Engineering Analysis with Boundary Elements 30 (2006) 426434 www.elsevier.

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Efcient stress evaluation of stationary viscoelastic rolling contact problems using the boundary element method: Application to viscoelastic coatings
Jose A. Gonzalez *, Ramon Abascal
Escuela Tecnica Superior de Ingenieros de Sevilla, Avda. de los Descubrimientos s/n, 41092 Seville, Spain Received 12 September 2005; accepted 12 January 2006 Available online 17 April 2006

Abstract The present work is a contribution towards the development of a new and novel technique to evaluate the contact stresses between linearviscoelastic cylinders under stationary rolling contact loading. A two-dimensional numerical model is considered using a reference system xed to the contact zone and including the effects of Coulomb friction between the rolling cylinders. The contact stresses are determined by solving a nonlinear system of equations coming from the combination of the discretized boundary element viscoelastic equations and the fulllment of the contact conditions, expressed using projection functions. The results obtained for viscoelastic rollers are compared with those from other authors for different rolling velocities, showing good agreement and consistency. Finally, some results for viscoelastic coatings are presented and commented. q 2006 Elsevier Ltd. All rights reserved.
Keywords: Boundary element method; Rolling contact; Viscoelasticity; Coating

1. Introduction Over the past years, a variety of new and novel coating materials have been designed and developed with the purpose of conveying the multifunctional qualities of low friction and low wear to various engineering components and devices under rolling contact. Many of these materials are based on polymers with a strong viscoelastic character that can considerably affect the contact stresses. A deep knowledge of the contact phenomena, usually obtained by the combination of experiments and numerical simulations, is needed for a better understanding of small-scale local wear/fracture initiation near the contact surface, in order to improve mechanical designs by reducing energy losses or surface damage. From a numerical point of view, the rolling contact problem has been traditionally treated using a combination of the inuence coefcients for the elastic half-space with contact iterative algorithms that iteratively solve the normal and tangential contact conditions, see for example, the texts by Johnson [14] and Kalker [15], but applications for more
* Corresponding author. Tel.: C34 954 487321; fax: C34 954 467370. E-mail address: japerez@us.es (J.A. Gonzalez).

0955-7997/$ - see front matter q 2006 Elsevier Ltd. All rights reserved. doi:10.1016/j.enganabound.2006.01.006

complex situations using this technique are limited to the availability of analytical or semi-analytical inuence coefcients. However, extensions of these classical rolling contact formulations were done by Wang and Knothe [24] for the viscoelastic half-space case and by Kalker [16], that formulated theoretically the problem for multilayered viscoelastic cylinders using complex transformations to calculate the inuence coefcients. Considering viscoelastic materials, analytical approaches to the problem of a moving rigid punch on the surface of a viscoelastic half-space without friction are rst obtained by Golden [7] and for the rolling contact case by Hunter [13] and by Morland [19,20]. Afterwards, other works proposed to eliminate the halfspace assumption using numerical methods. The nite element method (FEM) approaches to the problem began with the pioneering works of Lynch [18] and Batra [3] where a nite element model for the plane strain problem of a rubber cylinder rolling on a rigid roll using nite deformation theory and unilateral contact was developed. Texts by Kikuchi and Oden [17] introduced the appropriate variational principles and established the basis for modern works using the FEM, like the ones by Padovan [22,21] and Hu and Wriggers [12]. For the case of a rigid cylinder rolling on a viscoelastic halfspace, Gotoh [11] obtained numerical results using the FEM and compared them with experiments, also considering the temperature effect on the stresses.

