The accurate estimation of real contact area plays an important role in predicting the mechanical contact situation and associated electrical contact resistance for engineering rough surfaces. In this work, an improved peak identification method is proposed to reconstruct the rough surface morphologies numerically. A universal calculation process of real contact area and load force under the progressive indentation depth for rough surfaces is developed. Furthermore, a three-dimensional finite element model for analyzing the mechanical contact problem is built and the electromechanical coupling simulation results are compared with that obtained by our novel calculation method. The proposed solution is beneficial for accurate calculation of contact area, which is featured by high aspect ratio in the case of micro-contact. The relationship between electrical contact resistance and load force is also captured in the initial contact process.

Graphical Abstract

中文翻译：

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用于预测机械接触行为和相关电接触电阻的3D表面形态建模

实际接触面积的准确估计在预测工程粗糙表面的机械接触情况和相关的电接触电阻方面起着重要作用。在这项工作中，提出了一种改进的峰值识别方法，以数字方式重建粗糙表面的形态。建立了渐进压痕深度下粗糙表面实际接触面积和载荷力的通用计算方法。此外，建立了用于分析机械接触问题的三维有限元模型，并将机电耦合仿真结果与我们的新型计算方法得到的结果进行了比较。所提出的解决方案有利于精确计算接触面积，这在微接触情况下具有高的长宽比。

图形概要