. 13. Comparison between the results obtained using Godunov upwind approach (left) and least-squares upwind approach (right) for the rolling contact tractions: (a) kx , (b)ky , and (c) kn .
344 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
RðnÞ ¼R1 R2 Rk Rg 0
0 0 0 eDr �I0 0 PðnÞk PðnÞgn
PðnÞst
264375
zðnÞ ¼
d1
x2
Kkst
8>>>>><>>>>>:
9>>>>>=>>>>>;
ðnÞ
F ¼F�c0
8><>:9>=>;
ð80Þ
The matrices R1; R2; Rk and Rg , and vector F are defined for theFEM–BEM rolling contact formulation:
R1 ¼K1
0ðC1ÞT
264375; R2 ¼
0A2
x
�ðC2ÞT
264375; Rk ¼
M1
�A2peC2
0
264375;
Rg ¼00Cg
264375; F ¼
F1
F2
Cgkgo
264375 ð81Þ
Fig. 14. Comparison between the results obtained using Godunov upwind approach (left) and least-squares upwind approach (right) for the rolling contact kinematic variables:(a) sx , (b) sy , and (c) kn .
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 345
The matrices PðnÞk ; PðnÞgnand PðnÞst
are constructed from the assembling
of the I pair matrices PðnÞk
� I; PðnÞgn
� I
and PðnÞst
� I, respectively, as in
(49). Due to the approximation (77), the expressions (68)–(70) for
the contact-slip situation KðnÞn
� �I < 0 and KðnÞt
� I
P ljðKnÞIj�
are:
PðnÞk
� I¼
1 0 let1
0 1 let2
0 0 0
24 35I
; PðnÞg
� I¼
0 0 00 0 00 0 �rn
24 35I
;
PðnÞst
� I¼
0 0 00 0 00 0 0
24 35I
ð82Þ
con ðetÞI ¼ xðn�1Þt
� I.
346 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
11.5. B-derivative expression
The rolling contact restrictions are linearized, considering thedirection ðetÞI is constant for every step. Therefore, the Jacobianmatrices are:
JðnÞk ¼ PðnÞk JðnÞgn¼ PðnÞgn
JðnÞst¼ PðnÞst
ð83Þ
and the expression for the B-derivative:
BH zðnÞ;DzðnÞ� �
’ RðnÞDzðnÞ ð84Þ
11.6. Initial solution
The initial solution assumes that all points have zero tractions:Kð0Þ ¼ 0. Using the rigid body motions, ko, the gap variable kð0Þ isobtained, as well as other unknowns, zð0Þ.
11.7. Solution for the next step
The direction DzðnÞ is computed solving Eq. (63):
RðnÞ zðnÞ þ DzðnÞ� �
¼ F ð85Þ
Each iteration computes a tentative solution, ~zðnþ1Þ ~zðnþ1Þ ¼ zðnÞ�
þDzðnÞÞ, instead of direction DzðnÞ, solving:
RðnÞ~zðnþ1Þ ¼ F ð86Þ
Fig. 15. Tangential slip velocity component sy obtained on different meshes: (a) linearelements, and (d) quadratic triangular elements.
The variable ~zðnþ1Þ is the next step solution for aðkÞ ¼ 1. The solution~zðnþ1Þ will be obtained from the scale parameter aðnÞ as:
zðnþ1Þ ¼ aðnÞ~zðnþ1Þ þ 1� aðnÞ� �
zðnÞ ð87Þ
11.8. SLE size reduction
Being Ndofa ða ¼ 1;2Þ the number of degrees of freedom of solidXa and Ndofc the number of contact pairs degrees of freedomðNdofc ¼ 3NpÞ, the number of system (85) unknowns is:Ndof1 þ Ndof2 þ 8Ndofc=3. Some of the contact unknowns are nullsor known, thus, the number of variables is: Ndof1 þ Ndof2 þ Ndofc.Therefore, the SLE to solve in every iteration is:
R1 R2 RðnÞy
h i ~d1
~x2
~y
8><>:9>=>;ðnþ1Þ
¼ �FðnÞ ð88Þ
where matrix RðnÞy is constructed with the columns of matrices:Rk and Rg , depending on the contact situation. Vector �FðnÞ is com-puted as:
�FðnÞ ¼ F�X
I pair incontact-adhesion
ðRgtÞI ~kðnþ1Þ
t
� I
ð89Þ
being ~kðkþ1Þt
� I
the tangential vector estimated for I pair. The col-
umns of RðnÞy are defined according to the contact status on step (n):
quadrilateral elements, (b) quadratic quadrilateral elements, (c) linear triangular
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 347
– If KðnÞn
� �I P 0: the column of RðnÞy corresponding to the I pair nor-
mal component, RðnÞyn
� I, is equal to ðRgn
ÞI , and the tangential
components, RðnÞyt
� I, to ðRgt
ÞI . Consequently, the I pair rolling
contact unknowns are: ~yðnþ1Þ� �I ¼
~kðnþ1Þ�
I. The values of the
other variables are: ~Kðnþ1Þ� �I ¼ 0 and ~sðnþ1Þ
t
� I¼ �cð ÞI
þP
J~dr
� IJðkðkÞt ÞJ , being ~dIJ the matrix eDr coefficients relative to
pair J which compute the convective terms for I pair.