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On the other hand, the boundary element method (BEM) is a well-established numerical technique in many engineering applications, specially for situations of severe stress or strain gradients like contact problems, where only the surface of the solids have to be discretized. Although, there are many works related with applications of the BEM to the contact problem, little work has been published regarding to rolling contact. We can cite, related to the elastic rolling contact case, the contribution of Akama [1] proposing a BEM formulation to simulate the fracture initiation near the contact surface and previous works by the authors [8,9]. When solving rolling contact problems using the BEM, rst an appropriate fundamental solution is needed, that is, the solution for a transient load inside an innite space with the same constitutive law than the solids. A viscoelastic fundamental solution for steadily moving loads was proposed by the authors in [10] that allows the treatment of stationary viscoelastic rolling contact problems using the BEM. The aim of this work is to present a new computational technique based on the BEM to solve viscoelastic rolling contact problems in a general and effective way, more than to study real practical applications or particular congurations related with rolling contact. A complete formulation to solve stationary rolling contact problems with linear-viscoelastic rollers is developed, based on the BEM and without considering the inertial effects. The contact stresses are accurately calculated solving a non-linear system of equations obtained by the combination of the discretized viscoelastic equations and the fulllment of the contact conditions, expressed using projection functions. Finally, the proposed formulation is tested solving rst some example problems that can be compared with solutions from other authors. Next, some new cases are presented to demonstrate the efciency and accuracy of the formulation. They are related to rolling cylinders covered with viscoelastic coatings, obtaining contact stresses, creepages and resistant torques for different congurations and rolling velocities. 2. The viscoelastic rolling contact problem Let us consider two viscoelastic cylinders A and B, see Fig. 1, in contact due to the action of external loads P, Q and
P
u A , pA n n u A, t pA t

Fig. 2. Mechanical model for the linear viscoelastic standard linear solid constitutive law.

rotating with constant angular velocity around their parallel axes. In order to study the problem, an Eulerian approach is adopted introducing a reference system (x, y) that is moving with the contact zone (the speed of this reference system is equal to the rolling velocity) and describing the problem using this new system. There is an equivalent view to this approach, that is to consider the reference system stopped and the material owing with the rolling speed but in opposite direction. The rolling contact phenomena is essentially time dependent [9] but steady state conditions are reached after a short transient period if externally applied loads are constant in time and a reference system like the one described above is used. Under this assumption, the contact tractions pn, pt, will remain constant at the interface and can be expressed using an orthonormal base system xed to the contact zone that is oriented on its normal and tangential directions. The constitutive law used for the solids is a linear viscoelastic standard linear model with three mechanical elements, or Boltzmann model (Fig. 2), that presents a stressstrain relationship given by the stressstrain relation & ' (1)

h EE _ st C st Z 0 1 E0 C E1 E0 C E1

h _ 3t C 3t E1

Q V
A

RA M

Tractive Rigid Roller

p n(x )

uB , p B n n u B, p B t t

where E0, E1, are the instantaneous and delayed stiffness, h the viscoelastic damping and the dot indicates time derivative. With the assumption of small deformations and displacements, a node to node contact approximation is used combined with the Coulomb frictional law with dry friction. Under this last assumption, couples (or pairs) of contacting points belonging to each one of the cylinders A and B can present any one of the three following states: separation, adhesion or slip.

VB M Q

RB P

p t(x) 2a

3. Eulerian viscoelastic BEM formulation The boundary integral representation of displacements for a viscoelastic solid with boundary G can be expressed, relative to a reference system that is moving with a constant velocity v

Driven Layered Roller

Fig. 1. Rolling with a layered cylinder and tractions inside the contact area.

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(see [10] for details), in the following form cij yuj y;t 8 t 9 < = v uj x;tTij;t y;x C vtKt;tKtdt dGx C : ;
G K N

8 t < Z
G

K N

9 = v pj x;tUij;t y;x C vtKt;tKtdt dGx ;

tangential direction. The tribological model used in this work is the Coulomb frictional law, a common engineering approximation where normal and tangential tractions are coupled by the normal pressure. Under the assumption of small deformations and displacements, a node to node contact formulation is used imposing the contact conditions for each contact pair with the projection functions described in this section. (2) 4.1. Normal direction: unilateral contact law In the normal direction, the contact problem is governed by the non-penetration condition. This kinematic condition imposes that the gap between the contacting surfaces must remain always positive (then we say there is a separation situation) or zero (corresponding to a contact situation). The gap variable possesses a complementarity relation with its counterpart, the surface normal traction pn; where there is a separation (dnO0) the normal traction is zero (pnZ0) and only when there is a contact (dnZ0) we can have a reaction (pn%0). This behavior can be mathematically expressed by the complementarity condition pn dn Z 0; pn % 0; dn R 0 (6)

