Journal of Jilin University(Engineering and Technology Edition) ›› 2025, Vol. 55 ›› Issue (3): 866-876.doi: 10.13229/j.cnki.jdxbgxb.20230550

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Fatigue life prediction of brake treads for C80 trains with long downhill cycles

Jian-feng SONG1(),Xin-lei HUANG2,Si-ran WANG2,Guang-yao XIE2,Yong-gang DONG1()   

  1. 1.School of Mechanical Engineering，Changshu Institute of Technology，Changshu 215500，China
    2.School of Mechanical Engineering，Yanshan University，Qinhuangdao 066004，China
  • Received:2023-10-11 Online:2025-03-01 Published:2025-05-20
  • Contact: Yong-gang DONG E-mail:jfsong2003@163.com;d_peter@163.com

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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

CLC Number: 

  • U211.5

Fig.1

Three-dimensional model of wheel"

Fig.2

Tread node-set "Set-1""

Fig.3

Tensile test of CL60 steel at high temperature"

Table 1

Mechanical and physical properties of CL60 steel"

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）
26225.6605.6812.531.9470511.033
100203.3556.6768.137.2490491.112
200176.1507.8718.142.6530451.207
300152.6465.6662.147.4570421.226
400132.6437.8611.653.4620381.331
50097.3390.3567.859.0680351.392

Fig.4

Flow chart of Abaqus and subroutine secondary development"

Fig.5

Diagrams of rotation of load and heat properties"

Table 2

Damage parameter values at different temperatures"

温度/℃σf'/MPaεf'b'c'K'/MPan'
261 246.20.234-0.129-1.0821 481.30.119
1001 222.40.286-0.136-1.1381 419.70.119
2001 185.60.346-0.143-1.1961 345.60.119
3001 128.00.406-0.149-1.2461 256.10.119
4001 081.90.489-0.156-1.3041 178.40.119
5001 039.20.613-0.162-1.4121 099.40.115

Fig.6

Fitting curves between elastic modulus or damage parameters and temperature"

Fig.7

Flow chart of fatigue life program development"

Table 3

Supplementary table of train braking parameters"

初始温度/℃车轮承重量/kg初始制动速度v0/（km·h-1）缓解速度/（km·h-1）制动减速度ac/（m·s-2）
2612 83080400.12

Fig.8

Speed or mileage-time diagram"

Fig.9

Cloud diagram of wheel temperature distribution at the end of the fifth cycle braking stage"

Fig.10

Axial distribution of temperature in the fifth cycle"

Fig.11

Temperature distribution of tread in the six cycles"

Fig.12

Cloud diagram of wheel Mises Stress distribution at the end of the fifth cycle braking stage"

Fig.13

Mises stress axial distribution in the fifth cycle"

Fig.14

Mises stress distribution of tread in six cycles"

Fig.15

Stress-strain amplitude curve at danger point"

Fig.16

Axial distribution of fatigue damage and wheel cycles"

Fig.17

Axial distribution of temperature at no contact"

Fig.18

Axial distribution of Mises stress at contact center"

Table 4

Damage results under different brake pressures"

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

Nf /h

60.074N.E.0.3362.9756 3382.49
R.W.0.3323.0157 0052.51
80.125N.E.0.3712.7051 0922.25
R.W.0.3662.7351 7102.27
100.175N.E.0.4012.5047 2802.08
R.W.0.3962.5347 8872.11
120.226N.E.0.4382.2843 2931.90
R.W.0.4332.3143 7361.92
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