The document is a thesis defense presentation for a Masters degree in Mechanical Engineering. It discusses pre-sliding frictional analysis of a coated spherical asperity through finite element analysis (FEA) modeling in ABAQUS. Previous research on homogeneous and coated asperity models under normal and tangential loading are reviewed. The objective is to develop a 3D FEA model to analyze pre-sliding friction of coated asperities under combined loading and compare results. The methodology, FEA model development, verification studies, and results are presented.
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negatively skew roughness. Further variance (-ve) makes the situation furtherimproved even if moderate values of porosity are involved
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This presentation covers an introduction to quasi-static nanoindetation and how properties of hardness and elastic modulus are determined using the load-displacement curves. You are welcome to use these slides in your presentation on the condition that you give credit to Nanomechanics, Inc. on each slide used.
Interrelation of Friction-Wear and Mechanism of Energy Dissipation for MEMS A...ijceronline
Adhesion is a predominating force in Micro electro mechanical System (MEMS) due to high surface to volume ratio. In the present study of MEMS surfaces contact, adhesional friction force and adhesive wear volume have been computed numerically and new interrelation in between the wear and friction is developed after, finding their ratio. Also, mechanism of energy dissipation has been summarized on the basis of Arrhenius theory of mechanochemical reaction under working condition of MEMS devices.
EFFECT OF SURFACE ROUGHNESS ON CHARACTERISTICS OF SQUEEZE FILM BETWEEN POROUS...IAEME Publication
In investigation aims to analyse the effect of transverse surface roughness on the squeeze film performance between porous rectangular plates. The associated differential equation is stochastically averaged making use of stochastic averaging method of Christensen and Tonder for transverse surface roughness. The equation is solved with appropriate boundary conditions to obtain the pressure and consequentlythe load bearing. The graphical results suggest that the bearing suffers because of transverse surface roughness. However the situation is slightly better in the case of
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Prediction of joint strength and effect of the surface treatment on the singl...Filipe Giesteira
A two-component high-ductility adhesive (acrylic and catalyst based), SikaFast® - 5211 NT, was used to bond single overlap joints with mild steel adherends and 25 mm of overlap. One joint configuration used treated bonding surfaces while the other was did not employ treatment of the adherend surfaces, with the aim of studying the influence of the material surface treatment. The specimens were tensile tested in a INSTRON® universal testing machine and the non-treated surface have shown a strength four times lower than the treated surface. Several analytical methods were used to predict joint strength, with two methods achieving reasonably accurate failure load predictions.
This presentation covers an introduction to quasi-static nanoindetation and how properties of hardness and elastic modulus are determined using the load-displacement curves. You are welcome to use these slides in your presentation on the condition that you give credit to Nanomechanics, Inc. on each slide used.
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Acta Mater 57 (2009) 559 Investigation Of The Indentation Size EffectDierk Raabe
Investigation of the indentation size effect through the measurement of the geometrically necessary dislocations beneath small indents of different depths using EBSD tomography
Peculiarities of irrecoverable straining in stress-drop testIJERA Editor
The paper concerns with analytical description of the phenomena observed in stress drop tests, namely, negative increment in plastic and creep deformation due to the sudden decrease in the acting stresses while the net stress remains positive. The model is developed in terms of the synthetic theory of irrecoverable deformation which has been generalized by introducing interplay between the deformation properties of material in the direction of acting load and opposite to it.
Linear And Nonlinear Analytical Modeling of Laminated Composite Beams In Thre...researchinventy
The large current development of aerospace and automotive technologies is based on the use of composite materials which provide significant weight savings compared to their mechanical characteristics. Correct dimensioning of composite structures requires a thorough knowledge of their behavior in small as in large deflection.This work aims to simulate linear and nonlinear behavior of laminates composites under threepoint bending test. The used modelization is based on first-order shear deformation theory (FSDT), classical plate theory (CPT) and Von-Karman’s equations for large deflection. A differential equation of Riccati, describing the variation of the deflection depending on the load, was obtained. Hence, the results deduced show a good correlation with experimental curves
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Effect of lamination angle on maximum deflection of simply supported composit...RAVI KUMAR
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The main objective of the paper is to find out the lamination angle at which minimum deflection is obtained & to find out the effect of lamination angle on maximum transverse deflection of the beam.
The determination of the stress distribution around Pin-Loaded Holes in Mechanically Fastened Joints is presented to the Engineering Department, University of Technology - Jamaica
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Abstract The present research work is to determine buckling load per unit length in rectangular plate with circular cut-outs under bi-axial compression using 2D finite element analysis. The commercial finite element analysis software ANSYS has been successfully executed. The buckling factors are evaluated by changing the position of the holes, length to thickness ratio. The effect of changing the position of holes, a/b ratio, b/t ratio and buckling load per unit length is discussed. The results shows that buckling load per unit length is in clamped-clamped boundary conditions and buckling load is more at top positioned hole, decreases with increase in aspect ratio, decrease with increase breadth to thickness ratio. Keywords: Buckling analysis, Finite element method, Buckling load per unit length , carbon/epoxy composite plate, aspect ratio, b/t ratio, and Biaxial load.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
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PRE-SLIDING FRICTIONAL ANALYSIS OF A COATED SPHERICAL ASPERITY
1. Thesis defense presentation for the degree in
Masters of Engineering Science in Mechanical Engineering
Advisor: Dr. Ali Beheshti
Akshay Patel
Graduate Student
November 20th 2017
PRE-SLIDING FRICTIONAL ANALYSIS OF A
COATED SPHERICAL ASPERITY
2. Content
2
Future Work Recommendation
Conclusions
Results
Verification and Validation
FEA Model
Methodology
Objective
Previous Research
Background
3. Background
3
Introduction- Friction
Whenever two surfaces come in contact
with each other, friction comes into play.
