Publications

Abstract not provided.

When exposed to mechanical environments such as shock and vibration, electrical connections may experience increased levels of contact resistance associated with the physical characteristics of the electrical interface. A phenomenon known as electrical chatter occurs when these vibrations are large enough to interrupt the electric signals. It is critical to understand the root causes behind these events because electrical chatter may result in unexpected performance or failure of the system. The root causes span a variety of fields, such as structural dynamics, contact mechanics, and tribology. Therefore, a wide range of analyses are required to fully explore the physical phenomenon. This paper intends to provide a better understanding of the relationship between structural dynamics and electrical chatter events. Specifically, electrical contact assembly composed of a cylindrical pin and bifurcated structure were studied using high fidelity simulations. Structural dynamic simulations will be performed with both linear and nonlinear reduced-order models (ROM) to replicate the relevant structural dynamics. Subsequent multi-physics simulations will be discussed to relate the contact mechanics associated with the dynamic interactions between the pin and receptacle to the chatter. Each simulation method was parametrized by data from a variety of dynamic experiments. Both structural dynamics and electrical continuity were observed in both the simulation and experimental approaches, so that the relationship between the two can be established.

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An improved electrical contact resistance (ECR) model for elastic rough electrode contact is proposed, incorporating the effects of asperity interactions and temperature rise by frictional and joule heating. The analytical simulation results show that the ECR decreases steeply at the beginning of the contact between Al and Cu. However, it becomes stabilized after reaching a specific contact force. It is also found that the longer elapsed sliding contact time, the higher ECR due to the increase in electrical resistivity of electrode materials by the frictional temperature rise at the interface. The effects of surface roughness parameters on ECR are studied through the 32 full-factorial design-of-experiment analysis. Based on the two representative roughness parameters, i.e., root-mean-square (rms) roughness and asperity radius, their individual and coupled effects on the saturated ECR are examined. The saturated ECR increases with the rms roughness for a rough machined surface condition, but it is hardly affected by the asperity radius. On the other hand, the saturated ECR increases with both the rms roughness and the asperity radius under a smooth thin film surface condition.

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Electrical switches are often subjected to shock and vibration environments, which can result in sudden increases in the switch's electrical resistance, referred to as 'chatter'. This paper describes experimental and numerical efforts to investigate the mechanism that causes chatter in a contact pair formed between a cylindrical pin and a bifurcated receptacle. First, the contact pair was instrumented with shakers, accelerometers, laser doppler vibrometers, a high speed camera, and a 'chatter tester' that detects fluctuations in the contact's electrical resistance. Chatter tests were performed over a range of excitation amplitudes and frequencies, and high speed video from the tests suggested that 'bouncing' (i.e. loss of contact) was the primary physical mechanism causing chatter. Structural dynamics models were then developed of the pin, receptacle, and contact pair, and corresponding modal experiments were performed for comparison and model validation. Finally, a high-fidelity solid mechanics model of the contact pair was developed to study the bouncing physics observed in the high speed videos. Chatter event statistics (e.g. mean chatter event duration) were used to compare the chatter behavior recorded during testing to the behavior simulated in the high-fidelity model, and this comparison suggested that the same bouncing mechanism is the cause of chatter in both scenarios.

Sierra/SD provides a massively parallel implementation of structural dynamics finite element analysis, required for high-fidelity, validated models used in modal, vibration, static and shock analysis of weapons systems. This document provides a user's guide to the input for Sierra/SD . Details of input specifications for the different solution types, output options, element types and parameters are included. The appendices contain detailed examples, and instructions for running the software on parallel platforms.

Sierra/SD provides a massively parallel implementation of structural dynamics finite element analysis, required for high fidelity, validated models used in modal, vibration, static and shock analysis of structural systems. This manual describes the theory behind many of the constructs in Sierra/SD. For a more detailed description of how to use Sierra/SD, we refer the reader to Sierra/SD, User's Notes. Many of the constructs in Sierra/SD are pulled directly from published material. Where possible, these materials are referenced herein. However, certain functions in Sierra/SD are specific to our implementation. We try to be far more complete in those areas. The theory manual was developed from several sources including general notes, a programmer notes manual, the user's notes and of course the material in the open literature.

This document presents tests from the Sierra Structural Mechanics verification test suite. Each of these tests is run nightly with the Sierra/SD code suite and the results of the test checked versus the correct analytic result. For each of the tests presented in this document the test setup, derivation of the analytic solution, and comparison of the Sierra/SD code results to the analytic solution is provided. This document can be used to confirm that a given code capability is verified or referenced as a compilation of example problems.

The "how to" document is designed to help walk the analyst through difficult aspects of software usage. It should supplement both the User's manual and the Theory document, by providing examples and detailed discussion that reduce learning time for complex set ups. These documents are intended to be used together. We will not formally list all parameters for an input here — see the User's manual for this. All the examples in the "How To" document are part of the Sierra/SD test suite, and each will run with no modification. The nature of this document casts together a number of rather unrelated procedures. Grouping them is difficult. Please try to use the table of contents and the index as a guide in finding the analyses of interest.

Most experimental setups and environment specifications define acceleration loads on the component. However, Sierra Structural Dynamics cannot apply acceleration boundary conditions in modal transient analysis. Modal analysis of these systems and environments must be done through the application of a huge artificial force to a large fictitious point mass. Introducing a large mass into the analysis is a common source of numerical error. In this report we detail a mathematical procedure to directly apply acceleration boundary conditions in modal analyses without the requirement of adding a non-physical mass to the system. We prototype and demonstrate this procedure in Matlab and scope the work required to integrate this procedure into Sierra Structural Dynamics.

Abstract not provided.

This paper presents a method for predicting how sensitive a frictional contact’s steady-state behavior is to its initial conditions. Previous research has proven that if a contact is uncoupled, i.e. if slip displacements do not influence the contact pressure distribution, then its steady-state response is independent of initial conditions, but if the contact is coupled, the steady-state response depends on initial conditions. In this paper, two metrics for quantifying coupling in discrete frictional systems are examined. These metrics suggest that coupling is dominated by material dissimilarity due to Dundurs’ composite material parameter β when β ≥ 0.2, but geometric mismatch becomes the dominant source of coupling for smaller values of β. Based on a large set of numerical simulations with different contact geometries, material combinations, and friction coefficients, a contact’s sensitivity to initial conditions is found to be correlated with the product of the coupling metric and the friction coefficient. For cyclic shear loading, this correlation is maintained for simulations with different contact geometries, material combinations, and friction coefficients. Furthermore, for cyclic bulk loading, the correlation is only maintained when the contact edge angle is held constant.

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