Numerical Thermal Modeling and Analysis of Dry Sliding Contacts between Copper-Graphite and Bronze-Graphite

<div>Modeling the thermal behavior of dry sliding contacts is complex due to nonlinear thermal boundary conditions and intricate surface interactions. This study reviews and analyzes various thermal models applicable to dry sliding contacts, employing finite element analysis-based numerical simulations for model validation and deeper insights into the system’s physics. The primary goal is to assess the average contact temperatures in sliding pairs of copper-graphite, bronze-graphite, and graphite-graphite.</div> <div>A thermal model is developed, incorporating experimentally measured temperatures taken 2 mm from the contact point and considering the experimental setup’s boundary conditions. The temperature distribution in both the pin and the disc under different loads shows maximum temperatures at the contact point, decreasing with distance both laterally and in depth, reaching a minimum at the outer edges. Results show that the highest temperatures are observed at the contact points, with temperatures decreasing away from these points. The discussion focuses on the interfacial phenomena during the operation of these sliding pairs and the numerical calculation results, which highlight significant variations in temperature distributions and frictional heat generation based on material pairings and operating conditions.</div>