Friction with its many advantages and disadvantages, remains a complex
phenomenon till today.
Applied Force
Friction
Motion
Static Friction force
0 < 𝐹𝑠 ≤ 𝜇 𝑠 𝑁
Kinetic Friction force
𝐹𝑘 = 𝜇 𝑘 𝑁
Applied Tangential Force
FrictionalForce
𝐹𝑠 = 𝜇 𝑠 𝑁
𝐹𝑘 = 𝜇 𝑘 𝑁
4. Background
4
Motivation- Coatings
Magnetic disk drive
MEMS devices
The components are in contact and
relative sliding.
Experience friction, wear, adhesion
and high temperature.
Coatings on the contacting surfaces
has proven highly effective for
tribological improvements.
In absence of frictional study, solid
knowledge on the pre-sliding
behaviors of coated contact is
missing from the literature.
Cutting tools
Automobile engines
Biomedical prosthetics
5. Background
5
Solution- Coated Asperity
Coating surfaces are also rough.
Approach : Single asperity model is
extrapolated to all the asperities on
the surface.
Available approach to explore
frictional behavior of asperity:
1. Indentation
2. Flattening
Understanding the onset of sliding for coated asperity under combined
loading can help in selection of coatings.
Normal LoadingTangential
Loading
6. Previous Research
6
Homogeneous Asperity- Static Friction Model
Chang, Etsion, and Bogy (1988): CEB model
Plastic yield failure mechanism considered as sliding inception for the
shearing of small junction.
Under an applied normal load 𝑃, the maximum static frictional force
𝑄 𝑚𝑎𝑥 is the tangential force, when local yielding occurred.
Kogut and Etsion (2003): KE model
When local yielding occurred, elastic material surrounding the plastic
zone in the contact area can sustain more tangential load.
CEB and KE model underestimates the 𝑄 𝑚𝑎𝑥.
7. Brizmer, Kligerman, and Etsion (2007): BKE Model
By considering tangential stiffness criterion as sliding inception under
the full-stick contact condition.
(𝐾 𝑇)𝑖
(𝐾 𝑇)1
≤ 𝛼
Where, (𝐾 𝑇)𝑖=
𝜕𝑄
𝜕𝑢 𝑥 𝑖
≈
𝑄 𝑖−𝑄 𝑖−1
𝑢 𝑥 𝑖− 𝑢 𝑥 𝑖−1
′(𝐾 𝑇)𝑖′ Tangential contact stiffness at step 𝑖
′𝑄’ Tangential force
′𝑢 𝑥′ Tangential displacement of the rigid flat
′𝛼 ′ Pre-defined number
Sliding initiate when the tangential contact stiffness drops to 𝛼, and
the corresponding value of 𝑄𝑖 becomes 𝑄 𝑚𝑎𝑥.
Previous Research
7
Homogeneous Asperity- Static Friction Model
8. Previous Research
8
Homogeneous Asperity- Static Friction Model
Wu, Shi, and Polycarpou (2012):
Maximum frictional shear stress criterion used for sliding inception.
𝜏 𝑐= 𝜎𝑠 /√3
Where, ′𝜏 𝑐′ Critical frictional shear stress
′𝜎𝑠′ Yield stress under uniaxial tension
Once the frictional shear stress in contact area reaches the defined
critical shear stress, local sliding occurs at that point. When all the
points in contact area reach critical shear stress, the entire interface
starts sliding.
The corresponding tangential loading, at that moment is maximum
static friction force 𝑄 𝑚𝑎𝑥.
9. Previous Research
9
Coated Asperity- Normal Loading
Goltsberg, Etsion, and Davidi (2011):
At Onset of plastic yielding, relation of the dimensionless coating
thickness 𝑡/𝑅 𝑝 provided by considering the material property.
Typical location of onset of yielding found out.
10. Previous Research
10
Coated Asperity- Normal Loading
Goltsberg, and Etsion (2015):
Proposed universal model for the load-displacement relation in an
elastic coated spherical asperity for thin coating.
Chen, Goltsberg, and Etsion (2016):
Developed universal model for elastic-plastic coated spherical normal
contact for moderate to large coating thickness.
Analyzed contact for 𝑡/𝑅 > 𝑡/𝑅 𝑃 under slip condition.
Provided empirical expressions for first 𝜔 𝑐1 and second 𝜔 𝑐2 critical
interferences, corresponds the yield inception in coating and substrate
respectively.
11. Previous Research
11
Coated Asperity- Normal Loading
Ronen, Goltsberg, and Etsion (2017):
Provided the optimum coating thickness in stick condition 𝑡/𝑅 𝑝_𝑠𝑡.
Coated contact analyzed for 𝑡/𝑅 > 𝑡/𝑅 𝑝_𝑠𝑡 and obtained the
expressions for first 𝛿 𝑐1 and second 𝛿 𝑐2 critical interference:
𝛿 𝑐1
𝜔𝑐_𝑐𝑜
= 6.82𝑣 − 7.83 𝑣2
+ 0.0586 1 + 0.007
𝐸𝑐𝑜
𝐸𝑠𝑢
− 1
0.646
𝑌𝑐𝑜
𝐸𝑐𝑜
0.244
𝑡
𝑅
−1.21
𝛿 𝑐2
𝜔𝑐_𝑐𝑜
=
𝑡
𝑅
1.17
𝐸𝑐𝑜
𝐸𝑠𝑢
− 1
−0.09
𝑌𝑐𝑜
𝐸𝑐𝑜
−1.93
𝑌𝑠𝑢
𝐸𝑠𝑢
0.89
Where, ′𝑣′ Poisson’s ratio Subscript,
′𝐸′ Young’s modulus ′𝑐′ Critical value
′𝑌′ Yield strength ′𝑐𝑜′ Coating
′𝜔′ Interference in slip ′𝑠𝑢′ Substrate
12. Objective
12
To FE model of 3D coated asperity by using ABAQUS CAE.
