NUMERICAL ANALYSIS AND EXPERIMENTAL ASSESSMENT OF IMPACT WEAR RESISTANT COATINGS: ELECTRODE, NYLON, PC-ABS AND POLYURETHANE
Coatings; Numerical analysis; Compression test; Resistance and surface protection
Due to the need to increase the efficiency of operational processes, machines are being subjected to severe work operations. This leads to premature wear of their mechanical components, which results in a decrease in their useful life and an increase in maintenance costs. To extend the useful life of machine components under these severe operating conditions, materials are used for surface protection such as: electrodes, polymers, composites, tubular wire, among others. This work presents the numerical evaluation of the sphere-on-plane compression test. Two steel base materials (SAE 1045 and SAE 1020) and four coatings are studied. The objective is to evaluate the behavior of surface coatings when subjected to compressive loads, in order to protect the base material, as well as their Equivalent von Mises Stress, indentation and equivalent plastic deformation obtained in the critical contact node. Sphere – plane configuration compression tests are performed on samples using the hard electrode coating, in order to obtain information on the mechanical properties of this coating. For Nylon, PC-ABS and Polyurethane, information obtained from the literature on their mechanical behavior is used. All this information is used for the calibration of a finite element model. The simulation consists of five configurations, one of which is just the base material and four with surface coatings. All models are subjected to four loading conditions: 500N, 1000N, 1500N and 2000N. Given the results, it is concluded that the use of coatings can lead to a significant increase in the useful life of the equipment in which they are applied. However, for the choice of coating, it is necessary to evaluate the workloads that the coating can undergo. It is recommended to use electrodes for high loads and polymers for applications with compressive loads of small magnitude and high number of cycles.