Dear Saurabh,

Adjust to Touch zeros out the geometric interference that was present in the geometry which is why you got very low stress results.

Added offset, ramped effects (assuming you use the default value of 0), correctly resolves the geometric interference. The stress you see is the result of the interference. If the mesh on both sides of the frictional contact has node-to-node alignment, that is the best situation. If the mesh is coarse and you have linear elements, then you can get artificially high stresses due to a node on one side being inside the straight line edge of the other side. Using quadratic elements will allow the element edges to follow to curve of the geometry.