C80列车长大下坡周期制动踏面疲劳寿命预测

doi:10.13229/j.cnki.jdxbgxb.20230550

摘要/Abstract

摘要：

为预测C80列车长大下坡周期制动过程的车轮踏面疲劳寿命，在Abaqus软件中建立车轮有限元模型，通过高温拉伸试验确定CL60车轮钢26~500 ℃温度区间内的材料力学参数，同时考虑对流换热、轮轨接触传热、热辐射作用及行车阻力，利用功能转换关系、Hertz接触理论得到列车制动及惰行阶段作用在踏面上的热流载荷、法向载荷和切向载荷。开发子程序控制载荷、传热属性对踏面旋转加载，并对列车长大下坡周期制动过程进行热-机械耦合分析，得到并分析踏面温度、Mises应力-时间历程。分别基于N.E.损伤、R.W.损伤公式开发疲劳寿命程序，得到两种损伤下的踏面疲劳寿命，并分析闸瓦压力对疲劳寿命的影响。结果表明：踏面温度、Mises应力历程在同一循环后达到稳定；轮轨接触中心为踏面危险点，两种损伤下车轮服役转数误差百分比为1.28%；闸瓦压力越大，危险点温度越高，Mises应力越大，疲劳寿命越短。

关键词: 机械设计, 周期制动, 踏面疲劳寿命, 车轮服役转数, N.E.损伤, R.W.损伤

Abstract:

High-temperature tensile tests were used to establish the material mechanics parameters of CL60 wheel steel in the 26~500 ℃ temperature range， considering the convective heat transfer， wheel-rail contact heat transfer， thermal radiation， driving resistance， taking advantage of work-energy conversion relationships with Hertz contact theory to obtain the heat flow load， normal load， and tangential load. A wheel finite element model was developed in Abaqus to predict the fatigue life of wheel treads during the braking process of C80 trains with lengthy downhill cycles. The subroutine is created to manage the load with heat transfer qualities for rotational loading of the tread surface in order to determine the temperature of the tread surface and the Mises stress-time history. It also examines the thermal-mechanical interaction of the braking process for the lengthy downhill cycle of the train. By investigating the effect of gate tile pressure on fatigue life， the fatigue life procedures were developed based on the N.E. damage and R.W. damage formulas to evaluate the fatigue life of the tread surface under two types of damage. The results show that after the same cycle， the tread temperature and Mises stress history stabilize. The tread hazard point is the wheel-rail contact center， with the two different types of damage， the percentage inaccuracy of wheel service revolutions is 1.28%. The higher the pressure of the brake shoe， the higher the temperature of the danger point， the higher the Mises stress， and the shorter the fatigue life.

Key words: mechanical design, periodic braking, fatigue life of tread, wheel service revolutions, N.E. damage, R.W. damage

中图分类号:

U211.5

宋剑锋,黄鑫磊,王思然,谢光耀,董永刚. C80列车长大下坡周期制动踏面疲劳寿命预测[J]. 吉林大学学报(工学版), 2025, 55(3): 866-876.

Jian-feng SONG,Xin-lei HUANG,Si-ran WANG,Guang-yao XIE,Yong-gang DONG. Fatigue life prediction of brake treads for C80 trains with long downhill cycles[J]. Journal of Jilin University(Engineering and Technology Edition), 2025, 55(3): 866-876.

图/表 22

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表1

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表2

不同温度下的损伤参量数值"

温度/℃	$σ f'$ /MPa	$ε f'$	$b'$	$c'$	$K'$ /MPa	$n'$
26	1 246.2	0.234	-0.129	-1.082	1 481.3	0.119
100	1 222.4	0.286	-0.136	-1.138	1 419.7	0.119
200	1 185.6	0.346	-0.143	-1.196	1 345.6	0.119
300	1 128.0	0.406	-0.149	-1.246	1 256.1	0.119
400	1 081.9	0.489	-0.156	-1.304	1 178.4	0.119
500	1 039.2	0.613	-0.162	-1.412	1 099.4	0.115

表2

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图7

表3

图8

图9

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图11

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图18

表4

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温度/℃	弹性模量/GPa	屈服强度/MPa	抗拉强度/MPa	断面收缩率/%	比热容/ ［J·（kg·℃）^-1］	内部导热率/［W·（m·℃^-1）］	热膨胀系数/（10^-5·℃^-1）
26	225.6	605.6	812.5	31.9	470	51	1.033
100	203.3	556.6	768.1	37.2	490	49	1.112
200	176.1	507.8	718.1	42.6	530	45	1.207
300	152.6	465.6	662.1	47.4	570	42	1.226
400	132.6	437.8	611.6	53.4	620	38	1.331
500	97.3	390.3	567.8	59.0	680	35	1.392

闸瓦压力 /kN	制动减速度 /（m·s^-2）	温度趋于稳定的循环次数	损伤模型	最大疲劳损伤	疲劳循环次数/次	车轮服役转数/转	疲劳寿命 N_f /h
6	0.07	4	N.E.	0.336	2.97	56 338	2.49
6	0.07	4	R.W.	0.332	3.01	57 005	2.51
8	0.12	5	N.E.	0.371	2.70	51 092	2.25
8	0.12	5	R.W.	0.366	2.73	51 710	2.27
10	0.17	5	N.E.	0.401	2.50	47 280	2.08
10	0.17	5	R.W.	0.396	2.53	47 887	2.11
12	0.22	6	N.E.	0.438	2.28	43 293	1.90
12	0.22	6	R.W.	0.433	2.31	43 736	1.92

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