Моделювання процесу пресування контактних вставок тролейбуса з графітопластових композицій
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Дата
2026
Назва журналу
Номер ISSN
Назва тому
Видавець
Хмельницький національний університет
Анотація
У роботі досліджено процес пресування контактної вставки тролейбуса з графітопластової порошкової композиції з використанням тривимірного чисельного моделювання методом скінченних елементів. Об’єктом дослідження є базова конструкція контактної вставки серійного виробництва, що застосовується в системах струмознімання електричного транспорту. Чисельні експерименти виконано з використанням відкритого програмного комплексу Code_Aster, який дозволяє враховувати нелінійну поведінку матеріалу, великі деформації та контактну взаємодію з тертям. Основну увагу приділено аналізу розподілу відносної щільності
матеріалу, полів швидкостей течії графітопластової композиції та характеру зміни зусилля пресування впродовж усього циклу ущільнення. Показано, що геометрія базової конструкції вставки зумовлює формування зон зниженої щільності, локальних областей циркуляції матеріалу та різке зростання зусилля на фінальній стадії пресування. Отримані результати можуть бути використані як наукове обґрунтування для подальшої конструктивної модифікації контактної вставки з метою підвищення її експлуатаційної довговічності.
The work investigates the process of pressing a trolleybus contact insert from a graphite-plastic powder composition using threedimensional numerical modeling by the finite element method. The object of the study is the basic design of a mass-produced contact insert used in current collection systems of electric transport. Most current research on current collection systems for electric vehicles focuses on the analysis of wear of contact inserts during operation, as well as on how operating conditions and material composition affect the durability of the contact pair “insert–wire”. On the other hand, the problems associated with the formation of structural heterogeneity of contact inserts at the manufacturing stage remain insufficiently studied. In particular, the influence of the geometry of the main structure on the movement process remains unexplored. This limits the possibilities of consciously improving the design of inserts and optimizing their manufacturing technology. In this regard, it is important to study the process of movement of the main structure of the trolleybus contact insert, which is used in serial production. For this, it is necessary to use modern methods of numerical analysis. Such a method not only allows to explain the reasons for the structural heterogeneity of the material, but also creates a basis for further improvements in the design of the insert, taking into account operational and technological conditions. Numerical experiments were performed using the open software package Code_Aster, which allows taking into account nonlinear material behavior, large deformations and contact interaction with friction. The main attention was paid to the analysis of the distribution of the relative density of the material, the flow velocity fields of the graphite-plastic composition and the nature of the change in the pressing force throughout the entire compaction cycle. It was shown that the geometry of the basic design of the insert causes the formation of zones of reduced density, local areas of material circulation and a sharp increase in force at the final stage of pressing. The results obtained can be used as a scientific justification for further constructive modification of the contact insert in order to increase its operational durability.
The work investigates the process of pressing a trolleybus contact insert from a graphite-plastic powder composition using threedimensional numerical modeling by the finite element method. The object of the study is the basic design of a mass-produced contact insert used in current collection systems of electric transport. Most current research on current collection systems for electric vehicles focuses on the analysis of wear of contact inserts during operation, as well as on how operating conditions and material composition affect the durability of the contact pair “insert–wire”. On the other hand, the problems associated with the formation of structural heterogeneity of contact inserts at the manufacturing stage remain insufficiently studied. In particular, the influence of the geometry of the main structure on the movement process remains unexplored. This limits the possibilities of consciously improving the design of inserts and optimizing their manufacturing technology. In this regard, it is important to study the process of movement of the main structure of the trolleybus contact insert, which is used in serial production. For this, it is necessary to use modern methods of numerical analysis. Such a method not only allows to explain the reasons for the structural heterogeneity of the material, but also creates a basis for further improvements in the design of the insert, taking into account operational and technological conditions. Numerical experiments were performed using the open software package Code_Aster, which allows taking into account nonlinear material behavior, large deformations and contact interaction with friction. The main attention was paid to the analysis of the distribution of the relative density of the material, the flow velocity fields of the graphite-plastic composition and the nature of the change in the pressing force throughout the entire compaction cycle. It was shown that the geometry of the basic design of the insert causes the formation of zones of reduced density, local areas of material circulation and a sharp increase in force at the final stage of pressing. The results obtained can be used as a scientific justification for further constructive modification of the contact insert in order to increase its operational durability.
Опис
Ключові слова
контактна вставка тролейбуса, графітопласт, пресування, чисельне моделювання, Code_Aster, щільність, поле швидкостей, trolleybus contact insert, graphite–plastic composite, pressing, numerical simulation, density distribution, velocity field
Бібліографічний опис
Ковтун О., Бабак О. Моделювання процесу пресування контактних вставок тролейбуса з графітопластових композицій // Herald of Khmelnytskyi National University. Technical Sciences. 2026. Vol. 363, No. 2. P. 280-286.