Surface coatings have been introduced on the contact surfaces to protect the mechanical parts for a long time. However, in terms of the optimum design of coatings, some key coating parameters are still selected by trial and error. The optimum design of coatings can be conducted by numerical experiments. This paper aims to predict the contact behavior of the coated rough surfaces accurately. One improved asperity contact model for the coated rough surfaces considering the misalignment of asperities would be developed.
Incorporating the coated asperity contact model into the improved Greenwood Tripp-based statistical approach, the proposed model can predict the elastic-plastic behaviors of the interacting coated asperities.
According to numerical experiments, compared with the coated asperity contact model in which an equivalent rough surface against a plane is assumed, the improved asperity contact model for the coated contacts can account for the effect of permitting misalignment of two rough surfaces. The contacts having the thicker, stiffer and harder coatings result in higher asperity contact pressure and smaller real contact area fraction under the given Stribeck oil film ratio.
In this paper, one statistical coated asperity contact model for two rough surfaces was developed. The developed model can consider the elastic-plastic behavior of interacting coated asperities. The effects of the coating thickness and its mechanical properties on the contact behavior of the rough surfaces with coatings can be evaluated based on the developed model.