integral equation that must be solved in order to compute the boundary displacements uj and tractions pj at time t. If the boundary conditions were applied on the solid a long time ago, are now moving with constant velocity and have remained constant during the time interval (KN, t), the system when represented using an Eulerian description will reach to a steady state regime dropping the time variable from the eld unknowns, i.e. uj (x;t)Zuj (x), and pj (x;t)Zpj (x). Imposing these conditions in (2), a steady state viscoelastic formulation with constant boundary conditions is obtained v;s v;s cij yuj y C uj xTij y;xdGx Z pj xUij y;xdGx
G G

(3) where with FZU, T are the steady-state viscoelastic fundamental solution tensors, dened as Fv;s y;x ij
N

Fv;s ij

composed by two inequalities. If we dene the augmented normal variable pn(r) as pn r Z pn C rdn (7)

Z
K N

Fv y;x C vtKt;tKtdt ij;t

(4) with rO0 a penalty parameter, then Eq. (6) can be reduced to only one equation given by pn Z min0;pn r (8)

and where Fv is the static viscoelastic fundamental solution ij tensor that depends on the particular constitutive model. We use a closed expression of the steady-state fundamental solution tensor (4) derived in [10] for the particular case of a standard linear viscoelastic model that can be expressed in the following form
v;s Uij y;x

p  qKp Z U e y;x C 2 q ij q V0

N 0

 ij U e y;x C xeKx=qV0 dx

(5)

expression that guaranties by itself the fulllment of unilateral contact conditions. However, the price we have to pay for using this simple expression is that Eq. (8) is not a strictly differentiable function, because there is one point where only the directional derivative can be computed; exactly in the frontier between contact and separation. 4.2. Tangential direction: coulomb friction law with dry friction The tangential relative motion of the contact surfaces is governed by the frictional behavior, this behavior imposes that when there is contact between two boundary particles, their relative slip velocity will be zero (stZ0) traveling together in stick condition if their tangential stresses do not reach a friction limit g. If that friction limit is reached, the tangential stress will remain constant (jptjZg) during a relative slip in the same direction of the surfaces relative motion. The Coulomb friction law establishes that if we dene the closed and centred interval Ig h K g;g of size g 2RC, the

v;s  ij Tij y;x Z T e y;x

 ij  ij with pZh/(E0CE1), qZh/E1 and where U e , T e are the elastostatic fundamental solution tensors calculated with   material properties EZ E0 E1 =E0 C E1 and nZ n. An efcient method to calculate the innite integral of (5) is also proposed in the same reference.

4. Enforcement of the contact conditions The behavior of the contact interface is governed by the non-penetration condition in the normal direction to the contact zone and the frictional tribological law in the

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tangential conditions can be written ( 0 ifj pt j! g pt 2Ig and st Z apt with a% 0 ifj pt j Z g

This denition allows us to express the contact conditions with the nal expression (9) p Z Pzpr (15) with pZ pn ;pt T . The utility of the cone projection operator (14) is represented in Fig. 3; the contact conditions will be satised when a projection of the augmented traction vector on the friction cone returns the contact tractions back. 5. Discrete BEM equations (11) 5.1. Rolling variables The contact conditions expressed by (6) and (9) are functions of the kinematic variables normal distance and relative slip velocity, however, the boundary integral viscoelastic Eq. (3) is expressed as a function of the normal and tangential boundary displacements. Obtaining the relation between those different kinematic variables is the objective of this section. The gap or normal distance between two contacting particles, dn, is given by dn Z dno KuA C uB n n (16)

with a%0 to make sure that the frictional work is dissipative. Previous conditions can also be reduced to the fullment of only one equation; to do that, we dene the Coulomb interval projection function PIg in the following way PIg x Z xKmax0;xKgKmin0;x C g and introduce the augmented tangential variable pt r Z pt Krst (10)

so conditions (9) can be expressed projecting this augmented tangential variable on the centred interval of radius g, i.e. pt Z PIg pt r (12)

