Finite element analysis of frictional contact of elastic solids with thin and moderately thick coatings

The frictional contact of elastic solids with thin and moderately thick coatings is analysed by using the finite element method. It is assumed that 2 elastic, homogeneous substrates with elastic coatings are perfectly bonded and contact with each other under normal and horizontal forces. The coating and elastic substrate are modelled with 2D and 3D finite elements. After verifying the finite element solutions by analytical solutions, various geometric configurations are analysed such as ball and socket joint, ball on a flat plate, a roller on a guide, and spur gear. Different material combinations and coating thicknesses are considered in the coating-substrate system. Their effects on the total displacement and contact stress distributions along the contact line of coated members are presented.