CN-122020960-A - Simulation research method for wear performance of nano diamond ceramic coating

Abstract

The application provides a simulation research method for the abrasion performance of a nano diamond ceramic coating. The method aims to solve the problem that the existing wear simulation depends on a user subroutine, and the result is unreliable due to the fact that the coefficient is scaled empirically and grid-physical mismatch is needed. The method is based on Abaqus software, a high-fidelity contact-abrasion coupling model is constructed, the local grid size is determined by combining with the Hertz contact theory, multi-cycle automatic control is realized by utilizing a native x STEP CYCLING instruction, differential abrasion parameters are defined for the contact double surfaces respectively, and a termination criterion based on accumulated abrasion depth is introduced. By the technical scheme, the wear evolution simulation of the nano diamond ceramic coating, which does not need external programming, is high in precision, high in efficiency and stable, can be realized.

Inventors

• WANG MIN
• YANG JINGYI
• GONG JIAWEI
• Ai Shihao
• ZHAO WEIWEN
• WU LIJIE
• YUAN JIANHUI

Assignees

• 上海电子信息职业技术学院

Dates

Publication Date

20260512

Application Date

20251222

Claims (7)

1. 1. The simulation research method for the wear performance of the nano diamond ceramic coating is characterized in that the method is based on Abaqus software, and realizes numerical simulation of the wear evolution process of the nano diamond ceramic coating under the multi-physical field coupling working condition by constructing a high-fidelity contact-wear coupling finite element model and embedding an embedded multi-cycle control mechanism on the premise of not calling a user-defined subroutine; the method comprises the following steps: S1, creating a Model instance Model-1 in an Abaqus/CAE environment, and respectively constructing three-dimensional solid geometric components in a Part module, wherein the upper surface of a grinding ball Sphere and a abrasion Sample are Sample, and the upper surface of the abrasion Sample is a nano diamond ceramic coating region to be simulated; s2, in the Property module, establishing material characteristics of the grinding ball and the abrasion sample piece, including elastic modulus, poisson ratio and density; S3, establishing an Instance of the grinding ball and the abrasion Sample piece in an Assembly module, wherein the Instance of the grinding ball and the abrasion Sample piece are respectively Instance-Sphere and Instance-Sample; S4, in the Mesh module, dividing grids for the grinding balls and the abrasion sample pieces, and designating the grid type as C3D8R; S5, defining two static general analysis steps in a Step module, namely, step-1 for applying normal preload and Step-2 for applying tangential sliding motion, defining contact characteristics and contacts between contact pairs Sphere and Sample in an Initial analysis Step, and activating an Abaqus primary wear model; S6, in the Load module, creating a reference point RP-1 at the geometric center of the Sphere upper surface, and associating the RP-1 with all nodes of the Instance-Sphere upper surface through motion coupling constraint; S7, applying a Y-axis negative concentrated force to the RP-1 in Step-1 and applying a full-fixed boundary condition on the bottom surface of the Instance-Sample, and applying a rotation angular velocity around the Z-axis to the RP-1 in Step-2 to simulate a rolling-sliding compound motion; S8, after a single-cycle reference input file job-1.Inp is generated, copying the single-cycle reference input file job-2.Inp, and embedding a multi-cycle control instruction into the file: inserting a termination criterion based on the amount of wear before Step-2 ends: s9, explicitly requesting to output the accumulated abrasion depth variable CWEAR in Step-2, and S10, analyzing the output variable and predicting the life of the coating.
2. 2. The method for simulating abrasion performance of a nano-diamond ceramic coating according to claim 1, wherein in S3, an Instance-Sample is fixed at the origin of the global coordinate system, and the Instance-Sphere is initially placed at the Y-axis forward offset position, so as to ensure initial non-contact but proximity.
3. 3. The method according to claim 1, wherein in S4, the contact area between the grinding ball and the wear sample is grid-refined, so as to ensure that the error between the hertz pressure obtained by simulation calculation and the theoretical calculation value is controlled within 5% after the load is applied to the grinding ball, and the local grid size of the contact area is set to be between 1/3 and 1/5 of the contact radius calculated by using the Archard wear equation.
4. 4. The simulation research method of the wear performance of the nano diamond ceramic coating according to claim 1, wherein in the step S5, the contact is set as a general contact, the global characteristic of the contact is designated as a hard contact, the friction is a penalty function, the friction coefficient is set to a certain value between 0.1 and 0.7 according to practical conditions, the global wear surface characteristic is designated as a dimensionless wear coefficient, the wear coefficient is dimensionless and is set according to practical characteristics of materials, the contact area of Sphere and Sample is defined as two surfaces with wear characteristics, and a pair of surfaces with contact wear is respectively and independently set as surfaces with different wear characteristics.
5. 5. The method for simulating abrasion performance of nano-diamond ceramic coating according to claim 1, wherein in S8, the multi-cycle control command is inserted before Step-2 definition *STEPCYCLING,START Num1,1 Num2,Num3 Wherein, the virtual cycle number Num1, the 1 st virtual cycle represents the cycle number Num2 in practice, and the actual cycle number maximum value Num3 represented by each virtual cycle are specified.
6. 6. The method for simulating and researching the wear performance of the nano-diamond ceramic coating according to claim 1, wherein in the step S8, the termination criterion is that a circulation control method based on wear is adopted, the accumulated wear amount Num4 of a designated wear surface is adopted, and when the accumulated wear amount CWEAR calculated by simulation exceeds the designated value Num4 or the wear amount of a single analysis step exceeds Num5, the simulation calculation is terminated, specifically expressed as: *Output,history,variable=PRESELECT *STEP CYCLING CONTROL, CRITERION=WEAR-BASED, ACTION=END CYCLING, NAME=TEST ,AbsMax,Num4,Num5 *EndStep *STEPCYCLING, END。
7. 7. The simulation research method of wear performance of a nano-diamond ceramic coating according to claim 1, wherein in S10, the modified input file is submitted to an Abaqus solver for execution, historical output data of CWEAR and CPRESS are extracted, a wear depth-equivalent cycle number curve is drawn, and a predicted service life of the coating is determined according to a failure criterion that the wear surface is larger than the accumulated wear amount.

