M3-2S Special Session 19 th IFHTSE Congress Virtual test for rapid evaluation of engineered surface coatings Dr Simon Leefe (Wilde Analysis Ltd) Dr Pan Zhang, Dr Daniel Balint, Prof Jianguo Lin (Imperial College)
Jul 03, 2015
M3-2S Special Session 19th IFHTSE Congress
Virtual test for rapid evaluation
of engineered surface coatingsDr Simon Leefe (Wilde Analysis Ltd)
Dr Pan Zhang, Dr Daniel Balint, Prof Jianguo Lin (Imperial College)
M3-2S Special Session 19th IFHTSE Congress
Overview
• Rationale and benefits
• “Virtual test” workflow
• What’s going on under the hood?
• Illustration
• Summary
• Acknowledgement
M3-2S Special Session 19th IFHTSE Congress
Rationale and Benefits
Performance demands• Machine power density increase
• Weight decrease
Industrial drivers
Increased demand on machine elements• Increased load bearing capacity
• Better tribological performance
Innovation in surface engineering• Multi-layered systems
• Nano-structured
• etc
M3-2S Special Session 19th IFHTSE Congress
Rationale and Benefits
Identify candidate• Has worked before
• Some potential
Microindentation tests• Prepare samples
• Conduct tests
Load-bearing / tribo test• Prepare samples
• Conduct tests
Design / selection of coating
systems
Functional / endurance test
Pre-screen
Rank shortlist
Evaluate
performance
• Consider more
candidates
• Propose completely new
systems
• No lead time on
specimen procurement
• Simulations can run 24/7
• Understand route to
failure
• Inform surface system
design
“Virtual tests”
M3-2S Special Session 19th IFHTSE Congress
Approach
• Select “virtual test” type
• Micro-indentation
• Load bearing
• Machining application
• Specify test parameters
• Set off simulation
• Inspect results tailored to end-user requirements
M3-2S Special Session 19th IFHTSE Congress
What‟s going on under the hood?
• “Run” button kicks off DEFORMTM simulation
• Leading edge Finite Element Analysis program
• Usually GUI driven but can be driven by text files
• Here, uses text files generated by “virtual test” GUI
• Extensive set of user subroutines from M3-2S project to implement
damage model in coating layers
• DEFORM generates results
• Results normally post-processed visually in DEFORM GUI
• Here, specific repeatable set of results generated automatically in text
format
• Virtual test GUI displays application-specific results to user
• DEFORM post-processing functionality also available
M3-2S Special Session 19th IFHTSE Congress
Start-up screen
M3-2S Special Session 19th IFHTSE Congress
Indentation test set-up
Define coating
layers (expandable
M3-2S library)
Define substrate from
DEFORM library and
(optionally) depth of
hardened layer
Define test
parameters
M3-2S Special Session 19th IFHTSE Congress
Start-up screen: select load-bearing test
M3-2S Special Session 19th IFHTSE Congress
Load-bearing test set-up
Set-up
identical, but
solution is plane
strain, not
axisymmetric
Substrate library
from drop-down
(small subset of
DEFORM library
materials)
M3-2S Special Session 19th IFHTSE Congress
View layers (to scale)
M3-2S Special Session 19th IFHTSE Congress
Generate mesh (and view)
Mesh settings are
generated automatically
from built-in geometry-
based rules, to provide
optimum trade-off between
speed and accuracy
M3-2S Special Session 19th IFHTSE Congress
Simulation in progress
Progress reported
DEFORM solver info
echoed to screen
Yes, there IS a
„stop‟ button!
M3-2S Special Session 19th IFHTSE Congress
Results: progression of damage
Location and
instant of
initiation of
failure
Extent of damage
and instant of
surface failure
M3-2S Special Session 19th IFHTSE Congress
Advanced post-processing
Full functionality of
DEFORM post-
processor is available to
more advanced users
M3-2S Special Session 19th IFHTSE Congress
Some DEFORM output
Damage
contours
Force-
displacement
curve
M3-2S Special Session 19th IFHTSE Congress
Start-up screen: machining application
2-D simplified
representation
(for quick
comparative
results)
M3-2S Special Session 19th IFHTSE Congress
Machining set-up
Similar approach
to surface system
definition
Workpiece material
Tool tip geometry
Cutting parameters
M3-2S Special Session 19th IFHTSE Congress
Cutting - mesh
M3-2S Special Session 19th IFHTSE Congress
Load-bearing and cutting
• Simulation and results display similar to indentation
• Cutting also provides order-of-magnitude estimate of
tool wear rate for comparative purposes
M3-2S Special Session 19th IFHTSE Congress
Summary
• Simple-to-use “virtual test” tool
• Aids coating system selection and comparative
evaluation
• Quicker lead time than physical tests• Rapidly screen out weak candidate systems
• Quickly identify reduced shortlist for physical tests
• Brings state-of-the-art DEFORM finite element
simulation to non-expert users
• Incorporates leading-edge research into surface
coating damage via validated models
• Provides insights into initiation and progression of
failure not available from physical tests
• Allows exploration of completely new surface systems
M3-2S Special Session 19th IFHTSE Congress
Acknowledgement
The authors thank the European Commission for their
support on the FP7 project “Multiscale Modelling for
Multilayered Surface Systems (M3-2S)”, Grant No: CP-
FP 213600-2 M3-2Sion