木质剩余物轨枕复合技术研究
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摘要
铁路是保证我国经济快速发展的基础和根本,轨枕是铁路重要的硬件设施,是行车速度、行车安全和行车质量的保证,传统的轨枕材料已不能满足铁路高速发展对其质量、数量、类型及技术性能的要求。以木质剩余物为填充材料,以毛竹片和中碱玻璃纤维为增强材料,以甲阶酚醛树脂为基体材料,研究铁路轨枕新型复合材料的复合技术。通过对轨枕复合材料组分、结构方案、力学及其他性能的基础研究,确定铁路轨枕新型材料的复合工艺因子和工艺条件,最终获得符合铁路轨枕技术性能标准要求的新型材料研制技术。采用均匀实验和正交实验方法进行试验方案设计,利用DPS数据处理系统进行实验数据分析。主要研究的内容包括:铁路轨枕复合材料单元组分的选择及分析,单元组分特性及对复合材料整体性能的影响;轨枕复合材料结构设计原则、工艺性要求、结构方案设计及分析;轨枕复合材料力学性能分析的基本假设,复合材料增强体、基体及材料结构基本力学性能理论分析;轨枕复合材料最优复合工艺因子;轨枕复合材料制备的基本工艺条件等。
通过对上述内容的研究,获得以下主要结论:(1)确定以木质剩余物为填充材料,以玻璃纤维、毛竹片为增强材料,以甲阶酚醛树脂为基体材料,以偶联剂作为界面改质助剂,苯磺酸作为防水剂,尿素为甲阶酚醛树脂稀释剂的轨枕复合材料单元组分;(2)设计了层套式轨枕复合材料结构方案,该方案在静曲强度、弹性模量、吸水厚度膨胀率、干湿态内结合强度以及静载抗压强度等方面均具有明显优势,并确定混合木质剩余物为新型轨枕复合材料的最佳填充材料;(3)在对轨枕复合材料的拉伸、压缩、弯曲和剪切四种基本力学性能进行理论分析的基础上,对层套式轨枕复合材料结构的强度、模量、变形、刚度等主要基本力学性能进行了计算,得出其在不同载荷作用下的变化规律;(4)得出热压时间X_1、施胶量X_2、密度X_3复合因子对轨枕复合材料静曲强度Y_1、弹性模量Y_2、吸水厚度膨胀率Y_3、干态内结合强度Y_4、湿态内结合强度Y_5、抗压强度Y_6等物理力学性能的交互作用关系,确定最优复合工艺因子为:热压时间t=0.7min/mm;施胶量m=14.30%;密度ρ=0.96 g.cm~(-3);(5)确定轨枕复合材料制备的基本工艺条件为:热压温度T=180～200℃;复合压力:单位压力P=3.5MPa、保压单位压力P_1=1.9MPa、平衡单位压力P_2=0.3～0.5MPa;热压时间t=0.7min/mm;施胶量q=14.30%;密度ρ=0.96 g.cm~(-3);(6)根据美国ASTM D1037六循环加速老化法,六周期24h吸水厚度膨胀率符合标准要求,主要物理力学指标静曲强度、弹性模量符合标准要求。
Railway ensures the rapid economic development of China.Railway sleeper is an important hardware of the railway system,which determines the traffic speed,traffic safety and passenger comfort.With rapid development of the railroad system in China,the traditional sleeper materials could no longer meet the requirements for quality,quantity,and technical performance.A new composite material for railway sleeper was introduced by taking wood residues as filling,Moso bamboo slice and glass fiber as reinforcement,and taking resole phenol resin as substrate.The compounding technology of the composite material was studied. The compounding factors and process conditions for the compounding technology of the composite material were identified based on material component,structure design,mechanical properties,etc.The compounding technology for the new sleeper material compatible with the railway sleeper technical performance standards was proposed.Experiments with welldistribution design and orthogonal design were used in this study.Data were analyzed using DPS data processing system.The major content of this study include:the component selection and analysis for the railway sleeper composite material,component properties and their effect on material performance,structure design principles,technological requirements,and structure design of the composite material,basic assumptions for mechanical property analysis of the composite material,mechanical analysis for the reinforcement,substrate,and material structure of the composite,optimum compounding factors of the composite,and process condition for the preparation of the railway sleeper composite material.,etc.
The following conclusions were obtained:(1)Determined that the composite material could be prepared by taking wood residues as filling,glass fiber and Moso bamboo slice as reinforcement,resole phenol resin as substrate,aminoorganosilane as interface modification additives,benzene sulfonic acid as waterproof agent,and taking urea as diluent to the resole phenol resin;(2)Proposed a layer jacketed structure of the railway sleeper composite material. Which shows obvious advantages in MOR,elastic modulus,thickness swelling,internal bonding stringing under dry and wet state as well as compressive strength with static loading. It also identified that wood residues is the best filling material for the railway sleeper composite;(3)The major mechanical properties of strength,modulus,deformation and stiffness of the composite material were analyzed theoretically based on the study of tensile, compression,bending,and shearing cut of the material and their variations under varied loading were obtained;(4)Derived the interrelationship between compounding factors of pressing time(X_1),glue content(X_2),and density(X_3) and physical and mechanical properties of MOR(Y_1),elastic modulus(Y_2),thickness swelling(Y_3),internal bonding strength under dry (Y_4) and wet state(Y_5),compressive strength(Y_6) and determined that the optimum compounding factors are as follows:pressing time t=0.7min/mm;glue content m=14.30%; densityρ=0.96 g.cm-3;(5)Determined the basic processing condition of the composite material as follows:pressing temperature T=180～200℃;compound pressure:unit pressure P=3.5MPa、consistent unit pressure P_1=1.9MPa、balancing unit pressure P_2=0.3～0.5MPa; pressing time t=0.7min/mm;glue content q=14.30%;densityρ=0.96g.cm-3;(6) According to American ASTM D1037 Six-cycling Speeding Aging method,thickness swelling meets the requirement,and major physical and mechanical properties of MOR and elastic modulus also meet the requirements.