obtaining again a strictly non-differentiable function at the stick-slip frontier but with computable directional derivatives at that point. 4.3. Coupled contact conditions The complete fullment of contact conditions comes from union of Eqs. (8) and (12), coupled by the fact that the friction limit is a function of the normal traction; in the particular case of the Coulomb friction law gZmpn where m is the friction coefcient. To consider that the normal traction pn can only be negative, we make gZm min [0, pn (r)] and dene the cone projection operator Pz$:R2 / R2 : applied to the augmented traction vector ! pn C rdn pr Z (13) pt Krst in the following way " # min0;pn r Pzpr Z PIm min0;pn r pt r

where dno is the initial separation between the contact points and uA;B are the viscoelastic normal displacements in the n boundary of solid A or B. In the other hand, the relative slip velocity for a couple of particles owing through the contact zone, Fig. 4, can be computed by differentiation of the tangential displacements [15], obtaining an expression composed by a rigid body velocity term, a convective term and a time derivative part given by St Z V A KV B C V A uA C V B uB C uA C uB t;x t;x t;t t;t
a

(17)

(14)

where V are the rigid body speeds of solids A and B in the A;B x-direction at the contact zone and ut;x are the viscoelastic tangential displacement derivatives on that direction. When the steady-state regime arrives, the time variations disappear and Eq. (17) can be approximated using the nondimensional form st Z St Z x C sgnV uA C uB t;x t;x jVR j (18)

p(r)

where
p Friction cone pt pn

1 VR Z V A C V B 2 is dened as the rolling velocity, and xZ V A KV B jVR j

(19)

(20)

Fig. 3. Application of the cone projection operator Pz to the augmented variable p(r).

the creepage, or normalized relative rigid body slip velocity. Stability reasons make desirable to integrate the convective terms using upwind nite difference methods, a common practice when describing the continuum using an Eulerian

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VR VA Leading edge XP() VB ut(x,) ut(x-VR,) XP() x

Trailing edge

Fig. 4. Eulerian description of particles owing through the contact zone at current (left) and previous (right) time step.

description. In this work, the boundary tangential displacement derivatives present at (18) are calculated using a forward nite differences scheme with the sign criteria established in Fig. 4. 5.2. BEM equations A discretization process of the boundary integral Eq. (3) provides the viscoelastic equations of each cylinder Ha ua Z Ga pa ;a Z A;B (21)

Using previous expressions, after solving the viscoelastic problem using the BEM and later condensation, it can be obtained the linear relationship between the gap and the slip velocity (dn, st), and the normal and tangential tractions in the contact area (pn, pt), as ! " #    dn Snn Snt pn dn C Z (26) * st pt Btn Btt x This equation together with the contact conditions (15) for all contact nodes, completes the description of the problem. 6. The nal system The problem formulation is closed by the direct combination of the viscoelastic equations and the contact conditions. However, if the global external loads (P, Q) applied to the rollers are wanted to be specied as input parameters, replacing the rigid body approach d0 and the creepage x, it is convenient to introduce two new equations based on equilibrium. The net normal and tangential loads (P, Q), applied on the discretized contact surface Gc can be calculated integrating over the contact zone the normal and tangential tractions in the following way (27) P ZKf T pn ; Q Z f T pt where fi Z Gc Ni dGc is the nodal contribution to the total force, obtained by integration of the shape functions associated to node i in Gc. Finally, Eqs. (26) and (15) are included in the general formulation together with (27) to obtain the nal non-linear system of equations that we have to solve 3 2 dn Kdg C d0 eKgn KSnn pn KSnt pt 7 6 st Kxex Kgt KBtn pn KBtt pt 7 6 7 6 7 6 pKPzpr (28) Fz Z 6 7Z0 7 6 7 6 T P C f pn 5 4 QKf T pt