Verification of the FE model with available numerical and experimental
studies for normal and tangential loading.
Analyze pre-sliding frictional behavior of coated asperity under combined
loading for various coating thickness ratios and coating to substrate
Young’s modulus ratios, and provide the comparison of:
Von Mises stress and plastic strain
Tangential frictional force
Static friction coefficient
13. Methodology
13
ABAQUS/Explicit quasi-static scheme is used to analyzed pre-sliding of
coated asperity.
Normal loading is considered under the stick contact condition.
Inspired by Wu et al.(2012), the maximum frictional shear stress
criterion is used for the sliding inception by considering the shear
strength of coating material.
𝜏 𝑐= 𝜎𝑠_𝑐𝑜 /√3
Where, ′𝜏 𝑐′ Critical frictional shear stress
′𝜎𝑆_𝑐𝑜′ Yield stress of coating
14. FE Model
14
Components
Sphere:
o 3D Deformable
o Radius of sphere: 𝑅′
= 𝑅 + 𝑡
o Radius of substrate: 𝑅 = 10𝑚𝑚
o Thickness of coating: t
Rigid flat plate:
o Analytical Rigid
o Dimensions: 3𝑅 × 𝑅
15. FE Model
15
Material Property- Coated Sphere
The coating and the substrate material are defined as elastic-perfectly
plastic.
o Poisson's ratio: 𝑣 = 𝑣𝑠𝑢= 𝑣𝑐𝑜= 0.32
o Young's modulus of substrate: 𝐸𝑠𝑢 = 200GPa
o Young’s modulus of coating varies as: 2 ≤ 𝐸𝑐𝑜 𝐸𝑠𝑢 ≤ 10
o Young’s modulus to yield strength to ratio for substrate and coating:
𝐸𝑠𝑢 𝑌𝑠𝑢 = 𝐸𝑐𝑜 𝑌𝑐𝑜 = 1000
16. FE Model
16
Contact Interaction
Surface to surface (Explicit)
o Master surface: Rigid flat plate
o Slave surface: Deformable sphere
Contact interaction property:
o Normal loading: “Hard” contact pressure-overclosure used and
separation of the contact is not allowed.
o Tangential loading: The value of local friction coefficient is defined
as 1000 and shear stress limit is given by considering the coating
material.
17. FE Model
17
Mesh- Partition
Partitioning of sphere.
o Coating: Shielded only 20% of
radius of substrate sphere.
o Substrate: Rest of the sphere
Coating –Substrate Zones:
Zone Partition Size
I 0.2t
II 0.7t
III 0.05R
IV 0.1R
V 0.2R
VI 0.22R
19. FE Model
19
Loading and Boundary Conditions
ENCASTRE at bottom of sphere
U1=U2=U3=UR1=UR2=UR3=0
XY-plane symmetry
𝑍𝑆𝑌𝑀𝑀(𝑈𝑧 = 𝑈𝑅 𝑥 = 𝑈𝑅 𝑦 = 0)
Reference point
Normal displacement in Y and
tangential displacement in X.
20. Verification and Validation
20
Verification of Model under Normal Loading
Homogeneous model under elastic normal loading
Coated model under elastic normal loading
Coated model under elastic-plastic normal loading
Verification and Validation (experimental comparison) of Model under
Elastic-perfectly Plastic Combined Normal and Tangential Loading
22. Verification
22
Coated Model under Elastic Normal Loading
Goltsberg and Etsion (2015)
0
1
2
3
4
5
6
0 0.00005 0.0001 0.00015 0.0002
Load,P(N)
Interference, ω (mm)
Goltsberg and Etsion (2015)
t/R=0.009 FEM
t/R=0.007 FEM
t/R=0.005 FEM
t/R=0.003 FEM
t/R=0.001 FEM
𝑬 𝒄𝒐/𝑬 𝒔𝒖 = 𝟒
23. Verification
23
Coated Model under Elastic-plastic Normal Loading
Ronen, Goltsberg, and Etsion (2017)
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
DimensionlesscontatcLoad,L/Lc2
Dimensionless Interference, δ/δc2
t/R=0.05
Ronen et al. (2017)
Eco/Esu=10 FEM
Eco/Esu=8 FEM
Eco/Esu=6 FEM
Eco/Esu=4 FEM
Eco/Esu=2 FEM
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
DimensionlesscontatcArea,Ast/Ac2_st
Dimensionless Interference, δ/δc2
t/R=0.05
Ronen et al. (2017)
Eco/Esu=10 FEM
Eco/Esu=8 FEM
Eco/Esu=6 FEM
Eco/Esu=4 FEM
Eco/Esu=2 FEM
24. Verification
24
Homogeneous ( 𝑬 𝒄𝒐 𝑬 𝒔𝒖 = 𝟏) Model under Combined Loading
Wu, Shi, and Polycarpou (2012)
0
0.1
0.2
0.3
0.4
0 0.2 0.4 0.6 0.8 1
Q/Pc
ux/ωc
ω=0.5ωc
Wu et al. (2012)
FEM
0
0.5
1
1.5
2
2.5
0 0.5 1 1.5 2 2.5 3
