Plastic flattening of a sinusoidal metal surface: A discrete dislocation plasticity study

The plastic flattening of a sinusoidal metal surface is studied by performing plane strain dislocation dynamics simulations. Plasticity arises from the collective motion of discrete dislocations of edge character. Their dynamics is incorporated through constitutive rules for nucleation, glide, pinning and annihilation. By analyzing surfaces with constant amplitude we found that the mean contact pressure is inversely proportional to the wavelength. For small wavelengths, due to interaction between plastic zones of neighboring contacts, the mean contact pressure can reach values that are about 1/10 of the theoretical strength of the material, thus significantly higher than what is predicted by simulations that do not account for size dependent plasticity. Surfaces with the same amplitude to period ratio have a size dependent response, such that if we interpret each period of the sinusoidal wave as the asperity of a rough surface, smaller asperities are harder to be flattened than large ones. The difference between the limiting situations of sticking and frictionless contacts is found to be negligible. (C) 2012 Elsevier B.V. All rights reserved.