A parallel and memory-aware free-interface component mode synthesis framework for industrial-scale moving contact simulation

Industrial computer-aided engineering (CAE) analysis of moving contact assemblies often relies on finite element (FE) and component mode synthesis (CMS) methods because of their high accuracy in capturing local elastic deformation and contact behavior. However, their application to large-scale industrial simulations remains challenging due to the large number of degrees of freedom, expensive local deformation calculations, and repeated contact updates at moving interfaces. To address these challenges, this paper presents a parallel and memory-aware free-interface CMS framework for industrial-scale moving contact simulation. The framework integrates chunked block linear solves with factorization reuse, consistent interface load mapping under multi-point constraints, lock-free parallel post-processing for modal data construction, and parallel bounding volume hierarchy contact detection into a reusable CAE workflow. Three industrial examples, including a helical gear pair, a car differentia, and a gear-rack system, are used to assess accuracy and computational performance. The results show that the proposed method preserves FE-level accuracy while reducing peak memory of unchunked CMS method and achieving speedups of one order of magnitude in large drivetrain simulations.