The contact calculation of three-dimensional real rough surfaces is the frontier field of tribology and surface science. In this study, we consider the interaction and elastic-plastic deformation characteristics of asperities and further, propose an analytical contact calculation method for rough surfaces considering the interaction of asperities. Based on the watershed algorithm, the rough surface is segmented and the asperities are reconstructed into ellipsoids. According to the height relationship between the asperities, the definition of the deformation reference height of the matrix between each couple of asperities is provided. Subsequently, the calculation formula of the substrate deformation is provided according to the local contact pressure considering the elastic-plastic deformation of the asperity, and the contact state under a specific load is determined using the iterative correction method. The results correspond with those of finite element numerical calculation and the study reveals the following: (1) compared with the results obtained without considering the asperity interaction, contact area, distance, and stiffness will be reduced by 6.6%, 19.6%, and 49.5%, respectively, when the influence of asperity interaction is considered; (2) the interaction of the asperities has the greatest influence on the surface contact distance and stiffness. Under the same load, the existence of asperity interaction will reduce the contact distance, area, and stiffness; (3) considering the interaction of the asperities, the higher asperity will bear more load, but it will simultaneously reduce the contact of the surrounding area and increase that of the distant area. The calculation method proposed in this study has the advantages of high calculation efficiency and accuracy, thus, providing the calculation basis and method for subsequent studies on service performance of rough surfaces, such as the calculation of contact stiffness and fatigue performance analysis of rough surfaces.

The 3D rough surface modeling and contact analysis is a difficult problem in the study of rough surface contact. In this paper, a new method for reconstruction and contact analysis of asperities on 3D rough surfaces is proposed based on real rough surfaces. Watershed algorithm is used to segment and determine the area of asperities on the rough surface. According to the principle of minimum mean square error, ellipsoid fitting is carried out on asperities. Based on the elastic-plastic contact model of a single ellipsoidal asperity, a stable and efficient method for 3D rough surface contact analysis and calculation is proposed. Compared with existing calculating methods, the present method has the following characteristics: (1) the constructed surface asperity is closer to the real asperity in contact, and the calculation of asperity parameters has better stability under different sampling intervals and (2) the contact pressure, contact area, and other contact parameters of the 3D rough surface are calculated with high accuracy and efficiency, and the calculation convergence is desirable. The reconstruction and contact analysis method of the 3D rough surface asperity proposed in this paper provides a more accurate reconstruction and calculation method for the study of contact fatigue life and wear failure of rough surfaces.

Numerical simulation of three-dimensional rough surfaces based on fast Fourier transform (FFT) is revisited. A more systematic approach, which is an extension of the current FFT-based simulation models, is proposed to approach surface reconstruction. Moreover, the simulation of the surfaces with machining signature by prescribing the parameters, take ultrasonic-assisted grinding as an example, has been taken as the research focus for the first time. The effectiveness is tested by three cases of simulation examples. Excepting the surface with exponential autocorrelation function, the simulation of surfaces with grinding machining marks is considered both by prescribing the theory autocorrelation function and by measuring a small area as a sample. The results show that the proposed method has great potential in engineering applications.

The study investigates the impact of textured surface parameters and pump operating parameters on the friction performance of slipper pairs in axial piston pumps. The orthogonal experimental scheme was developed, and the influence of several factors was explored, such as rotational speed, area ratio, micro-pit shape, diameter, depth-to-diameter ratio and film thickness. Optimal dimension combinations of the micro-pit were identified by numerical simulation and standard pin–disk friction experiment. In the pin–disk friction pair test, the friction coefficient of the textured surface compared to the smooth surface showed a maximum average friction reduction rate of 26.974%. Under various pump pressures (4, 8, 12 MPa) and pump displacements (10, 20, 35 L/min), the friction reduction rates of the textured surface slipper pairs (texture diameter 500 µm, depth 250 µm, area ratio 20%) ranged from 0.78% to 18.13%. The study underscores the importance of surface texture in enhancing the operational efficiency and reliability of axial piston pumps, offering valuable insights for the design and maintenance of hydraulic pumps.