Abstract
The elevator industry is constantly expanding creating an increased demand for the integration of high technological tools to increase elevator efficiency and safety. Towards this direction, Additive Manufacturing (AM), and especially metal AM, is one of the technologies that could offer numerous competitive advantages in the production of industrial parts, such as integration of complex geometry, high manufacturability of high-strength metal alloys, etc. In this context, the present study has 3D designed, 3D printing manufactured, and evaluated novel bioinspired structures for elevator safety gear friction pads with the aim of enhancing their dynamic friction performance and eliminating the undesired behavior properties observed in conventional pads. Four different friction pads with embedded bioinspired surface lattice structures were formed on the template of the friction surface of the conventional pads and 3D printed by the Selective Laser Melting (SLM) process utilizing tool steel H13 powder as feedstock material. Each safety gear friction pad underwent tribological tests to evaluate its dynamic coefficient of friction (CoF). The results indicated that pads with a high contact surface area, such as those with car-tire-like and extended honeycomb structures, exhibit high CoF of 0.549 and 0.459, respectively. Based on the acquired CoFs, Finite Element Models (FEM) were developed to access the performance of braking pads under realistic operation conditions, highlighting the lower stress concentration for the aforementioned designs. The 3D-printed safety gear friction pads were assembled in an existing emergency progressive safety gear system of KLEEMANN Group, providing sufficient functionality.