Development of an Easy Method for Apparent Contact Area Determination in the Twin-Disc Test
摘要
Punctual or non-conformal contact is the simplified form used in most wheel/rail contact theories, like the Hertzian theory. The results obtained for contact pressure depends on the contact area between the wheel/rail. Using geometric parameters and mechanical properties, it is possible to calculate the contact area using the Hertz theory that supposes perfect contact between the two surfaces (without roughness). But how close is this result from the measured apparent contact area? In order to simulate in the twin-disc test the same pressure used in the railroad, it is necessary to know the apparent contact area. Analytical methods require complex computer programs and finite elements requires the use of specific software for simulations. Experimental measurement methods, such as Nomarski interference technique or ultrasonic, demand complex laboratory arrangements. Thus, the purpose of this work was to develop a simple method, using only commercial aluminum foil, found in the kitchen, and an optical microscope to measure the apparent contact area and compare with the contact area calculated by Hertz equations. The applied load between the discs varied from 196 to 1960 N (20–200 kgf), with an increase of 196 N per measure, and a total of 10 measures. Two types of configurations, named configuration CF (disc with a curved surface against disc with a flat surface) and configuration FF (disc with a flat surface against another disc with a flat surface) were used. The values of apparent areas obtained from experimental measurements for configuration CF were 50–70% higher for Rc = 1.66 µm and 20–60% higher for Rc = 0.28 µm than those obtained using Hertz equations for contact between two ellipses (HEE). The values of apparent areas obtained from experimental measurements for configuration FF were 60–160% higher for Rc = 1.82 µm and near the same (absolute difference less than 10%) for Rc = 0.14 µm than those obtained using Hertz equations for contact between two cylinders (HCC).