Q/Pc
ux/ωc
ω=3ωc
Wu et al. (2012)
FEM
0
3
6
9
12
0 3 6 9 12 15
Q/Pc
ux/ωc
ω=12ωc
Wu et al. (2012)
FEM
0
20
40
60
80
100
0 10 20 30 40 50
Q/Pc
ux/ωc
ω=72ωc
Wu et al. (2012)
FEM
𝑬 𝒄𝒐 𝑬 𝒔𝒖 = 𝟐
25. Verification
25
Homogeneous ( 𝑬 𝒄𝒐 𝑬 𝒔𝒖 = 𝟏) Model under Combined Loading
Wu, Shi, and Polycarpou (2012)
0
0.3
0.6
0.9
1.2
1.5
1.8
-5 5 15 25 35 45 55 65 75
Staticfrictiuoncoefficient,µs
Dimensionless normal loading, ω/ωc_su
Wu et al. (2012)
Current FEM, Eco/Esu=1
26. Validation
26
Homogeneous ( 𝑬 𝒄𝒐 𝑬 𝒔𝒖 = 𝟏) Model under Combined Loading
Ovcharenko et al. (2008)
0
0.3
0.6
0.9
1.2
1.5
1.8
-5 5 15 25 35 45 55 65 75 85 95 105
Staticfrictiuoncoefficient,µs
Dimensionless normal load, P/Pc_su
Cu D=5mm, Ovcharenko et al. (2008)
Current FEM, Eco/Esu=1
27. Results
27
Coated Model under Combined Loading
Stress and Strain
Frictional Force
Static Friction
Input Parameters of Coating-Substrate model
Radius of substrate sphere, 𝑹 10 𝑚𝑚
Dimensionless coating thickness, 𝒕/𝑹 0.005, 0.025, 0.05
Young’s modulus of rigid surface, 𝑬 ∞
Young’s modulus of substrate, 𝑬 𝒔𝒖 200 𝐺𝑃𝑎
Coating to substrate ratio, 𝑬 𝒄𝒐/𝑬 𝒔𝒖 1,2,4
Young’s modulus to yield strength to
ratio for substrate and coating,
𝑬 𝒔𝒖/𝒀 𝒔𝒖 = 𝑬 𝒄𝒐/𝒀 𝒄𝒐
1000
Poisson’s ratio, 𝒗 0.32
29. Results
29
Stress and Strain, 𝜹 𝝎 𝒄_𝒔𝒖 = 𝟏, t/R=0.005
In the tangential loading,
the maximum stress area
moves to the surface,
reaching the yield stress,
and yielding covers the
whole contact area
gradually. At that moment
𝑄 becomes 𝑄 𝑚𝑎𝑥.
No yielding during the
normal loading because of
𝛿 < 𝛿 𝑐1 .
30. Results
30
Stress and Strain, 𝜹 𝝎 𝒄_𝒔𝒖 = 𝟏𝟎
When, 𝛿 𝑐1 < 𝛿 < 𝛿 𝑐2 , yielding of
the coating can be seen during the
normal loading.
For 𝑡/𝑅 = 0.005 , 𝛿 > 𝛿 𝑐2 ,
yielding of substrate occurred
during normal loading.
Plastic strain development shrinks
in the coating with increment of
the Young’s modulus ratios.
31. Results
31
Stress and Strain, 𝜹 𝝎 𝒄_𝒔𝒖 = 𝟏𝟎
Higher coating thickness ratio
t/R, protects the substrate
from yielding.
37. Results
37
Tangential Frictional Force vs. Tangential Displacement for 𝑡/𝑅 = 0.005
0
0.5
1
1.5
2
2.5
3
0 0.2 0.4 0.6 0.8 1
Q/Pc_su
ux/ωc_su
δ=1ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
0
5
10
15
20
25
30
35
0 2 4 6 8 10
Q/Pc_su
ux/ωc_su
δ=10ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
0
20
40
60
80
100
120
0 5 10 15 20 25 30
Q/Pc_su
ux/ωc_su
δ=30ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
0
50
100
150
200
250
0 10 20 30 40 50 60
Q/Pc_su
ux/ωc_su
δ=60ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
As Young’s modulus ratio
increases, it delays the
stiffness softening.
Coated asperity can sustain
much higher loads before the
onset of sliding.
Ability to sustain higher
friction force increases with
increment of 𝐸𝑐𝑜/𝐸𝑠𝑢.
38. Results
38
Tangential Frictional Force vs. Tangential Displacement for 𝑡/𝑅 = 0.025
As Young’s modulus ratio
increases, it delays the
stiffness softening.
Coated asperity can sustain
much higher loads before the
onset of sliding.
Ability to sustain higher
friction force increases with
increment of 𝐸𝑐𝑜/𝐸𝑠𝑢
0
0.5
1
1.5
2
2.5
3
0 0.2 0.4 0.6 0.8 1
Q/Pc_su
ux/ωc_su
δ=1ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
0
5
10
15
20
25
30
35
0 2 4 6 8 10
Q/Pc_su
ux/ωc_su
δ=10ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
0
20
40
60
80
100
120
0 5 10 15 20 25 30
Q/Pc_su
ux/ωc_su
δ=30ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
0
50
100
150
200
250
0 10 20 30 40 50 60
Q/Pc_su
ux/ωc_su
δ=60ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
39. Results
39
Tangential Frictional Force vs. Tangential Displacement for 𝑡/𝑅 = 0.05
As Young’s modulus ratio
increases, it delays the
stiffness softening of contact.
