Analytical Modeling of Joule Heating in Electro-Thermal Contacts for Short-Term Industrial Applications

Abstract

In industrial processes such as machining, molding, disc brake operation, and spot welding, the thermal transfer at solid-solid interfaces, particularly with heat generation at the interface, is a critical area of study. This research presents a theoretical framework for addressing the direct problem of thermal conduction in electro-thermal contacts, with a focus on short-term scenarios where heat dissipation occurs through the Joule effect. This aspect, not extensively explored in existing literature, is investigated using a semianalytical method. The study also encompasses a simulation-based exploration, aimed at deepening the understanding of physical phenomena at the contact level. Special attention is given to the thermal transfers initiated at the asperity level of the electro-thermal contact. Findings from this investigation underscore the significance of incorporating the thermal diffusivity of materials into the model for achieving convergence. A notable observation is the increasing divergence over time between the temperatures predicted by numerical and analytical solutions, a trend more pronounced in materials with higher thermal diffusivity, such as titanium. This research contributes valuable insights into the modeling of contact parameters essential for simulating various industrial applications, potentially enhancing efficiency and efficacy in thermal engineering practices.