Description

Simulation research method for wear performance of nano diamond ceramic coating Technical Field The invention relates to the technical field of coating life performance simulation, in particular to a simulation research method for the wear performance of a nano diamond ceramic coating. Background In the key industrial fields of high-end equipment manufacturing, aerospace propulsion systems, energy power equipment and the like, a high-temperature wear-resistant coating technology is widely paid attention in recent years as an important means for improving service life and reliability of core components. The Nano-diamond (NDs) reinforced ceramic matrix composite coating is considered as an ideal candidate material for a new generation of high-performance wear-resistant protection system because of the combination of high hardness, excellent thermal stability, low friction coefficient and other comprehensive properties. However, the abrasion behavior of the coating under the complex working condition is highly dependent on load, sliding speed, environment temperature, and multiple physical field coupling factors such as the pair characteristic, and the failure mechanism of the coating presents obvious nonlinear and multi-scale characteristics. Therefore, establishing a simulation research method capable of accurately and efficiently predicting the wear evolution process of the nano diamond ceramic coating has become a key technical bottleneck for promoting engineering application of the method. For a long time, research on wear characteristics of a coating mainly depends on physical test means, namely, data such as wear amount, friction coefficient and surface morphology are obtained under specific working conditions through pin-disc type or ball-disc type friction wear experiments. While the method can provide visual experimental basis, the inherent limitation is increasingly prominent, on one hand, a single test can only reflect the abrasion response under a group of fixed parameter combinations, if the multi-parameter coupling action rule is required to be systematically inspected, a large number of orthogonal or full factor test groups must be designed, so that the research and development cost is exponentially increased, on the other hand, the abrasion test essentially belongs to a destructive process, a sample can not be reused once tested, not only waste of expensive coating materials is caused, but also continuous observation and comparison analysis of the same sample at different stages are difficult to realize. In this context, numerical simulation techniques based on finite element methods are becoming an important path for alternative or complementary experimental studies. The existing simulation method mostly adopts commercial software such as Abaqus, and combines user-defined subroutines (such as UMESHMOTION) to realize dynamic update of the wear surface. The proposal generally needs to call Fortran language to write contact surface node displacement update logic, relies on external compiling environments such as visual studio and the like to carry out link debugging, puts high requirements on programming capability of a user and software integration experience, and is extremely easy to cause calculation interruption due to interface incompatibility or logic errors. More importantly, in order to overcome the contradiction that the real abrasion process has extremely long time scale and limited calculation resources, the prior art generally introduces a scaling factor strategy, namely, the simulation process is accelerated by artificially amplifying the physical circulation times corresponding to each increment step. However, the method mathematically breaks the physical consistency of transient dynamics process, is extremely easy to induce non-physical oscillation or convergence failure, and meanwhile, the selection of the scaling coefficient lacks general rule, so that repeated trial and error aiming at different geometric configurations, material matching pairs and working conditions is often needed, and the simulation efficiency and the result reliability are severely restricted. The above-mentioned dilemma is based on the fundamental contradiction that the existing simulation framework is difficult to reconcile between physical fidelity and computational feasibility, namely, on one hand, in order to ensure the applicability of the Archard wear model in the local contact area, the Hertz contact pressure distribution must be finely characterized, which requires that the mesh size be much smaller than the theoretical contact radius, and on the other hand, the real wear process involves thousands of cycles, and if solved cycle by cycle, the computational effort is not affordable. While the existing acceleration strategy tries to alleviate the contradiction, the simulation result is highly sensitive to human intervention at the expense of model stability and parameter robustness, and a standardize