Coated asperity can sustain
much higher loads before the
onset of sliding.
Ability to sustain higher
friction force increases with
increment of 𝐸𝑐𝑜/𝐸𝑠𝑢
0
0.5
1
1.5
2
2.5
3
0 0.2 0.4 0.6 0.8 1
Q/Pc_su
ux/ωc_su
δ=1ωc_suEco/Esu=1
Eco/Esu=2
Eco/Esu=4
0
5
10
15
20
25
30
35
0 2 4 6 8 10
Q/Pc_su
ux/ωc_su
δ=10ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
0
20
40
60
80
100
120
0 5 10 15 20 25 30
Q/Pc_su
ux/ωc_su
δ=30ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
0
50
100
150
200
250
0 10 20 30 40 50 60
Q/Pc_su
ux/ωc_su
δ=60ωc_su
Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
40. Results
40
Tangential Frictional Force vs. Tangential Displacement for 𝛿 𝜔𝑐_𝑠𝑢 = 1
At same 𝐸𝑐𝑜/𝐸𝑠𝑢, higher t/R is
suitable to resist stiffness
softening of the coated contact.
0
0.5
1
1.5
2
2.5
3
0 0.2 0.4 0.6 0.8 1
Q/Pc_su
ux/ωc_su
Eco/Esu=1
Eco/Esu=2, t/R=0.05
Eco/Esu=2, t/R=0.025
Eco/Esu=2, t/R=0.005
41. Results
41
Tangential Frictional Force vs. Tangential Displacement for 𝛿 𝜔𝑐_𝑠𝑢 = 1
At same 𝐸𝑐𝑜/𝐸𝑠𝑢, higher t/R is
suitable to resist stiffness
softening of the coated contact.
Combination of higher 𝐸𝑐𝑜/𝐸𝑠𝑢
with higher t/R can present
good tribological performance
of the coated contact for high
load applications. 0
0.5
1
1.5
2
2.5
3
0 0.2 0.4 0.6 0.8 1
Q/Pc_su
ux/ωc_su
Eco/Esu=1
Eco/Esu=4, t/R=0.05
Eco/Esu=4, t/R=0.025
Eco/Esu=4, t/R=0.005
43. Results
43
Static Friction
Higher 𝐸𝑐𝑜/𝐸𝑠𝑢 predicts
slightly more µs.
With the increase of the t/R
from 0.005 to 0.05 the static
friction deviates for chosen
𝐸𝑐𝑜/𝐸𝑠𝑢.
0
0.3
0.6
0.9
1.2
1.5
0 10 20 30 40 50 60 70 80 90 100
Staticfrictiuoncoefficient,µs
Dimensionless normal load, P/Pc_su
t/R=0.025 Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
44. Results
44
Static Friction
Higher 𝐸𝑐𝑜/𝐸𝑠𝑢 predicts
slightly more µs.
With the increase of the t/R
from 0.005 to 0.05 the static
friction deviates for chosen
𝐸𝑐𝑜/𝐸𝑠𝑢.
0
0.3
0.6
0.9
1.2
1.5
0 10 20 30 40 50 60 70 80 90 100
Staticfrictiuoncoefficient,µs
Dimensionless normal load, P/Pc_su
t/R=0.05 Eco/Esu=1
Eco/Esu=2
Eco/Esu=4
45. Conclusions
45
A 3D spherical coated model is developed upon the verification and
validation against the available numerical and experimental studies.
Von Mises stress and strain distribution are studied, and failure
mechanisms for coating and substrate are observed for 𝛿 < 𝛿 𝑐1 ,
𝛿 𝑐1 < 𝛿 < 𝛿 𝑐2 and 𝛿 > 𝛿 𝑐2 under combined loading.
It is found that,
For 𝛿 < 𝛿 𝑐2 , higher 𝑡/𝑅 with higher 𝐸𝑐𝑜/𝐸𝑠𝑢 shows good resistance
against the yield failure of coating.
For 𝛿 > 𝛿 𝑐2 , higher 𝑡/𝑅 with lower 𝐸𝑐𝑜/𝐸𝑠𝑢 shows good resistance
against the yield failure of substrate.
46. Conclusions
46
Under the same normal displacement pre-load,
Coated asperity can sustain much higher loads before the onset of
sliding.
Ability to protect the coated contact from the softening is increased
with the increment of 𝐸𝑐𝑜/𝐸𝑠𝑢 and t/R.
For the load control model, increase of 𝐸𝑐𝑜/𝐸𝑠𝑢 and t/R results in slightly
higher friction coefficient.
47. Future Work Recommendation
47
Different failure criterion can be used to analyze coating contact interface
based on yield failure and stiffness failure criterion.
Similar study can be conducted for soft coatings. Moreover, it can be
further expanded for multi-layer and functionally graded coating
materials.
For a large range of coating thickness ratio and material property study
can be extended and solid empirical relation for the friction coefficient
can be developed in terms of frictional force, material properties and
coating thickness ratio.
Study can be extended to different geometries such as Cylindrical and
Sinusoidal shapes.
48. Acknowledgement
48
I would like to thank my advisor, Dr. Ali Beheshti, for his encouragement
and constant kind support.
I also thankful to my committee members Dr. Xuejun Fan and Dr. Jenny
Zhou, for their time from busy schedules.
I appreciate all the tidbits of knowledge, care, and motivation provided
by my colleagues at the µTCM.
Good Afternoon prof and dear friends, I am Akshay Patel, Today I am going to present my thesis work on “” which I have been working under the guidance of DR. Ali Beheshti since Fall2016
(Tune the voice)
Let’s talk about the outline First,
I will go through the background and previous research.