Grouping the BEM equations of the two cylinders, and condensing all the variables not associated with the contact areas the following equation can be obtained ! " a # a! ! ua Snn Sa pn ga n nt ne Z C (22) ua Sa Sa pa ga t tn tt t te where ua , ua and pa , pa are the vectors containing the normal n t n t and tangential displacements and tractions in the contact area; ga , ga are the normal and tangential displacements associated ne te to the external boundary conditions; and Sa is a matrix rs containing inuence coefcients where one column represents the contact nodal displacements in the r -direction due to the application of a unit traction in the s-direction at node i, maintaining equal to zero the rest of the boundary conditions and tractions. Substituting the second equation of (22) in (18) we nd that st Z x C T gA C gB C T SA C SB pn te te tn tn C T SA C SB pt tt tt or in condensed form st Z x * C Btn pn C Btt pt where T is the forward nite difference operator and x * Z x C gt ; gt Z T gA C gB te te Btn Z T SA C SB ; Btt Z T SA C SB tn tn tt tt (25) (24) (23)

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with the unknown zZ(dn, st, pn, pt, d0, x) and where the rst two terms represent the viscoelastic solid equilibrium equations, the third one imposes the contact conditions and the last two ones satisfy equilibrium with external loads. Special consideration must be taken to the fact that previous system is non-linear and strictly non-differentiable; the reason is that the contact conditions contain certain points where a conventional derivative cannot be computed, exactly at the change of contact state frontiers. For those points, a directional derivative can be computed making (28) a B-differentiable system and using the expressions presented in [8]. 6.1. Solving the non-linear system

1.6
Elastic =0.0. =infinite B.E.M. limit cases Knothe (1993) B.E.M.

1.2 pn(x)/ph , pt(x)/ph

=7.07

0.8

=1.41

0.4

=100

=0.01

0.0

To solve system (28) the Generalized Newtons Method with Line Search (GNMLS) has been used. GNMLS is an effective extension of the Newtons Method for B-differentiable functions proposed by Pang [23] in a general context and particularized by Alart [2] and Christensen [6] for the contact case. This method is based on the computation of the non-linear directional derivative of the objective function; however, it is well known that in contact problems this nonlinear directional derivative rarely needs to be computed and can be substituted by a linearized version without affecting the algorithm convergence. If we dene the scalars b2(0, 1), s2(0, 1/2), and 3O0 but small, the application of GNMLS algorithm to solve the nonlinear equations, can be summarized in the following steps: (1) Start iterations, loop k. (2) Solve for Dzk in the system vFzk ;Dzk ZK k . Fz (3) Obtain rst integer mZ1, 2, . that fullls the following decreasing error condition Hzk C bm Dzk % 1K2sbm H zk with HzZ 1 Ft zFz. 2 (4) Actualize solution zkC1 Z zk C tk Dzk with tkZbm. (5) If H(zkZ1)%3 solution is zkC1, else compute new iteration k)kC1. The algorithm uses a loop k for the Newton subiterations to obtain the solution z. On each one of this subiterations a linear system has to be solved to compute the search direction and when a direction Dzk is obtained, it is scaled by a factor of tk obtained from the decreasing error condition.

1.0

0.5

0.0 x/ah

0.5

1.0

Fig. 5. Similar viscoelastic cylinders: inuence of the rolling velocity on the contact stresses. ph and ah are the maximum normal stress and contact zone size for the equivalent Hertz problem.

After validating the formulation using this basic problem that can be compared with results from other authors, a more complicated situation is considered; it is the case of a rolling cylinder covered with a viscoelastic layer. The effect of the layer thickness on the contact stresses together with the inuence of rolling speed on the rolling resistance is presented and discussed. First, an explanation about the convention used to represent the results in Figs. 5, 6, 8, 10 and 11. In those gures the position inside the contact zone x is represented versus the contact tractions: the friction limit mpn is always positive and represents the maximum value that the tangential tractions can reach without sliding. The tangential tractions pt can be positive or negative but always with an absolute value below this friction limit; zones with the same value are sliding and zones with a lower value are in adhesion. This convention
1.6 1.2 0.8 pn(x)/ph , pt(x)/ph 0.4 0.0 0.4 0.8 1.2 1.0 0.5 0.0 x/ah 0.5 1.0
=1 Knothe (1993) Elastic limit cases B.E.M.
nf in ite

i = 0 0. =

=5

7. Results The applications contained in this section validate the proposed formulation by comparison with some classical stationary viscoelastic rolling contact problems and provide solutions for some new congurations. We will start solving the particular case of two viscoelastic cylinders where the halfspace approach can be assumed, replacing the real geometry by half-spaces and computing the initial separation dno from analytical expressions. The effects considered are the rolling velocity and material dissimilarity with their inuence on the contact stresses.

