Flash Temperature Characteristics and Mechanism of Double Rough Interface in Tread Braking

FAN Wenming; MENG Xianguo; DING Ying; WEN Fulong; WU Lei

doi:10.16490/j.cnki.issn.1001-3660.2026.13.005

PDF(7612 KB)

Surface Technology ›› 2026, Vol. 55 ›› Issue (13) : 47-60. DOI: 10.16490/j.cnki.issn.1001-3660.2026.13.005

Friction, Wear and Lubrication

Flash Temperature Characteristics and Mechanism of Double Rough Interface in Tread Braking

FAN Wenming¹, MENG Xianguo¹, DING Ying¹, WEN Fulong², WU Lei^2,*

Author information +

History +

Abstract

This work presents a micro-scale thermo-mechanical modelling framework that quantifies flash-temperature behaviour at a wheel-shoe interface with realistic dual-rough surfaces and identifies the micro-mechanisms that promote metal pick-up. Three-dimensional rough surfaces with randomized asperity morphology are generated using the Weierstrass- Mandelbrot fractal function, and a fully coupled transient thermo-mechanical finite-element model is established to simulate frictional heating with explicit heat partitioning, heat conduction and elastic-plastic contact mechanics. Model verification against the Hertzian theory and an analytical smooth-surface temperature solution demonstrate close agreement, with only minor deviations in both contact pressure and temperature rise, confirming that the model can reliably capture micro-scale flash-temperature phenomena.
Parametric simulations are conducted by varying normal pressure from one to six megapascals, sliding speed from forty to one hundred and twenty kilometres per hour, and surface morphology using four rough surfaces with similar average roughness but different asperity distributions. When normal pressure increases, the real contact area increases from about twelve percent of the nominal contact area to nearly one-third, and the contact pattern evolves from sparse, isolated micro-spots into continuous, interconnected regions. The peak flash temperature rises from slightly above fifty degrees Celsius to nearly one hundred degrees, followed with a distinctly nonlinear trend because interactions among deformed asperities cause shifting stress peaks and saddle-shaped deformation. Higher pressure also enlarges the size of hot spots, increases thermal penetration into the subsurface and creates three-dimensional high-temperature regions that promote softening and local plastic shearing. In terms of temporal response, higher pressure shortens the time needed for flash temperature to reach its peak, increases the amplitude of temperature oscillation and reduces the oscillation frequency as the micro-contact network becomes more stable.
Sliding speed influences flash temperature through a different mechanism. As speed increases from forty to one hundred and twenty kilometres per hour, the peak flash temperature increases by more than twenty degrees Celsius in a nearly linear fashion because the rate of frictional heat generation grows proportionally. However, higher speeds significantly reduce thermal penetration depth. This occurs because the contact time of individual asperities becomes shorter than the characteristic heat diffusion time, concentrating thermal effects within the near-surface layer. Higher speeds also accelerate the renewal of micro-contacts and increase the frequency of temperature fluctuations, while the reduction in peak-arrival time becomes less pronounced once the speed exceeds roughly eighty kilometres per hour.
Surface morphology randomness introduces temperature variations comparable to those caused by changes in pressure or speed. Although all four surfaces have similar roughness, their different asperity heights, curvatures and spatial distributions result in peak flash temperature ranging from just above one hundred degrees Celsius to more than one hundred and twenty-five degrees. The peak temperature fluctuation can reach 4.0% to 30.5%. This change indicates that locally sharp roughness can dominate stress concentration and heat generation, and that surface flash temperature has a relatively small relationship with the overall contact area.
In summary, flash temperature at the wheel-shoe interface is transient, spatially drifting and strongly dependent on micro-scale morphology. Pressure governs asperity participation and the scale of thermal influence, speed controls heat-input rate and thermal diffusion depth, and morphology randomness introduces substantial stochastic fluctuations. These findings clarify the thermal-mechanical conditions that promote metal pick-up formation and provide a modelling tool for safety-margin evaluation and morphology-sensitive design of braking interfaces.