>>After that by defining objective of the study, let you know about the used methodology and development of the finite element model.
>>Later on, with the verification and validation of the FE model, I will discuss about the results and conclusions followed by the future work recommandations.
Let’s begin the main presentation NOW
What is friction??
>>In a layman’s term, Friction is resistance to the motion/applied force.
>>Whenever two surfaces come in to contact with each other, friction is there.
>>Friction with many of its advantages and disadvantages, remains a complex physical phenomenon to understand.
>>In simple terms friction can be classified into Pre-sliding and sliding friction.
>>Pre-sliding friction keeps the body in the rest by resisting the applied force. And whenever applied force becomes greater than the maximum static friction force, body moves into the motion from its rest position.
>>In the engineering applications mechanical components are in contact and relative sliding.
>>For example, cutting tools, MEMS devices, optical micro switches, magnetic disk drive, electrical circuits, automotive engines and as well as in biomedical prosthetics.
>>And often, experience friction, wear, adhesion and high temperature.
>>In critical operation conditions, coatings on the contacting surfaces has proven highly effective technique for tribological improvements.
>>Despite the application and benefits, study of the pre-sliding for coated asperity is missing from the literature.
>>
>>All real surfaces are rough at micro level, and this is true for coated surfaces as well.
>>as shown here, we can analyze the single coated asperity under combined normal and tangential loading to get the idea about its frictional behavior and later on it can be extrapolated by statistical distribution.
>>There are two paths available to explore frictional study of curve asperity: Indentation and Flattening
>>flattening is preferable choice because Indentation involves High abrasive friction & wear due to plowing .
>> Comprehensive frictional study of coated asperity can help in coating selection.
>> Flattening involves Mild adhesive friction & wear
>>Before jumping into the friction analysis of coated asperity first lets talk about, the available frictional model for homogeneous asperity in contact with rigid flat for different sliding inception.
>>and they defined a Qmax at occurrence of local yielding.
>> later on in 2003
>> At very first by considering the material property for the failure mechanism chang et al. represented a frictional model analytically.
between the contacting surfaces.
>>KE semi analytically represented the friction model on same sliding inception.
>>Another frictional model is proposed by brizmer et al. by considering tangential stiffness criterion.
>>According to their model, during tangential loading when tangential stiffness of contact drops to the 10% of its initial stiffness, sliding of interface initiates. And at that moment Q becomes Qmax
Analytical study has some limitation for defining the BC and Contact Interaction so FEM is best tool to simulate asperity contact.
>> BKE presents model,
>>A more accurate friction model for homogeneous asperity, is proposed by wu et al. by considering the max. frictional shear stress criterion as sliding inception.
They defined the critical shear stress as the upper limit of the sliding by this eq. where the sigma s is the yield strength of the material
another group of researchers, find new way to define sliding criterion by considering the
>> because in practical experiments FULL stick condition is hard to develop. Over estimate the friction
>>now lets Discuss about the research work, Done by the etsion and his group for 2D axisymmetric coated asperity.
In 2011 they studied the onset of plastic yielding, and provided the expression for the optimum coating thickness ratio
And based on that coating thickness they three typical location of onset of yielding found out as shown here in figure.
And to protect the surface form the weakening effect coating thickness ratio should be larger than its critical value.
>>for very first, slip condition 2D axisymmetric model
After that, in 2015 they presented the universal model for load-displacement of elastic coated asperity for thin coating
And continuing that work later on proposed the model for moderate to large thickness ratio
By studying the coating thickness ratios to avoid the weakening of substrate, provided the expression for first and second interference in slip contact condition
>> under slip condition,
0.0005 to 0.02
0.02 to 0.05
>> recently in 2017 they compare the stick and slip contact condition for the coated asperity and found out the negligible effect of it on contact parameters.
>> and they provide the improved expression of the coating thickness ratio and other contact parameters under the stick contact condition by the curve fitting their numerical results. Here the expression of the first and second critical interference is shown.
After observing the coated asperity in slip condition they observed in stick contact condition and provided eqation for stick condtion as shown here which are going to use later for the calculation in this study,
To analyze the coated asperity
>> under slip condition
After the background and previous research we know there is no study available for the pre-sliding of coated asperity, Now lets talk about the objective of this study
Stick :sticking to each other,
This is the methodology of the study, read slide
>>as upper bound
quasi-static slowly enough for the system to remain in internal equilibrium.
>>Now lets talk about the development of FE model
>>half of the deformable asperity in contact with a analytical rigid flat is modeled as shown here.
The rigid flat is assembled to the sphere by using coincident constrain between the reference point of rigid flat and topmost node of the spherical asperity.
RP>>spherical asperity contact model with a rigid flat can be modeled as half-half of the asperity in contact with a rigid flat
>>deformable spherical solid part is partitioned to create coating layer covered on the substrate.
>>0.002≤𝑡/𝑅≤0.05 by keeping 𝑡/𝑅 > 𝑡/𝑅 𝑝_𝑠𝑡
>> A rigid body reference point is created as shown in Figure 3.4 which transmits the motion of the entire rigid body. The rigid flat is assembled to the sphere by using coincident constrain between the reference point of rigid flat and topmost node of the spherical asperity.
Homogeneous sections of coating and the substrate are defined as elastic-perfectly plastic.
To inpute material property, Values of poission’s ratio, young's modulus and yield strength are provided
Materials which undergo irreversible deformation without any increase in stresses or loads.
