Effect of Pressure Fluctuations on the Temperature During Braking

The aim of this study is to develop the numerical–analytical model of frictional heating in a pad/disc system during braking including the pressure fluctuations, engendered by the pump in an anti-skid braking operation. For this purpose, the problem of motion and the one-dimensional thermal problem of friction for a semi-space/semi-space tribosystem were formulated and solved. Obtained solutions allow to calculate temperature distribution on the contact surface and inside the friction elements. Thermal analysis was performed for a metal–ceramic pad and a cast iron disc during one-time braking including the time-dependent, oscillating pressure. The influence of amplitude of pressure fluctuations on the temperature variations was investigated, especially on the value of maximum temperature achieved during braking

Influence of Thermal Sensitivity of Functionally Graded Materials on Temperature during Braking

The model of the frictional heating process during single braking to determine the temperature of the functionally graded friction elements with an account of the thermal sensitivity of materials was proposed. The basis of this model is the exact solution of the one-dimensional thermal problem of friction during braking with constant deceleration. The formulas approximating the experimental data of the temperature dependencies of properties of the functionally graded materials (FGMs) were involved in the model to improve the accuracy of the achieved results. A comparative analysis was performed for data obtained for temperature-dependent FGMs and the corresponding data, calculated without consideration of thermal sensitivity. The results revealed that the assumption of thermal stability of FGMs during braking may cause a significant overestimation of temperature of the friction pair elements

Influence of Functionally Graded Protective Coating on the Temperature in a Braking System

A mathematical model of heat generation due to friction in a disc–pad braking system was developed with consideration of a thermal barrier coating (TBC) on the friction surface of the disc. The coating was made of functionally graded material (FGM). The three-element geometrical scheme of the system consisted of two homogeneous half-spaces (pad and disc) and a functionally graded coating (FGC) deposited on the friction surface of the disc. It was assumed that the frictional heat generated on the coating-pad contact surface was absorbed to the insides of friction elements along the normal to this surface. Thermal contact of friction between the coating and the pad as well as the heat contact between the coating and the substrate were perfect. On the basis of such assumptions, the thermal friction problem was formulated, and its exact solution was obtained for constant and linearly descending specific friction power over time. For the first case, the asymptotic solutions for small and large values of time were also found. A numerical analysis was performed on an example of the system containing a metal ceramic (FMC-11) pad, sliding on the surface of a FGC (ZrO2–Ti-6Al-4V) applied on a cast iron (ChNMKh) disc. It was established that the application of a TBC made of FGM on the surface of a disc could effectively reduce the level of temperature achieved during braking

The Mutual Influence of Thermal Contact Conductivity and Convective Cooling on the Temperature Field in a Tribosystem with a Functionally Graded Strip

An analytical model to find the temperature field that has been developed for friction systems consists of a strip and semi-space. The strip is made of a two-component functionally graded material (FGM) with an exponentially changing coefficient of thermal conductivity. In contrast, the material of the semi-space is homogeneous. An appropriate boundary-value problem of heat conduction with constant specific friction power was formulated and solved using the Laplace integral transform method. The model takes into consideration the imperfect thermal friction contact between the strip and the semi-space, and also the convective cooling on the exposed surface of the strip. The appropriate asymptotic solutions to this problem for low and high values of Fourier number were obtained. It is shown how the determined exact solution can be generalized using Duhamel’s formula for the case of a linearly reduction in time-specific friction power (a braking process with constant deceleration). Numerical analysis for selected materials of the friction pair was carried out in terms of examining the mutual impact on the temperature of the two Biot numbers, characterizing the intensity of the thermal contact conductivity and convective heat exchange on the exposed surface of the strip. The obtained results can be used to predict the temperature of friction systems containing elements made of FGM. In particular, such systems include modern disc braking systems

Temperature during Repetitive Short-Term Operation of a Brake with Functionally Graded Friction Element

The object of study is the temperature of a braking system, operating in repetitive short-term (RST) mode. One element of the considered friction pair is made of a functionally gradient material (FGM), and the other of a homogeneous material. To determine the temperature on the friction surfaces of both elements, the previously obtained, exact solution of the boundary value problem of heat conduction was adopted, with account of the heat generation due to the friction. A calculation scheme was proposed that takes into consideration thermal sensitivity of materials and variations of the friction coefficient under the influence of temperature. Calculations were performed for two-component FGM (ZrO2–Ti-6Al-4V) in combination with gray cast iron (ChNMKh). It was found that for selected friction pair materials, consideration of their thermal sensitivity reduces the time of braking and the value of temperature achieved on the friction surfaces. At the same time, the whole process was characterized by a good stability of braking with a slight decrease in efficiency in each subsequent cycle

The Heat Partition Ratio during Braking in a Functionally Graded Friction Couple

The theoretical scheme for determining the heat partition ratio (HPR) in a friction couple made of functionally graded materials (FGMs) was proposed. As a result, the formula for the calculation of the HPR was found, which depends on the thermal properties and the parameters of the material’s gradient. In specific cases of these parameters, the known formulas for estimating the HPR for homogeneous materials were obtained. Calculations were carried out for the friction couple consisting of the following two-component FGMs: Al2O3–Cu (first body) and ZrO2–Ti–6Al–4V (second body), under the conditions corresponding to a single braking with a constant deceleration. It was established that the vast majority (almost 90%) of heat that was generated by friction was absorbed by the first body in the selected couple. The possibilities of using the obtained results were discussed herein

Temperature in the Friction Couple Consisting of Functionally Graded and Homogeneous Materials

An analytical model was developed to determine the temperature of friction coupling, in which one element was made of a functionally graded material (FGM) and the other was homogeneous. First, for such a system, the boundary–value problem of heat conduction was formulated with consideration of the heat generation due to friction. Then, using the Laplace integral transform, an exact solution to this problem was obtained for uniform sliding, and braking with constant deceleration. A numerical analysis was performed for the selected friction pair consisting of the FGM (zircon dioxide + titanium alloy) and cast iron. It was established that the use of elements made of a FGM consisting of ZrO2 and Ti-6Al-4V can significantly reduce the maximum temperature achieved in the friction system

Reverse engineering of parts with asymmetrical properties using replacement materials

Reverse engineering (RE) aims at the reproduction of products following a detailed examination of their construction or composition. Nowadays, industrial applications of RE were boosted by combining it with additive manufacturing. Printing of reverse-engineered elements has become an option particularly when spare parts are needed. In this paper, a case study was presented that explains how such an approach can be implemented in the case of products with asymmetric mechanical properties and using replacement materials. In this case study, a reverse engineering application was conducted on a textile machine spare part. To this end, the nearest material was selected to the actual material selection and some mechanical tests were made to validate it. Next, a replacement part was designed by following the asymmetric push-in pull-out characteristic. Finally, the finite element analysis with Additive Manufacturing was combined and validated experimentally