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Virtual test for rapid evaluation of engineered surface coatings                Dr Simon Leefe (Wilde Analysis Ltd)  Dr Pa...
Overview   • Rationale and benefits   • “Virtual test” workflow   • What’s going on under the hood?   • Illustration   • S...
Rationale and BenefitsIndustrial drivers   Performance demands        • Machine power density increase        • Weight dec...
Rationale and BenefitsDesign / selection of coating                   “Virtual tests”systems                        Identi...
Approach   • Select “virtual test” type        • Micro-indentation        • Load bearing        • Machining application   ...
What‟s going on under the hood?• “Run” button kicks off DEFORMTM simulation    • Leading edge Finite Element Analysis prog...
Start-up screenM3-2S Special Session                     19th IFHTSE Congress
Indentation test set-up                                       Define coating                                       layers ...
Start-up screen: select load-bearing testM3-2S Special Session          19th IFHTSE Congress
Load-bearing test set-up                                     Set-up                                     identical, but    ...
View layers (to scale)M3-2S Special Session                       19th IFHTSE Congress
Generate mesh (and view)                            Mesh settings are                            generated automatically  ...
Simulation in progress                                 Progress reported                                 DEFORM solver inf...
Results: progression of damage                                Extent of damageLocation and                                ...
Advanced post-processing                              Full functionality of                              DEFORM post-     ...
Some DEFORM output      Force-   displacement       curve                             Damage                             c...
Start-up screen: machining application                            2-D simplified                            representation...
Machining set-up                                       Similar approach                                       to surface s...
Cutting - meshM3-2S Special Session                    19th IFHTSE Congress
Load-bearing and cutting   • Simulation and results display similar to indentation   • Cutting also provides order-of-magn...
Summary   • Simple-to-use “virtual test” tool   • Aids coating system selection and comparative     evaluation   • Quicker...
Acknowledgement    The authors thank the European Commission for their     support on the FP7 project “Multiscale Modellin...
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M3- 2S Multiscale Modelling for Multi-layered Surface Systems European Research Project

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The presentation was made by Wilde Analysis and Imperial College during the IFTHSE'11 Congress (17-20 October 11), hosted by the University of Strathclyde in Glasgow.

This marked the final meeting of a European collaborative research project to provide users and developers of coatings for machine elements and cutting tools with a state-of-the art simulation-based toolkit.

Known as M3-2S (Multiscale Modelling for Multi-layered Surface Systems), the toolkit is designed to assist in the coatings development and selection process, with the following principal benefits:

- Reduction in physical tests (pre-screening and evaluation tests)
- Corresponding reduction in cost and lead-time
- Evaluation and ranking of alternative candidate surface systems
- Insight into coating failure mechanisms

A key project deliverable, developed by Wilde Analysis and Imperial College was the “virtual test” tool, which helps users who are not simulation experts to set up and run simulations of substrate-case-coating systems of their own construction, in three situations:

- Micro-indentation tests
- Load bearing (line contact) tests
- Approximate evaluation of coating system for cutting tool applications

The software is designed for maximum simplicity and quick results and is aimed at mainly at reducing the time and cost of coating selection. For more details of the software and for a quick demonstration, please contact us at http://WildeAnalysis.co.uk/contact.

Full details of the project can be found at www.m3-2s.bham.ac.uk.

Acknowledgement: Wilde Analysis thanks the European Commission for its support on the FP7 project “MultiscaleModelling for MultilayeredSurface Systems (M3-2S)”, Grant No: CP-FP 213600-2 M3-2S.

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M3- 2S Multiscale Modelling for Multi-layered Surface Systems European Research Project

  1. 1. 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)M3-2S Special Session 19th IFHTSE Congress
  2. 2. Overview • Rationale and benefits • “Virtual test” workflow • What’s going on under the hood? • Illustration • Summary • AcknowledgementM3-2S Special Session 19th IFHTSE Congress
  3. 3. Rationale and BenefitsIndustrial drivers Performance demands • Machine power density increase • Weight decrease Increased demand on machine elements • Increased load bearing capacity • Better tribological performance Innovation in surface engineering • Multi-layered systems • Nano-structured • etcM3-2S Special Session 19th IFHTSE Congress
  4. 4. Rationale and BenefitsDesign / selection of coating “Virtual tests”systems Identify candidate • Has worked before • Some potential • Consider more candidates Microindentation tests • Propose completely newPre-screen • Prepare samples systems • Conduct tests • No lead time on specimen procurement Load-bearing / tribo test • Simulations can run 24/7Rank shortlist • Prepare samples • Understand route to • Conduct tests failure • Inform surface system Evaluate Functional / endurance test designperformanceM3-2S Special Session 19th IFHTSE Congress
  5. 5. Approach • Select “virtual test” type • Micro-indentation • Load bearing • Machining application • Specify test parameters • Set off simulation • Inspect results tailored to end-user requirementsM3-2S Special Session 19th IFHTSE Congress
  6. 6. 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 availableM3-2S Special Session 19th IFHTSE Congress
  7. 7. Start-up screenM3-2S Special Session 19th IFHTSE Congress
  8. 8. Indentation test set-up Define coating layers (expandable M3-2S library) Define substrate from DEFORM library and (optionally) depth of hardened layer Define test parametersM3-2S Special Session 19th IFHTSE Congress
  9. 9. Start-up screen: select load-bearing testM3-2S Special Session 19th IFHTSE Congress
  10. 10. 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
  11. 11. View layers (to scale)M3-2S Special Session 19th IFHTSE Congress
  12. 12. Generate mesh (and view) Mesh settings are generated automatically from built-in geometry- based rules, to provide optimum trade-off between speed and accuracyM3-2S Special Session 19th IFHTSE Congress
  13. 13. Simulation in progress Progress reported DEFORM solver info echoed to screen Yes, there IS a „stop‟ button!M3-2S Special Session 19th IFHTSE Congress
  14. 14. Results: progression of damage Extent of damageLocation and and instant of instant of surface failure initiation of failure M3-2S Special Session 19th IFHTSE Congress
  15. 15. Advanced post-processing Full functionality of DEFORM post- processor is available to more advanced usersM3-2S Special Session 19th IFHTSE Congress
  16. 16. Some DEFORM output Force- displacement curve Damage contoursM3-2S Special Session 19th IFHTSE Congress
  17. 17. Start-up screen: machining application 2-D simplified representation (for quick comparative results)M3-2S Special Session 19th IFHTSE Congress
  18. 18. Machining set-up Similar approach to surface system definition Workpiece material Tool tip geometry Cutting parametersM3-2S Special Session 19th IFHTSE Congress
  19. 19. Cutting - meshM3-2S Special Session 19th IFHTSE Congress
  20. 20. Load-bearing and cutting • Simulation and results display similar to indentation • Cutting also provides order-of-magnitude estimate of tool wear rate for comparative purposesM3-2S Special Session 19th IFHTSE Congress
  21. 21. 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 systemsM3-2S Special Session 19th IFHTSE Congress
  22. 22. 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 M3-2SionM3-2S Special Session 19th IFHTSE Congress

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