通过对上述内容的研究,获得以下主要结论:(1)确定以木质剩余物为填充材料,以玻璃纤维、毛竹片为增强材料,以甲阶酚醛树脂为基体材料,以偶联剂作为界面改质助剂,苯磺酸作为防水剂,尿素为甲阶酚醛树脂稀释剂的轨枕复合材料单元组分;(2)设计了层套式轨枕复合材料结构方案,该方案在静曲强度、弹性模量、吸水厚度膨胀率、干湿态内结合强度以及静载抗压强度等方面均具有明显优势,并确定混合木质剩余物为新型轨枕复合材料的最佳填充材料;(3)在对轨枕复合材料的拉伸、压缩、弯曲和剪切四种基本力学性能进行理论分析的基础上,对层套式轨枕复合材料结构的强度、模量、变形、刚度等主要基本力学性能进行了计算,得出其在不同载荷作用下的变化规律;(4)得出热压时间X_1、施胶量X_2、密度X_3复合因子对轨枕复合材料静曲强度Y_1、弹性模量Y_2、吸水厚度膨胀率Y_3、干态内结合强度Y_4、湿态内结合强度Y_5、抗压强度Y_6等物理力学性能的交互作用关系,确定最优复合工艺因子为:热压时间t=0.7min/mm;施胶量m=14.30%;密度ρ=0.96 g.cm~(-3);(5)确定轨枕复合材料制备的基本工艺条件为:热压温度T=180～200℃;复合压力:单位压力P=3.5MPa、保压单位压力P_1=1.9MPa、平衡单位压力P_2=0.3～0.5MPa;热压时间t=0.7min/mm;施胶量q=14.30%;密度ρ=0.96 g.cm~(-3);(6)根据美国ASTM D1037六循环加速老化法,六周期24h吸水厚度膨胀率符合标准要求,主要物理力学指标静曲强度、弹性模量符合标准要求。
Railway ensures the rapid economic development of China.Railway sleeper is an important hardware of the railway system,which determines the traffic speed,traffic safety and passenger comfort.With rapid development of the railroad system in China,the traditional sleeper materials could no longer meet the requirements for quality,quantity,and technical performance.A new composite material for railway sleeper was introduced by taking wood residues as filling,Moso bamboo slice and glass fiber as reinforcement,and taking resole phenol resin as substrate.The compounding technology of the composite material was studied. The compounding factors and process conditions for the compounding technology of the composite material were identified based on material component,structure design,mechanical properties,etc.The compounding technology for the new sleeper material compatible with the railway sleeper technical performance standards was proposed.Experiments with welldistribution design and orthogonal design were used in this study.Data were analyzed using DPS data processing system.The major content of this study include:the component selection and analysis for the railway sleeper composite material,component properties and their effect on material performance,structure design principles,technological requirements,and structure design of the composite material,basic assumptions for mechanical property analysis of the composite material,mechanical analysis for the reinforcement,substrate,and material structure of the composite,optimum compounding factors of the composite,and process condition for the preparation of the railway sleeper composite material.,etc.
The following conclusions were obtained:(1)Determined that the composite material could be prepared by taking wood residues as filling,glass fiber and Moso bamboo slice as reinforcement,resole phenol resin as substrate,aminoorganosilane as interface modification additives,benzene sulfonic acid as waterproof agent,and taking urea as diluent to the resole phenol resin;(2)Proposed a layer jacketed structure of the railway sleeper composite material. Which shows obvious advantages in MOR,elastic modulus,thickness swelling,internal bonding stringing under dry and wet state as well as compressive strength with static loading. It also identified that wood residues is the best filling material for the railway sleeper composite;(3)The major mechanical properties of strength,modulus,deformation and stiffness of the composite material were analyzed theoretically based on the study of tensile, compression,bending,and shearing cut of the material and their variations under varied loading were obtained;(4)Derived the interrelationship between compounding factors of pressing time(X_1),glue content(X_2),and density(X_3) and physical and mechanical properties of MOR(Y_1),elastic modulus(Y_2),thickness swelling(Y_3),internal bonding strength under dry (Y_4) and wet state(Y_5),compressive strength(Y_6) and determined that the optimum compounding factors are as follows:pressing time t=0.7min/mm;glue content m=14.30%; densityρ=0.96 g.cm-3;(5)Determined the basic processing condition of the composite material as follows:pressing temperature T=180～200℃;compound pressure:unit pressure P=3.5MPa、consistent unit pressure P_1=1.9MPa、balancing unit pressure P_2=0.3～0.5MPa; pressing time t=0.7min/mm;glue content q=14.30%;densityρ=0.96g.cm-3;(6) According to American ASTM D1037 Six-cycling Speeding Aging method,thickness swelling meets the requirement,and major physical and mechanical properties of MOR and elastic modulus also meet the requirements.
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