Hybrid methods which combine the experimental results with FEM simulations are the most applicable methods to extract the plastic properties of thin-film coatings. In order to make such methods more applicable, they should be merged with the dimensional analysis approach. To make such solution more applicable, a method to reduce the number of dimensionless functions is proposed in order to consider the effect of the probable errors of each parameter. Due to the lack of proper criteria for determining the compliance of the analytical results with empirical data, it was necessary to provide an effective criterion. A complementary new algorithm named as Minimum Resultant Error Method (MREM) is also introduced, which combines the errors of both dimensionless functions. By this algorithm, the yield stress, strain hardening exponent and consequently the strain hardening coefficient are extracted in the form of unique measures. This approach is implemented by minimum empirical data obtained by a single indenter nanoindentation test results. The FEA simulation results are processed with the combination of the aforementioned modified dimensional analysis and MREM algorithms. Such procedure is undergone to calculate plastic properties of AM200®, TiN and TiAlN thin-film coatings. Some of the results, especially for AM200® coating, are developed for the first time. The results obtained by nonlinear solution of the modified dimensional analysis equations and MREM algorithm are compared with one another. The results of both approaches show very small difference to each other which approves that MREM approach is an effective replacement for nonlinear solution. The sensibility of the answer to the hardening exponent and the errors combining exponent are investigated.

Obtaining the plastic properties of thin film coatings has been the main challenge for decades. Implementing the hybrid methods seems to be an applicable way to address this issue. Unfortunately, limitations of nonunique answers together with the need for enormous amount of calculations are counted as the main challenges. To overcome such difficulties, a modified dimensional analysis method is proposed, which is able to reduce the number of dimensionless parameters. Another novel algorithm named “minimum resultant error method” is developed to provide proper criteria to investigate the compliance of the analytical results with empirical data. With this algorithm, yield stress, strain hardening exponent, and strain hardening coefficient are extracted as unique values by using a single indenter nanoindentation results. The simulation results are processed with combined modified dimensional analysis method and minimum resultant error method algorithms. The effects of interlayer, friction coefficient, and indenter tip radius are investigated. Error analysis to the modulus of elasticity is undertaken and the results show less than 2% error for the infimum point, while the individual dimensionless functions errors are below 3.4%. According to the results, this new approach is well-coped with the earlier studies.

Improving the mechanical properties of the material surface has been the main aim of the researchers for a long time. Utilizing of mechanical treatment procedures, such as direct impact, has been widely used for the bulk materials, but determination of the change in the mechanical properties of impacted material has not been exactly investigated. The main novelty of this paper is the determination of the effect of mechanical treatments on the mechanical properties of bulk materials. For this purpose, the new developed combined algorithm of modified dimensional analysis and minimum resultant error methods were emerged with FEA and experimental data. The finite element analysis (FEA) included the analysis of the impact with nanoindentation in a continued procedure to allow the investigation of the impact on the results of the nanoindentation. Previously, this trend had not been applied to analyze such phenomenon. The challenges of preparing a perfect analysis model to suit the nanoscale process (nanoindentation) and macro process (ball impact) were another investigation field of this research work. The result of this research was a complete calculation of the parameters of Johnson–Cook constants for titanium (Ti) bulk material including the most important strain rate coefficient (C). Comparison of Ti mechanical characteristics shows high improvement in yield stress (24%) against lower change in the elastic modulus (1.2%).

Working with continuously harder materials and higher cutting speeds requires novel mechanical properties for cutting tools. The application of titanium-based coatings deposited by PVD is experienced as one of the most effective solutions. To assure achievement of the required characteristics in the metal cutting process, which mainly includes turning, milling, drilling and some other methods, extracting the plastic properties has been the main challenge for a long time. In this paper, a hybrid method emerging the modified dimensional analysis method (MDAM) and experimental data with novel algorithm named as minimum resultant error method is proposed. By using this algorithm, yield stress, strain hardening exponent and strain hardening coefficient are extracted as unique measures via using a single indenter nanoindentation result. An existing experimental output data and numerical solution of TiN thin film nanoindentation test are used to verify the proposed approach. The same procedure is implemented to calculate the plastic properties of TiAlN coating. Some of the results for TiAlN are among the rarely investigated matters. The effects of mesh refinement, friction coefficient and indenter tip radius are elucidated. According to the results attained from the new approach, there is an excellent agreement between MDAM and the combined algorithm results (4% for yield stress and 7% for strain hardening exponent). The resultant error is calculated in the range of 0.47-4.1% for optimized deviation. To provide another criterion of the adaptability of the results, the elastic modulus and hardness are calculated within less than 5% and 9% errors, respectively.