Key words

tread brake / double rough surface / micro flash temperature / fractal theory / thermal coupling friction

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

FAN Wenming, MENG Xianguo, DING Ying, WEN Fulong, WU Lei. Flash Temperature Characteristics and Mechanism of Double Rough Interface in Tread Braking[J]. Surface Technology. 2026, 55(13): 47-60

References

[1] 沈民民, 杨晓东. 连接结构界面摩擦力学建模研究进展[J]. 力学进展, 2024, 54(3): 477-521.
SHEN M M, YANG X D.Modeling of Joint Structure Interface Friction Mechanics: A Review[J]. Advances in Mechanics, 2024, 54(3): 477-521.
[2] 冯刚珍, 康皓, 刘宁, 等. 温度对高速列车制动盘用24CrNiMo钢摩擦磨损行为的影响[J]. 机械工程材料, 2026, 50(2): 61-65.
FENG G Z, KANG H, LIU N, et al.Effect of Temperature on Friction and Wear Behavior of 24CrNiMo Steel for High-Speed Train Brake Discs[J]. Materials for Mechanical Engineering, 2026, 50(2): 61-65.
[3] 张金玉, 左建勇, 温泽峰, 等. 长大坡道紧急制动工况下货车车轮踏面温升和热应力影响规律研究[J]. 同济大学学报(自然科学版), 2026, 54(3): 385-395.
ZHANG J Y, ZUO J Y, WEN Z F, et al.Temperature and Thermal Stress Behavior of Freight Wagon Wheel Tread under Emergency Brake Conditions for Long Downhill Ramps[J]. Journal of Tongji University (Natural Science), 2026, 54(3): 385-395.
[4] 马永靖, 郑魏婧, 李松, 等. 高速动车组异常制动诊断及控车方案设计研究[J]. 铁道车辆, 2026, 64(1): 55-59.
MA Y J, ZHENG W J, LI S, et al.Diagnosis of Abnormal Braking in High-Speed EMUs and Design of Train Control Strategies[J]. Rolling Stock, 2026, 64(1): 55-59.
[5] 汪志洋. 高摩合成闸瓦金属镶嵌机理研究[J]. 中国铁道科学, 1998, 19(4): 111-119.
WANG Z Y.Study on the Metal Mounting Mechanism of High Friction Coefficient Composition Brake Shoe[J]. China Railway Science, 1998, 19(4): 111-119.
[6] 纪懿轩. C80型敞车车轮磨耗规律浅析[J]. 内燃机与配件, 2024(8): : 75-77.
JI Y X. Analysis of Wear Law of C80 Vehicle Wheels[J]. Internal Combustion Engine & Parts, 2024(8): : 75-77.
[7] ARCHARD J F.Elastic Deformation and the Laws of Friction[J]. Proceedings of the Royal Society of London Series A Mathematical and Physical Sciences, 1957, 243(1233): 190-205.
[8] MANDELBROT B B, AIZENMAN M.Fractals: Form, Chance, and Dimension[J]. Physics Today, 1979, 32(5): 65-66.
[9] WANG S, KOMVOPOULOS K.A Fractal Theory of the Interfacial Temperature Distribution in the Slow Sliding Regime: Part I—Elastic Contact and Heat Transfer Analysis[J]. Journal of Tribology, 1994, 116(4): 812-822.
[10] WANG S, KOMVOPOULOS K.A Fractal Theory of the Interfacial Temperature Distribution in the Slow Sliding Regime: Part II—Multiple Domains, Elastoplastic Contacts and Applications[J]. Journal of Tribology, 1994, 116(4): 824-832.
[11] RAY S, ROY CHOWDHURY S K. An Analysis of Surface Temperature Rise at Small Scale Sliding Contacts[J]. MRS Online Proceedings Library, 2006, 890(1): 834.
[12] RAY S, ROY CHOWDHURY S K. Prediction of Flash Temperature at the Contact between Sliding Bodies with Nanoscale Surface Roughness[J]. Journal of Tribology, 2007, 129(3): 467-480.