>> Surface to surface contact interaction is selected between the rigid flat and deformable coated sphere as shown here. For better convergence and improve the accuracy of contact stress.
>> contact interaction properties are given.
>> to define Stick condition in normal loading the hard contact pressure over closure relation is used.
>> to define the shear stress as upper bound for sliding initiation of contact interface ,
>>Mechanical Constraint: Penalty is used because the involvement of analytical surface. And convergance easly with lower increament in time step
>>For better convergence and improves the accuracy of contact stresses due to a better distribution of contact forces
>>to get the frictional behavior
>> to define stick contact condition in normal direction
>> to give the shear limit as upper bound of sliding,
remain fully bonded together
And gives the any value of contact presuure.
>>To have the time effective, and better accuracy of the results, the half-half sphere is divided into different partition and zones.
>>It should be noted here that the coating partition is shielded on only 20% of the radius of substrate sphere for the computational efficiency as it reduced unnecessary meshing andThe area is chosen large enough to simply provide identical results compare to whole cover substrate coating for all combined loading ranges.
>>for different model of the coating thickness ratios this zones and partitions varies accordingly to values of R and t.
The zones are meshed with structure and free meshing techniq
>>The area is chosen large enough to simply provide identical results compare to whole cover substrate coating for all combined loading ranges.
>>the Zone entities I, II, III, IV, V are meshed with structural control mesh to have a good visualization of the stress behavior in the contact region
>>Structure zone: Continuum 3D eight node Reduce integration mesh used to get optimal stress and strain behavior. plastic behavior
Free zone: modified 10-node second-order tetrahedral element
ements take advantage of automatic triangular and tetrahedral mesh generators and are robust for large deformation problems and contact.
>>The deformable hemisphere is constrained in all direction in at the bottom with encastre condition
>> symmetry condition is applied in symmetry plane as shown in fig.
>>A displacement is applied to the reference point of the rigid flat at the topmost node of spherical contact in normal direction 𝒀
and then displacement loading is applied in the tangential direction 𝑿
Now lets talk about the verification and validation of the developed FE model to check its Accuracy.
>>To verify the current FEM model, its results are compared with available numerical and experimental studies.
>>At fist, homogeneous and coated asperity verified under normal loading.
>>And after verification under normal loading, current FEM model is verified and validate under combined normal and tangential loading.
mesh convergence study
the loading rate of 0.1 𝑚/𝑠
>>The basic verification of model is done through comparison with the elastic Hertz analytical solution for Load vs interference, and normalized contact pressure vs normalized interference
>>observed that, Results of the Current homogeneos FEM follows the hartzian curves less than 1% of error.
Close agreement is observed with analytical data and error is less than 1%
>> homogeneous model Under perfect slip contact condition for elastic normal loading is compared for analytical values of Hertz for load displacement
>>Following parameters: radius of sphere 10.09𝑚𝑚, Young’s modulus 74000𝑀𝑃𝑎, yield strength 325𝑀𝑃𝑎, and Poisson’s ratio 0.32.
>>Close agreement with the analytical data and the error is approximately 1%
>>After the hartzian verification, the Coated model is compared for load-displacement curves under elastic normal loading and the numerical results provided by G and E.
>>Here, the young’s modulus ratio is constant and coating thickness ratios are varied as shown.
>>results displays Good Harmony within 2.2% error for the maximum normal load.
>> under slip condition, compared with their FE results.
>> 𝑅=10𝑚𝑚, 𝐸 𝑠𝑢 =200𝐺𝑃𝑎 and 𝐸 𝑐𝑜 / 𝐸 𝑠𝑢 =4 , t/R varies
>>displays good harmony within 2.2% error for the maximum normal load
>>Similar to elastic normal loading , the current coated model can be also verified under elastic-plastic normal loading under stick contact condition,
>>by keeping the coating thickness ratio constant and changing material properties
>>the Comparison of the FEM results with the analytical results of Ronen et al. for dimensionless values of….
>>Its Shows the close approximation.
>> under stick contact condition, compared to empirical relations.
>>𝑡/𝑅= 0.05,, 𝑣= 𝑣 𝑠𝑢 = 𝑣 𝑐𝑜 =0.32, 𝐸 𝑠𝑢 =200𝐺𝑃𝑎, 𝐸 𝑠𝑢 𝑌 𝑠𝑢 = 𝐸 𝑐𝑜 𝑌 𝑐𝑜 =1000 , and, 2≤ 𝐸 𝑐𝑜 𝐸 𝑠𝑢 ≤10 , i.e., 2, 4, 6, 8 and 10.
>> 𝛿=𝛿 𝑐2 , according to emperical equation by curve fitting (when yielding takes place in to the substrate)
>> holds true for all ratios of coating.
>> consider in permissible limits.
>> Before the going to results for coated asperity, under combined loading for current FEM model it is needed to verify with available friction model.
>>the current model is compared for dimensionless tangential force vs dimensionless displacement with numerical results of wu et al. and results are found within close approximation.
>>frictionless during the normal loading in both directions, contact under full stick in a tangential direction, tangential shear stress is limited to critical shear stress and sliding happens when the shear stress at all contacting points reaches its threshold
>>𝑅’=10.5𝑚𝑚 ,Young’s modulus, Poisson’s ratio, and yield strength are 74000𝑀𝑃𝑎, 0.33, and 325𝑀𝑃𝑎,
>>reasonably accurate having the maximum 5.6% error for any case of combined loading.
>>Moreover, the behavior of the Von mises stress distribution is observed and found similar to their results.
>> in addition, the model is compared for the static friction coefficient for the selected normal displacement preload and it proves good conformity with their results.
