Study on rough surfaces: A novel method for high-precision simulation and interface contact performances analysis

Surface morphology of the components is a key factor that influences the quality and performance of precision systems. The influence of different morphologies on the contact performance of mating surfaces may be studied by simulating a real rough surface and calculating the contact performance. First, the micro-geometric characteristics of the surfaces of the machined parts are measured by a 3D surface profilometer (NV5000 5022S), and the distribution law of the surface micro-geometric characteristics is obtained by statistical and characterization methods. Second, the rough surface conforming to this law is simulated by a non-Gaussian mathematical algorithm, and the contact model between the mating parts with micro-geometric characteristics of the simulated surface is reconstructed using reverse engineering. Finally, the mechanical properties of the mating surfaces are obtained using a numerical algorithm based on Yoshimura's integral method and tests. The comparison of mechanical properties obtained from numerical analysis and test shows that the maximum errors in the contact stiffness obtained by the two methods are 9.4% (grinding surface) and 11.5% (milling surface), respectively. Therefore, it is feasible to use a non-Gaussian simulation method and Yoshimura's integral method to realize an effective simulation of the micro-geometric characteristics of the surface and the analysis of the contact performance of the mating surface respectively. The results obtained from this study is thus important as a reference for the analysis of the surface morphology and mechanical properties between the matching parts.