– If KðnÞn
� �I < 0 and KðnÞt
� I
< �l KðnÞn
� �I : RðnÞyn
� I¼ ðRkn ÞI and
RðnÞyt
� I¼ ðRkt ÞI . In this case the I pair rolling contact unknowns
are: ~yðnþ1Þ� �I ¼ ~Kðnþ1Þ� �
I . The tangential slip, ~kðnþ1Þ�
I, is com-
puted knowing that ~stð ÞI ¼ 0, from any of the followingapproximations:
Fig. 16. (a) CPU times spent by different methods for solving the SLE in the Newton algormethods for solving the SLE for different linear quadrilateral meshes.
– Jacobi approximation:
~kðnþ1Þt
� I¼ � 1
~d�
II
0B@1CA �cð ÞI þ
XJ–I
~dr
� IJ
kðnÞt
� J
!ð90Þ
– Pseudo-temporal approximation:
~kðnþ1Þt
� I¼ kðnÞt
� I� ðDtÞ �cð ÞI þ
XJ
~dr
� IJ
kðnÞt
� J
!ð91Þ
– Extrapolation:
~kðnþ1Þt
� I¼ ð1� hÞ kðnÞt
� I
� h1
~dr
� II
0B@1CA �cð ÞI þ
XJ
~dr
� IJ
kðnÞt
� J
!ð92Þ
ithm, for the same mesh. (b) CPU times relative to LU factorization spent by different
Fig. 17. Wheel rolling over a railway.
348 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
The Pseudo-temporal approximation and the Extrapolationapproximation are variations of Jacobi approximation, trying toaccelerate the problem resolution, choosing appropriate valuesfor parameters: Dt and hðh > 1Þ, respectively. Their values areadjusted by trial-error on each problem. In our case, we have used:Dt ¼ 0:15 and h ¼ 1:2. Choosing a low value for Dt and close to 1for h, we have tested no convergence problems.
– Finally, if KðnÞn
� �I < 0 and KðnÞt
� I
P �l KðnÞn
� �I : RðnÞyn
� I¼
ðRkn ÞI � lðRkt ÞI eðnÞt
� I
h i, and RðnÞyt
� I¼ ðRgt
ÞI . Therefore, the I pair
rolling contact unknowns are: ~yðnþ1Þn
� I¼ ~Kðnþ1Þ
n
� I
and
~yðnþ1Þt
� I¼ ~kðnþ1Þ
t
� I. The values of the other variables are:
eKðnþ1Þt
� I¼l eKðnþ1Þ
n
� IðetÞðnÞI and ~sðnþ1Þ
t
� I¼ �cð ÞIþ
PJ
~dr
� IJ
kðnÞt
� J.
12. Numerical examples
This section presents some numerical examples that enable usto validate the methodology presented, as well as the algorithmof resolution and the approximation techniques for the materialderivative.
12.1. Example 1: two rings rolling
The first example under study is the rolling contact between twotwin rings of radii: R1 ¼ 25 mm and R2 ¼ 50 mm, and L ¼ 8 mm, asFig. 7(a) shows. The resultant loads are: jFt j=ljFnj ¼ 0:6271 (being
jFnj ¼ 1233:85 N and the coefficient of friction: l ¼ 0:1), the meanangular velocity x ¼ 0:2 s�1, and the material properties are: E1 ¼E2 ¼ 104 MPa and m1 ¼ m2 ¼ 0:3 (rolling contact similar problem).
The two rings are modeled using a boundary element mesh of1474 nodes and 1472 quadrilateral elements (see Fig. 7(b)). Thepotential contact zone is discretized by 12 12 elements. Thisproblem has been solved using both methodologies for materialderivative computing (Godunov scheme and least-squares scheme),obtaining the same results in both cases.