Fig. 6. Free rolling of a viscoelastic cylinder with a elastic cylinder: inuence of the rolling velocity on surface stresses.

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when representing results in contact problems is very common and useful for the identication of sliding zones, a source of surface damage.
4 el.

10 el.

un , pn ut , pt
B

B B

Body A 21 el.

R 2a
10 el. 4 el.

7.1. Rolling contact of viscoelastic cylinders 7.1.1. Similar problem We suppose rst that the rolling cylinders are made of the same viscoelastic material. The parameters used for the material model are E0ZE1Z3.2 GPa and Poisson ratio nZ 0.4, the friction coefcient between the contact surfaces is mZ 0.3 and the applied loads fulll the relation Q/mPZ0.6. Finally, the geometry of the cylinders satises the requirements for an equivalent radius RZ100 mm. For this particular conguration, Fig. 5 represents the friction limit (normal tractions multiplied by the friction coefcient) together with the tangential tractions obtained at the contact zone for different rolling velocities VR. This rolling velocity is expressed by a non-dimensional parameter zZ (qvVR)/ah, where qvZh/E1 is the viscoelastic relaxation parameter and ah, ph are the half size of the contact zone and the maximum normal traction for the equivalent Hertz problem, respectively. The problem is solved for different non-dimensional velocities zZ0.01, 1.41, 7.07 and 100, together with the elastic limit cases zZ0, N. It can be observed that the rolling velocity has a considerable inuence on the normal tractions and also that when the rolling motion is slower, i.e. z/0, the traction distribution tends correctly to an elastic solution with EZ(E0E1)/(E0CE1). When the rolling velocity goes to innity, z/N, the traction distribution tends again to another elastic solution but now with EZE0, that is, relaxation effects on a particle occur after the contact zone is left. For the inner limit cases the normal tractions present an asymmetric distribution, creating a resistant torque opposed to the rolling rotation that disappears in the elastic cases where the normal tractions are symmetric. It can be observed that, for this particular conguration, the tangential tractions are not signicantly affected by the rolling velocity and that the contact zone presents only one slipstick transition for all velocities. The elastic case has been solved analytically by Carter [5] and the viscoelastic case by Wang and Knothe [24] using a semi-analytical approach. Results are compared with both authors obtaining a good agreement with their calculations. 7.1.2. Dissimilar problem The effect of replacing one of the viscoelastic cylinders by an elastic one is now considered. The material parameters are obtained from the classical problem studied by Bentall and Johnson in [4] for the elasticelastic and static contact case. For the elastic cylinder (Body A) the material constants are Youngs modulus EAZ200 GPa and Poisson ratio nAZ0.22 B B and for the viscoelastic one, material constants are E0 Z E1 Z B 10:5 GPa and n Z0.28 together with a friction coefcient mZ0.1.
10 el. 21 el. 10 el.

2R
Fig. 7. Boundary element mesh used for the layer.

The contact tractions for free rolling (Q/mPZ0) are presented in Fig. 6 compared with results from Wang and Knothe. Again, non-symmetrical normal tractions for intermediate velocities are obtained, combined with a resistant torque that has to be overcome in order to maintain the steady state regime. For this conguration the contact zone appears divided into four regions: one stick zone and three different slip regions following a sequence that is not considerably affected by the viscoelastic effects. 7.2. Rolling contact of a cylinder coated with a viscoelastic layer Our second conguration consists of a viscoelastic layer attached to a rigid cylinder that rolls on the surface of another rigid cylinder, considering the inuence of the layer thickness and the rolling velocity on the contact stresses. The schematic representation of this problem is shown in Fig. 7 together with the boundary element mesh used. 7.2.1. Thick layer with rigid cylinder The geometry used for this situation is a layer thickness bZ0.375 mm combined with an equivalent contact radius RZ100 mm. The viscoelastic parameters for the layer are E0Z3852 MPa, E1Z1926 MPa and nZ0.3 together with a
B. E. M. qvVR=100 qvVR=10 qvVR=1 2 qvVR=0.5

ptB(x) , pn(x)

1 1.0

0.5

0.0

0.5

1.0

x
Fig. 8. Thick layer and rigid cylinder rolling with Q/mPZ0.66.