>>With the increase of the tangential loading, the stress distribution changes to asymmetric and the maximum stress moves to the contact surface and reaches the well-defined yielding stress limit.
>>proves good conformity with the Wu et al. under displacement control. 𝒕/𝑹=𝟎.𝟎𝟓
>> same as verification, validation is also required to trust the results,
>>hence, the current FEM model is compared with the available experimental study of ovcharenko et al
and result of current FEM for static friction coefficient under the range of normal load are found very close to their experimental results especially at high loads for static friction coefficient.
>>This all verification/validation proves the capability of model to anlyze pre-sliding behavior.
>>validity of the current frictional FEM model can be furthered examined with the available experimental results of Ovcharenko et al.
>>very close to the experimental results especially at high loads.
>>This all verifications and validations, verifies the capability of the current coated model to capture accurately tangential loading effect, to analyze pre-sliding for different coating thickness ratio and coating-substrate material properties, and it can be utilized for further frictional analysis. 𝒕/𝑹=𝟎.𝟎𝟓
>>Now lets discuss about the results,
>>coated model under combined normal and tangential loading is simulated for various coating thickness ratios and coating to substate youngs modulus ratios to observe…..stress
>>used input parameter used for the model are provided here.
>>before jump into the results, mesh convergence study carried out, and optimum mesh size decided and also check for maintain the true quasi-static condition 0.0003R at contact 0.006R (stress),
>> after that for provided input parameters this results are observed for various coating thickness ratios and material property.
>>to check truly true pre-sliding quasistatic loading rate 0.1m/s, kinetic energy/ internal energy 2.6%
>> range of coating thickness ratio is carefully selected to avoid the weakening effect of substrate after the comprehensive study of dimensionless critical contact parameters.
>>And similarly the range of normal loading is selected, to observe the effect of sliding inception under various normal displacement preload.
1. When Normal displacement pre-load is lower than first critical interference
2. between the frist and second
3. Beyond the second
>>the lower range of coating thickness ratio up to 𝑡/𝑅≤0.005 and higher Young’s modulus ratio of the coating to the substrate 𝐸 𝑐𝑜 𝐸 𝑠𝑢 =6, 8 𝑜𝑟 10 , calculated first critical interference is higher as compared to the second critical interference
>> loading range gives full exploration, i.e., (i) before first critical interference, (ii) between the first and second critical interferences and (iii) beyond the second critical interference.
>> on page 50 you can see the calculated values of dc1 and dc2
>> here results for the stress and strain development are shown for normal displacement preload is equal to 1 critical interfence of the sphere made of substrate material, for coating thickness ratio 0.005
>>the distribution of stress is axisymmetric before the tangential loading, and with increasing loading the stress distribution turn into asymmetric.
>>At this moment the static tangential force becomes the maximum tangential force 𝑄 𝑚𝑎𝑥 .
>> same behavior can be seen for other t/R
>> there is no yielding in normal loading because applied normal displacement preload is lower than first critical interference.
the stress and strain development is observed at q=0 and q=max
.IT is observed that
>>Yielding occurs only on the top surface of the coating
>>Further tangential displacement loading results in a larger yield area,
>> same behavior can be seen for other t/R
>> here results for the stress and strain development are provided for normal displacement preload is equal to 10, for different coating thickness ratios.
>>
>>It can also seen from the development of stress and strain that
>>Similar kind of behavior can be seen for other two cases of normal displacement loading.
>>Now lets discuss the failure mechanism in reference to plastic yielding
first case: when applied normal displacement loading is lower then the first critical interference,
there is no plastic yielding in normal loading, but with the increase of tangential loading yielding initiates directly on coated contact surface.
Second case: when applied normal displacement preload is greater then the first critical but still lower than the second , failure is initiated in the coating and extended to the coated contact surface with increasing tangential loading. ,
>>it can be seen that with increase of young modulus ratio plastic region shrinks, and resist the yield failure of coating.
>>Now lets discuss the third case, when the applied normal displacement preload is larger than second critical interference,
yielding of the substaret and coating can be seen during normal loading and with application of tangential loading it covers the contact region. As shown
>>it is found that lower ratio of young’s modulus resist the yield failure of substrate .
>>If the effect is not clear then lets see for higher coating thickness ratio, for the case of higher coating thickness ratio this failure can bee seen clearly as shown here
the large coating thickness ratio resistance of yield failure in substrate can be seen like this,
>> so it is found here that higher coating thickness ratio with lower young modulus ratio of coating to substrate resists the yield failure of substrate.
After the observation of the stress and strain,
Now lets discuss the comparison of the tangential force and displacement displacement
It is observed that
Similar kind of results can be observed with the increment of coating thickness ratios.
Here we observed clear effect of change in young ,modulus ratio
Now, let’s see the clear effect of change in coating thickness ratio. It is observed that
After observing for the higher young modulus ratio we can say that
We already discuss the results for the stress strain and tangential force,
Now lets see effect of change in coating thickness ratios and youngs modulus ratios for coated asperity, for the results of the static friction coefficient under applied normal preload is plotted .
, here it can be seen that the
for load control coated modelwe seen the effect of youngs modulus and
Read,
Now lets conclude,
Lets conclude the research now,
Delta = normal displacement preload
>>softening=become less hard
>> SO, for the protection of the substrate, higher young’s modulus ratio with higher coating thickness ratio is best combination.
>>In this study, the maximum shear stress criterion is used to understand the frictional behavior of the coating.
>>All the simulation is done for the flattening of the single-layered coated asperity, coated with a hard homogeneous material. However,