Wear prediction and material selection of contact inserts for electric transport based on energy model using the finite element method

Authors

DOI:

https://doi.org/10.15587/1729-4061.2026.354922

Keywords:

frictional interaction, fullerene soot, contact insert, wear prediction, energy model

Abstract

This study explores the contact pair «trolleybus contact insert «TCI-power wire». The task addressed relates to the lack of consideration of thermal effects, phase changes, and thermal softening of the material in the classical Archard and Karman models, which complicates wear prediction.

To solve this problem, an energy-temperature wear model (ETW) has been constructed, which integrates mechanical, thermal, and energy processes in the contact zone. Unlike existing approaches, the model considers the temperature-dependent hardness H(T) and local fields of contact pressure and frictional stresses, determined by the finite element method (FEM) in the Ansys environment.

The research features involve a hybrid approach to wear prediction – the integration of mathematical modeling and FEM simulation. The results include von Mises stresses σmax = 16.24 MPa (amorphous carbon), 18.99 MPa (electrographite – EG), and 30.53 MPa (copper-graphite composite Cu-40%C(f) 0.90 – CU). Under sliding conditions of Stotal = 0.2 m at contact pressure p = 0.5 MPa, the wear depth for EG is 1.99·10⁻5 mm, which is extrapolated to 47.8 mm at 450 km and exceeds the permissible 10 mm, while for CU the wear decreases to 2.2 mm. The wear reduction is associated with the greater hardness of CU (120–135 HV) and a uniform distribution of contact stresses, which confirms the ETW effectiveness.

Practical significance of the results is the possibility of a reasonable choice of TCI materials, in particular copper-fullerene composites (Cu-0.5% FS), to increase wear resistance and stability of current collection with priority insert wear over the contact wire. The scope of practical implementation of the results includes the design of materials for current collection systems of electric transport

Author Biographies

Kostiantyn Holenko, Khmelnytskyi National University

PhD, Senior Lecturer

Department of Tribology, Automobiles and Materials Science

Oleksandr Dykha, Khmelnytskyi National University

Doctor of Technical Sciences, Professor, Head of Department

Department of Tribology, Automobiles and Materials Science

Orest Horbay, Lviv Polytechnic National University

Doctor of Technical Sciences, Professor

Department of Design Machine and Automotive Engineering

Oleksii Kovtun, Khmelnytskyi National University

PhD Student

Department of Tribology, Automobiles and Materials Science

Volodymyr Dytyniuk, Khmelnytskyi National University

Doctor of Philosophy (PhD), Lecturer

Department of Tribology, Automobiles and Materials Science

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Wear prediction and material selection of contact inserts for electric transport based on energy model using the finite element method

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Published

2026-04-30

How to Cite

Holenko, K., Dykha, O., Horbay, O., Kovtun, O., & Dytyniuk, V. (2026). Wear prediction and material selection of contact inserts for electric transport based on energy model using the finite element method. Eastern-European Journal of Enterprise Technologies, 2(7 (140), 44–61. https://doi.org/10.15587/1729-4061.2026.354922

Issue

Vol. 2 No. 7 (140) (2026): Applied mechanics

Section

Applied mechanics

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Copyright (c) 2026 Kostiantyn Holenko, Oleksandr Dykha, Orest Horbay, Oleksii Kovtun, Volodymyr Dytyniuk

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