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2.0x103 Viscoelastic coating /R 1.0x103

433

80
R

1.5x103

60

ptB(x) , pn(x)

/R ,

B. E. M. qvVR=100 qvVR=1 qvVR=0.5 qvVR=0.2

40 20 0

P 5.0x104

0.0 0.00

0.05

0.10

0.15

0.20

qvVR/R
Fig. 9. Inuence of the rolling velocity on the creepage and the rolling resistance (advance g of the net normal load).

20 1.0 -0.5 0.0 0.5 1.0

x
Fig. 11. Driven rigid roller and thin viscoelastic layer with Q/mPZ0.41.

friction coefcient mZ0.1. Finally, a net normal load PZ 28 N/mm is xed. The results presented in Fig. 8 are the tangential tractions in the surface of the layer obtained when the external loads fulll the relation Q/mPZ0.66. For this particular conguration the tractive layered cylinder rotates a little bit slower than the driven cylinder, satisfying the condition VAZVB but VA!VB! 0 (condition that will be written VA(VB) using the sign criteria established in Fig. 4. Compared with the half-space dissimilar case, it can be observed that the layer thickness is not small enough to cause signicant effects on the stresses, making only a new slip zone to appear at the edge of the contact zone. A main difference between elastic and viscoelastic analyses in rolling contact problems is that viscoelastic models can reproduce the rolling resistance, see also [19,16]. A source of this resistance is the advance of the net normal load in the rolling direction g that can be quantied integrating the normal tractions in the contact area, i.e. gZ 1 P
GC

velocity on this resistance for this particular conguration is presented in Fig. 9 together with the creepage x. It can be observed that the rolling resistance due to viscoelastic effects presents a maximum and asymptotically decreases to zero when the rolling velocity increases. It is important to remember that inertial effects were not considered in the formulation making this result only valid when rolling is slower than the velocity of stress waves on the viscoelastic solid. 7.2.2. Thin layer with rigid cylinder The effect of a layer thickness reduction is now considered using bZ0.088 mm and RZ100 mm. The viscoelastic material parameters used are E0Z4 GPa, E1Z1 GPa and nZ0.5 together with a friction coefcient mZ0.1. Fixing a net normal load PZ550 N/mm, two different congurations are studied depending on the cylinder where the traction is applied, that is, only the Q/mP relation is changed. 7.2.2.1. Traction on the rigid roller. Fig. 10 shows a case where the driven layered cylinder rolls faster than the rigid cylinder with VB(VA. It is interesting to observe that, compared to the elastic case and depending on the rolling velocity, new slip zones can appear on the leading edge of the contact zone. This effect has been observed only for this particular conguration, and it is important to remark that the identication of slip zones is useful in contact problems because they are one factor of surface damage. As we can see, the normal tractions become considerably affected by the layer thickness and the rolling velocity. 7.2.2.2. Traction on the layered roller. Finally, the net tangential load is reversed up to Q/mPZ0.41 applying now the traction on the layered cylinder. This will make the coating to roll a little bit slower than the rigid cylinder with VA(VB. Some results are presented in Fig. 11 where a comparison with Fig. 10 shows the importance of external net loads on the contact stresses.

pn xx dx

(29)

magnitude that multiplied by P gives the resistant torque opposed to the rolling motion. The inuence of the rolling
80 60
B.E.M. qvVR=100 qvVR=10 qvVR=1 qvVR=0.5 qvVR=0.025

p tA(x) , pn(x)

40 20 0 20 40 1.0

Velocity dependent slip zones

0.5

0.0

0.5

1.0

x
Fig. 10. Tractive rigid roller and thin viscoelastic layer with Q/mPZK0.74.