[13] SOFUOGLU H, OZER A.Thermomechanical Analysis of Elastoplastic Medium in Sliding Contact with Fractal Surface[J]. Tribology International, 2008, 41(8): 783-796.
[14] OZER A.Thermo-Elastic-Plastic Deformation of Semi-Infinite Medium under Effects of Fractal Dimension and Sliding Speed[J]. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2016, 38(2): 609-619.
[15] 栾嘉宾. 双粗糙表面高速干滑动摩擦过程多尺度仿真[D]. 秦皇岛: 燕山大学, 2021: 36-58.
LUAN J B.Multiscale Simulation of High-Speed Dry Sliding Friction between Dual Rough Surfaces[D]. Qinhuangdao: Yanshan University, 2021: 36-58.
[16] 孙令涛, 王兆强, 韩博, 等. 表面粗糙度对配流副润滑特性的影响[J]. 润滑与密封, 2024, 49(5): 144-151.
SUN L T, WANG Z Q, HAN B, et al.Effect of Surface Roughness on Lubrication Characteristics of Port Plate Pair[J]. Lubrication Engineering, 2024, 49(5): 144-151.
[17] 莫继良, 张棋翔, 陈伟, 等. 长大坡道下高速列车制动系统摩擦学和动力学行为[J]. 清华大学学报(自然科学版), 2025, 65(2): 201-214.
MO J L, ZHANG Q X, CHEN W, et al.Tribological and Dynamic Behaviors of High-Speed Train Braking Systems on Long Steep Slopes[J]. Journal of Tsinghua University (Science and Technology), 2025, 65(2): 201-214.
[18] 刘宇, 邓宏盛, 张生芳, 等. 基于W-M分形函数的三维粗糙表面摩擦生热研究[J]. 中国工程机械学报, 2018, 16(3): 194-201.
LIU Y, DENG H S, ZHANG S F, et al.Research on Friction Heat Generation of Three Dimensional Rough Surface Based on W-M Fractal Function[J]. Chinese Journal of Construction Machinery, 2018, 16(3): 194-201.
[19] 李玲, 田海飞, 云强强, 等. 微动接触中分形粗糙表面的温升分布研究[J]. 表面技术, 2019, 48(6): 238-244.
LI L, TIAN H F, YUN Q Q, et al.Temperature Rise Distribution of Fractal Rough Surface in Fretting Contact[J]. Surface Technology, 2019, 48(6): 238-244.
[20] 李玲, 李港华, 吕刚, 等. 双粗糙表面的微动磨损行为研究[J]. 表面技术, 2022, 51(2): 193-201.
LI L, LI G H, LYU G, et al.Research on Fretting Wear Behaviour of Double Rough Surface[J]. Surface Technology, 2022, 51(2): 193-201.
[21] 葛世荣, 朱华. 摩擦学的分形[M]. 北京: 机械工业出版社, 2005: 118-124.
GE S R, ZHU H.Fractal of Tribology[M]. Beijing: China Machine Press, 2005: 118-124.
[22] 陈奇. 基于分形理论的汽车变速箱齿轮接触强度研究[D]. 合肥: 合肥工业大学, 2010: 59-60.
CHEN Q.Research on Gear Contact Strength Analysis of Automobile Gearbox by Fractal Theory[D]. Hefei: Hefei University of Technology, 2010: 59-60.
[23] 黄乾兴. 我国铁路快捷货车转向架悬挂系统特点分析[J]. 时代汽车, 2024(4): : 51-53.
HUANG Q X. Analysis on the Characteristics of Bogie Suspension System of Railway Express Freight Cars in China[J]. Auto Time, 2024(4): : 51-53.
[24] 山本贵光. 新干线列车提速的基础技术[J]. 国外铁道机车与动车, 2022(2): : 1-4.
TAKAMITSU Y. Development of Basic Technology for Speed-up Shinkansen Train[J]. Foreign Railway Locomotive and Motor Car, 2022(2): : 1-4.
[25] 党佳. 铁路货车高摩擦系数合成闸瓦评价体系研究[D]. 北京: 中国铁道科学研究院, 2009: 40-50.
DANG J.Research on the Evaluation System of Composite Brake Shoe with High-Friction Coefficient for Railway Freight Car[D]. Beijing: China Academy of Railway Sciences, 2009: 40-50.
[26] 杨子杰, 朱文良, 孙宁远, 等. 城轨列车踏面制动温度场仿真分析与试验验证[J]. 铁道机车车辆, 2024, 44(3): 159-166.
