Scratch visibility modeling on flat & textured polymeric surfaces

Abstract

Polymer materials have gained widespread usage in the marketplace due to their lightweight properties, versatility, and cost-effectiveness. However, their susceptibility to scratches has been a longstanding issue. To overcome this shortcoming, surface texturing is one of the most low-cost, efficient ways to improve scratch performance by utilizing the inherent moldability of polymers. Textures rely on both the improvement of contact properties in terms of reduction in surface friction and the perceived visibility of scratches by masking the scratch-induced deformations. The current testing of the effectiveness of a particular texture design on scratch resistance requires tedious and costly psychophysical and/or experimental verification. In this paper, we present a comprehensive framework for scratch visibility analysis in virtual reality, integrating a novel scheme and finite element methods simulation. Our approach considers material, topographical, and optical properties, replicating perceived scratch visibility within the virtual space. The FEM model was found to overpredict the scratch depth and underpredict the shoulder height. A parametric study based on the material constitutive and surface properties has been carried out to highlight the effect of different material and surface factors on scratch performance and visibility. This study opens the door for a complete virtual design-development-analysis cycle for scratch performance evaluation of polymers.