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J.A. Gonzalez, R. Abascal / Engineering Analysis with Boundary Elements 30 (2006) 426434 [5] Carter FW. On the action of a locomotive driving wheel. Proc R Soc Ser A 1926;112:1517. [6] Christensen PW, Klarbring A, Pang JS, Stromberg N. Formulation and comparison of algorithms for frictional contact problems. Int J Numer Methods Eng 1998;42:14573. [7] Golden JM. The problem of a moving rigid punch on an unlubricated viscoelastic half-space. Mech Appl Math 1979;32:2552. [8] Gonzalez JA, Abascal R. An algorithm to solve coupled 2d rolling contact problems. Int J Numer Methods Eng 2000;49:114367. [9] Gonzalez JA, Abascal R. Solving 2d transient rolling contact problems using the bem and mathematical programming. Int J Numer Methods Eng 2002;53:84374. [10] Gonzalez JA, Abascal R. Linear viscoelastic boundary element formulation for steady state moving loads. Eng Anal Bound Elem 2004; 28:81523. [11] Gotoh J, Yu Q, Shiratori M. Experimental/numerical analyses of a viscoelastic body under rolling contact. Mech Time Dependent Mater 1999;(3):24561. [12] Hu GD, Wriggers P. On the adaptive nite element method of steady-state rolling contact for hyperelasticity in nite deformations. Comput Methods Appl Mech Eng 2002;(191):133348. [13] Hunter SC. The rolling contact of a rigid cylinder with a viscoelastic half space. J Appl Mech 1961;28(4):6117. [14] Johnson KL. Contact mechanics. Cambridge: Cambridge University Press; 1985. [15] Kalker JJ. Three-dimensional elastic bodies in rolling contact. Dordrecht: Kluwer; 1990. [16] Kalker JJ. Viscoelastic multilayered cylinders rolling with dry friction. J Appl Mech 1991;58:66679. [17] Kikuchi N, Oden JT. Contact problems in elasticity: a study of variational inequalities and nite element methods. SIAM Stud Appl Math 1988. [18] Lynch FS. A nite element method of viscoelastic stress analysis with application to rolling contact problems. Int J Numer Methods Eng 1969;1: 37994. [19] Morland LW. A plane problem of rolling contact in linear viscoelasticity theory. J Appl Mech 1962;29:34552. [20] Morland LW. Exact solutions for rolling contact between viscoelastic cylinders. Q J Mech Appl Math 1967;20:73106. [21] Padovan J. Finite element analysis of steady and transiently moving/rolling nonlinear viscoelastic structure. Comput Struct 1987;2: 24957. [22] Padovan J, Paramadilok O. Transient and steady state viscoelastic rolling contact. Comput Struct 1985;1:54553. [23] Pang JS. Newtons method for b-differentiable equations. Math Oper Res 1990;15(2):31141. [24] Wang G, Knothe K. Stress analysis for rolling contact between two viscoelastic cylinders. Trans ASME 1993;60:3107.

8. Conclusions A formulation of the 2D rolling contact problem using the BEM that obtains in a general and accurate way the solution of stationary rolling problems between viscoelastic cylinders is presented. The results obtained using this formulation are compared with results from other authors with a good agreement and also solutions for some new problems are presented. Related with the novel problems studied, it has been observed that for cylinders covered with viscoelastic coatings, the layer thickness considerably affects the contact stresses making the Hertzian contact assumptions not reasonable. The rolling resistance due to viscoelastic effects can also be effectively calculated as a function of the rolling velocity using this formulation. Numerical experiments represent the physical evidence that the rolling velocity affects the rolling resistance and predict the presence of new velocity dependent slip zones for the viscoelastic coating case. Considering that, among other factors, contact stresses and slip zones are closely related with damage on the rolled surface, the proposed formulation and results can become an effective design tool for rolling components if combined with appropriate wear models. Acknowledgements This work was funded by Spains DGICYT in the framework of Project DPI 2003-00487. References
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