YANG Z J, ZHU W L, SUN N Y, et al.Simulation Analysis and Experimental Verification of Tread Braking Temperature Field of Urban Rail Trains[J]. Railway Locomotive & Car, 2024, 44(3): 159-166.
[27] 张金玉, 陶功权, 温泽峰. 长大坡道下货车车轮全磨耗周期制动温度影响研究[J]. 铁道科学与工程学报, 2024, 21(6): 2442-2452.
ZHANG J Y, TAO G Q, WEN Z F.Analysis of Influencing Factors of Braking Temperature on Wheel of Freight Wagon in Full Wear Cycle under Long Ramps[J]. Journal of Railway Science and Engineering, 2024, 21(6): 2442-2452.
[28] 孙宁远, 朱文良, 杨子杰, 等. 考虑接触传热的城市轨道交通列车摩擦副温度场仿真及试验验证[J]. 城市轨道交通研究, 2025, 28(7): 183-189.
SUN N Y, ZHU W L, YANG Z J, et al.Simulation and Experimental Verification of Urban Rail Transit Train Friction Pair Tem-Perature Field Considering Contact Heat Transfer[J]. Urban Mass Transit, 2025, 28(7): 183-189.
[29] 董永刚, 仪帅, 黄鑫磊, 等. 列车紧急制动过程中踏面温度分布及磨耗预测[J]. 中国机械工程, 2021, 32(4): 431-438.
DONG Y G, YI S, HUANG X L, et al.Temperature Distribution of Treads and Wear Prediction during Train Emergency Braking[J]. China Mechanical Engineering, 2021, 32(4): 431-438.
[30] BLOK H.The Flash Temperature Concept[J]. Wear, 1963, 6(6): 483-494.
[31] 赵锋. 提速重载列车合成闸瓦评价技术改进研究[D]. 北京: 北京交通大学, 2015: 25-30.
ZHAO F.Study on the Improvement of Evaluation Technology of Composite Brake Shoes in Speed-Raising and Heavy-Haul Train[D]. Beijing: Beijing Jiaotong University, 2015: 25-30.
[32] 宋剑锋, 时迎港, 黄伟建, 等. 重载列车紧急制动过程踏面轮廓变化定量预测[J]. 中国机械工程, 2025, 36(2): 369-379.
SONG J F, SHI Y G, HUANG W J, et al.Quantitative Prediction of Tread Profile Variations during Emergency Braking of Heavy Duty Trains[J]. China Mechanical Engineering, 2025, 36(2): 369-379.
[33] 宋剑锋, 黄鑫磊, 仪帅, 等. 列车制动过程踏面温度场及应力-应变分布特性[J]. 吉林大学学报(工学版), 2023, 53(10): 2773-2784.
SONG J F, HUANG X L, YI S, et al.Temperature Field and Stress-Strain Distribution of Tread during Train Braking[J]. Journal of Jilin University (Engineering and Technology Edition), 2023, 53(10): 2773-2784.
[34] 朱爱华. 制动时车轮型面演变及表面硬化对车轮磨耗的影响[J]. 北京交通大学学报, 2025, 49(2): : 174-182.
ZHU A H.Influence of Wheel Profile Evolution and Surface Hardening on Wheel Wear during Braking[J]. Journal of Beijing Jiaotong University, 2025, 49(2): : 174-182.
[35] 陈建平, 王志伟, 莫继良, 等. 基于轮瓦非均匀接触压力的重载列车踏面制动温度预测方法[J]. 摩擦学学报(中英文), 2025, 45(6): 812-822.
CHEN J P, WANG Z W, MO J L, et al.Temperature Prediction Method of Heavy-Haul Trains Tread Braking Based on Non-Uniform Contact Pressure between Wheel and Brake Shoe[J]. Tribology, 2025, 45(6): 812-822.
[36] 孙培文, 朱爱华, 付曹政, 等. 新型CL60钢地铁车轮摩擦磨损试验研究[J]. 润滑与密封, 2023, 48(6): 32-37.
SUN P W, ZHU A H, FU C Z, et al.Experimental Study on Friction and Wear of New CL60 Steel Subway Wheel[J]. Lubrication Engineering, 2023, 48(6): 32-37.
[37] 高红梅, 汪贵松, 杨火顺, 等. 合成摩擦材料在轨道交通领域的应用与发展[J]. 轨道交通材料, 2024, 3(1): 32-36.
GAO H M, WANG G S, YANG H S, et al.Application and Development of Organic Friction Materials in Rail Transit Field[J]. Materials for Rail Transportation System, 2024, 3(1): 32-36.