Fig. 7(b) shows the nondimensional rolling contact variables onx ¼ 0. The characteristic magnitudes are the two infinite cylindersHertz maximum normal pressure, po;Hertz ¼ 103:87 MPa, and contactzone width, a ¼ 0:9453 mm. The normal gap and the tangential slipvelocity are non-dimensionalized by their maximum values on thecontact zone: maxðknÞ ¼ 0:0156 mm and maxðstÞ ¼ 0:0428 mm=s,respectively.
Fig. 8(a) presents the traction components distribution, andFig. 8(b) the tangential slip velocity vectors (top panel), and tan-gential traction vectors over the normal contact pressure contour(bottom panel). We can see in Fig. 8 how the tangential contactrestriction is fulfilled.
12.2. Example 2: ring rolling over an elastic halfspace
The next example is the rolling contact of a wheel over an elastichalf-space. The wheel dimensions are: R1 ¼ 25 mm; R2 ¼ 50 mmand L ¼ 8 mm, as Fig. 9(a) shows.
The wheel is discretized by means of a 2016 hexaedrical finiteelement mesh, and the elastic half-space is discretized with 288
Fig. 18. (a) Boundary element mesh. (b) Mesh details. (c) Quadrilateral boundary element mesh on potential contact zone.
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 349
quadrilateral boundary elements, with 12 12 elements in the po-tential contact zone (see details in Fig. 9(b) and (c)).
The material properties are: E1 ¼ 104 MPa; E2 ¼ 106 MPa, andm1 ¼ m2 ¼ 0:3. The resultant applied loads are: jFt j=ljFnj ¼ 0:5373,being jFnj ¼ 1345; N and the coefficient of friction: l ¼ 0:1. Theangular velocity is equal to: x ¼ 0:2 s�1.
This problem has been solved using Godunov scheme and least-squares scheme, obtaining the same results in both cases. Fig. 9(b)shows the nondimensional rolling contact variables on x ¼ 0. Inthis case, the characteristic magnitudes are the infinite cylinderover a flat Hertz maximum normal pressure, po;Hertz ¼ 107:9 MPa,and contact zone width, a ¼ 0:99 mm. The normal gap and thetangential slip velocity are nondimensionalized by their maximumvalues on the contact zone: maxðknÞ ¼ 0:0086 mm and maxðstÞ ¼0:0139 mm=s, respectively.
Fig. 10(a) presents the traction components distribution, andFig. 10(b) the tangential slip velocity vectors (top panel), and tan-gential traction vectors over the normal contact pressure contour(bottom panel). We can see maximum energy dissipation principlerestriction fulfilment in Fig. 8.
12.3. Unstructured meshes and CPU times
Two aspects will be dealt with below. The first one pertains thebehavior that the suggested formulations show when differentkinds of elements are used on the contact interfaces: quadrilateraland triangular (linear or quadratic), and different kind of meshes
(structured and unstructured) are considered. Secondly, the focuswill be placed on the CPU times used to solved the problem bythe GNMls with the resolution of the linear system of equations(LSEs) by means of: LU factorization, GMRES iterative resolution,and GMRES resolution with adaptative error. To that end, the follow-ing examples will be solved and commented on:
12.3.1. Example 3: sphere rolling over a rigid planeThis example presents the rolling contact problem of a sphere of
radii R1 ¼ 50 mm, over e rigid flat (see Fig. 11(a)). The resultant ap-plied loads are: jFt j=ljFnj ¼ 0:75, being jFnj ¼ 298:6 N and the coef-ficient of friction: l ¼ 0:1. The angular velocity is x ¼ 0:2 s�1, andthe material properties are: E ¼ 104 MPa and m ¼ 0:3.
The problem is solved using the two methodologies presentedfor material derivative approximation (Godunov scheme and least-squares scheme), different kind of elements and meshes, and differ-ent kind of SLE resolution techniques and acceleration techniques.
The sphere is modeled as an elastic halfspace, using a quadrilat-eral and triangular (linear and quadratic) boundary elements mesh(see Fig. 11(b) and (c)). The meshes details are presented on Table 1.
Fig. 11(d) shows the nondimensional rolling contact variableson x ¼ 0. In this case, the characteristic magnitudes are the sphereover a flat Hertz maximum friction less normal pressure,po;Hertz ¼ 140.
The rolling contact tractions distributions are presented inFig. 12(a), and the tangential slip velocity vectors and the tangen-tial tractions vectors in Fig. 12(b) and (c), respectively.
