Simulation Analysis of Mixed Contact using Finite Element Method Stress Behavior of Elastoplastic Material

Abstract

This paper presents a numerical investigation of mixed elastoplastic contact between a cylindrical wire and a flat rectangular plate using the Adaptive Mixed Contact Finite Element Method (AMC-FEM). The influence of contact geometry and frictional conditions on contact behavior is analyzed for both single- and double-contact configurations.  The effects of wire diameter (5, 10, and 15 mm), contact spacing (20, 25, and 33 mm), and coefficients of friction  (0.3, 0.5, and 1.0) are examined under a constant normal load. The numerical results are evaluated in terms of real contact area, normal contact force, stress distribution, and artificial strain energy. The results show that increasing wire diameter enlarges the contact area and redistributes contact pressure, leading to reduced local stress concentrations despite higher normal forces. Friction significantly affects stress asymmetry, stick–slip behavior, and energy dissipation. In double-contact configurations, increasing the distance between contact zones reduces peak stresses and limits interaction effects.  The numerical results exhibit qualitative behavior consistent with Hertzian contact theory in the elastic regime while capturing elastoplastic and frictional effects beyond classical models. The proposed approach provides a reliable numerical framework for the analysis and design of mixed contact interfaces in engineering applications.