M3- 2S Multiscale Modelling for Multi-layered Surface Systems European Research Project
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Transcript of M3- 2S Multiscale Modelling for Multi-layered Surface Systems European Research Project
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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)
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M3-2S Special Session 19th IFHTSE Congress
Overview
• Rationale and benefits
• “Virtual test” workflow
• What’s going on under the hood?
• Illustration
• Summary
• Acknowledgement
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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
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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”
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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
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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
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M3-2S Special Session 19th IFHTSE Congress
Start-up screen
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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
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M3-2S Special Session 19th IFHTSE Congress
Start-up screen: select load-bearing test
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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)
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M3-2S Special Session 19th IFHTSE Congress
View layers (to scale)
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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
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M3-2S Special Session 19th IFHTSE Congress
Simulation in progress
Progress reported
DEFORM solver info
echoed to screen
Yes, there IS a
„stop‟ button!
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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
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M3-2S Special Session 19th IFHTSE Congress
Advanced post-processing
Full functionality of
DEFORM post-
processor is available to
more advanced users
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M3-2S Special Session 19th IFHTSE Congress
Some DEFORM output
Damage
contours
Force-
displacement
curve
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M3-2S Special Session 19th IFHTSE Congress
Start-up screen: machining application
2-D simplified
representation
(for quick
comparative
results)
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M3-2S Special Session 19th IFHTSE Congress
Machining set-up
Similar approach
to surface system
definition
Workpiece material
Tool tip geometry
Cutting parameters
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M3-2S Special Session 19th IFHTSE Congress
Cutting - mesh
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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
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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
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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