Finite deformations induce friction hysteresis in normal wavy contacts

Since Hertz's pioneering work in 1882, contact mechanics has traditionally been grounded in linear elasticity, assuming small strains and displacements. However, recent experiments clearly highlighted linear elasticity limitations in accurately predicting the contact behavior of rubbers and elastomers, particularly during frictional slip, which is governed by geometric and material nonlinearity. In this study, we investigate the basic scenario involving normal approach-retraction contact cycles between a wavy rigid indenter and a flat, deformable substrate. Both frictionless and frictional interfacial conditions are examined, considering finite strains, displacements, and nonlinear rheology. We developed a finite element model for this purpose and compared our numerical results with Westergaard's linear theory. Our findings show that, even in frictionless conditions, the contact response is significantly influenced by geometric and material nonlinearity, particularly for wavy indenters with high aspect ratios, where normal-tangential stresses and displacements coupling emerges. More importantly, interfacial friction in nonlinear elasticity leads to contact hysteresis (i.e., frictional energy dissipation) during normal loading–unloading cycles. This behavior cannot be explained in a linear framework; therefore, most of the experiments reporting hysteresis are typically explained invoking other interfacial phenomena (e.g., adhesion, plasticity, or viscoelasticity). Here we present an additional suitable explanation relying on finite strains/displacements with detailed peculiarities, such as vanishing pull-off force. Moreover, we also report an increase of hysteretic losses as for confined systems, stemming from the enhanced normal-tangential nonlinear coupling.