Finite elements procedure for evaluating temperature distribution in polyurethane-coated wheels

Polymeric materials find extensive applications across various engineering sectors. Among these, a particularly critical application for these materials is in the field of roller coasters. The wheels are typically made with an aluminum hub and a dense polyurethane coating, which, being in contact with the track, endures dynamic loads at high speeds. Due to the viscoelastic behavior typical of polymeric materials, these loads induce overheating of the coating leading to rapid degradation of the wheel. This results in machine downtime and a significant waste of time and money. In this manuscript, a methodology for finite element thermal-structural analysis has been developed. This method allows for the rapid evaluation of temperatures reached during operational cycles if compared to classical coupled-field thermal-structural analysis. The proposed methodology proves to be useful in selecting the appropriate type of wheels during the design phase requiring short computational time. The study first involved the development of the methodology, followed by validation through a comparison of analysis results with data obtained from experimental tests conducted by the manufacturer.