Fig. 19. Rolling contact variables distribution on Cc: (a) sx , (b) kx , (c) sy , (d) ky , (e) kn , and (f) kn.
350 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
Figs. 13 and 14 compares the rolling contact traction vari-ables and the rolling contact kinematic variables, respectively,obtained using the Godunov scheme (left) and Least-squarescheme (right), on an unstructured triangular elements mesh.Both methodologies provide very similar results, even thoughthe Least-square scheme keeps better the symmetries of theresults.
The comparison between the different kind of meshes (struc-tured and unstructured) is presented in Fig. 15, where the tangen-tial slip velocity component, sy, is presented. As Figure shows, theresults presents a high agreement for the linear and quadraticcases, even using different elements density.
Finally, the CPU studies are presented. Fig. 16(a) compares theCPU times spent on problem resolution, using different method
Fig. 21. (a) Error function evolution for the GNMls, using different methods for SLE resolution. (b) CPU times spent by different methods for solving the SLE in the Newtonalgorithm.
Fig. 20. (a) Tangential slip velocity vectors. (b) Tangential traction vectors.
L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353 351
solving the SLE and different slip estimation strategies: Pseudo-temporal, Jacobi and Extrapolation, for the same linear quadrilateralmesh. The CPU times are very similar for the slip estimation strat-egies, but not between the SLE resolution methods. Using an itera-tive GMRES with adaptative error, an important CPU timereduction is obtained. This fact is even more important when themesh density increases the number of degrees of freedom(Fig. 16(b)).
12.3.2. Example 4: wheel rolling over a railwayThe last example presents a wheel rolling over a rail (see
Fig. 17). The wheel is subjected to a rigid body displacement:kzo ¼ 0:015 mm (equivalent to jFzj ¼ 457 N), and jFt j=ljFnj ¼ 0:57,being the coefficient of friction: l ¼ 0:1. The angular velocity is:x ¼ 0:1 s�1. The material that the wheel is made of is characterizedby the values of the elastic constants: E1 ¼ 104 MPa and m1 ¼ 0:3.The rail, in turn, consists of a material whose E2 � E1. Conse-quently, the rail will be taken as infinitely rigid.
Fig. 18(a) shows the region of the wheel discretized using linearquadrilateral boundary elements. The mesh has 1954 nodes and1952 elements. In Fig. 18(b) and (c) it is possible to see the meshdetails next to the potential contact zone of dimensions: A B(A = 5.49 mm and B = 7 mm).
Fig. 19(a) and (b), (c) and (d) and (e) and (f) presents, respec-tively: sx—kx; sy—ky and kn—kn. Fig. 20(a) shows the tangential slipvelocity vectors, and Fig. 20(b) the tangential traction ones.
Finally, Fig. 21(a) presents the error function evolution onthe MNGbd for different methods of SLE resolution, andFig. 21(b) shows the total CPU time comparison. We cansee how the number of Newton iterations is very similar forthis three SLE methods, but the total CPU resolution timespent using GMRES or GMRES with adaptative error is less thana half.
13. Conclusions
This work presents a new formulation for solving 3D rollingcontact problems valid for Finite Elements and/or BoundaryElements techniques. Furthermore, an algorithm of resolutionbased on Generalized Newton Method is presented for solvingthe resulting nonlinear rolling contact equations set.
The rolling contact problem is formulated from an Eulerianpoint of view, presenting two different methodologies for comput-ing the material derivative. Those methodologies are based on fluiddynamic techniques, allowing to model structured and unstruc-tured interface meshes.
352 L. Rodríguez-Tembleque, R. Abascal / International Journal of Solids and Structures 47 (2010) 330–353
The restrictions are defined by projection function acting overthe augmented rolling contact tractions, presenting in this worka new projection function which provides a quasi-complementar-ity on the contact variables. This fact, allows to know one of therolling contact complementarity variables during the iterativeNewton’s process, so the number of contact unknowns have beenreduced.
Some validation examples have been solved using differentmeshes, showing a very good accuracy achieved for different kindof 3D rolling contact problems, different kind of elements, andstructured and unstructured meshes.
In conclusion, the proposed methodology is a new and versatilenumerical tool that allows to solve rolling contact problems usingthe FEM and/or the BEM for solids modeling.
Acknowledgements
This work was co-funded by the DGICYT of Ministerio de Cien-cia y Tecnología, Spain, research Project DPI2006-04598, and bythe Consegería de Innovación Ciencia y Empresa de la Junta deAndalucía, Spain, research Projects P05-TEP-00882 and P09-TEP-03804.
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