不同工况下轮轨材料摩擦磨损行为研究
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摘要
轮轨接触问题一直是铁路运行中最基本、最复杂的问题之一。当今世界的铁路运输网络所具有的几大特点是运输量提高、轴重加大、速率增加、行车量密集。由此衍生出的轮轨材料接触面磨损程度加剧、减短轮轨材料的使用寿命、增粘剂的使用对轮轨材料的深层影响等轮轨接触带来的问题,都对铁路运输系统有着深远的影响。
利用MMS-2A型摩擦磨损试验机进行不同工况下轮轨材料的摩擦磨损实验,分析了同一加载情况下,干态、水态以及水砂态对轮轨材料摩擦磨损性能的影响,研究了水态下不同的加载情况对轮轨材料摩擦磨损性能的影响；结合前述模拟试验部分,利用有限元软件ANSYS得到轮轨静接触工况下的应力、接触斑等特征数值。
论文通过研究得到以下几个结论：
1.相比于干态,水会使轮轨材料的摩擦因数、磨损量明显下降；水介质下撒砂可增加轮轨材料滚动摩擦因数和磨损量,且加重轮轨表面的损伤,撒砂后续的干摩擦会使摩擦因数恢复到干态下的正常水平；随水态、干态到水砂态工况的变化,车轮试样表面从粗糙凸起并伴有轻微剥落向严重剥落损伤转变,钢轨材料的表面损伤主要表现为片层状剥离并伴有剥落现象,但较车轮材料的剥落损伤程度轻微。
2.随着载荷的增加,轮轨材料的磨损程度降低,其中摩擦因数、磨损量有所下降；载荷从110N到170N的增加过程中,车轮材料表面从多处分布点蚀及剥离到仅极少的呈现出点蚀的情况,钢轨材料表面也呈现同样的变化趋势,且车轮材料损伤程度重于钢轨材料。
3.有限元模拟结果表明：在相同的载荷条件下,轮轨材料静接触面间代入不同的摩擦因数计算时,对接触面间的最大接触应力及接触斑的影响不大；当代入相同的摩擦因数时,随着载荷的增加,轮轨材料接触面的接触半径呈平缓的上升趋势,接触区域面积渐增。接触面的最大接触应力随载荷的增加呈现非线性增长趋势,且随着载荷的不断增大,接触应力变化趋于平缓。
The wheel/rail contact is the most basic and complex problem in the operation of the railway system. In today's world of railway transport network has there are several primary characteristics of railway-transportation network, which concluding increased amount of carriage,axle load on rail and rate, high density of transportation. Thus it comes to the results that contact surface of wheel/rail material wearing aggravated, the servicing life of wheel/rail material shorten, the impact of using tackifier on the wheel/rail materials and so on. Such problems have a profound influence on railway transportation system.
The friction and wear experiments of wheel/rail materials were carried out using MMS-2A friction and wear tester under different working conditions. Furthermore, the effect of dry, water and sanding conditions on friction and wear behaviors of wheel/rail materials was explored in detail. The effect of axle load on friction and wear behaviors of wheel/rail materials was investigated and analyzed under the water condition. The contact stress and contact zone of wheel/rail specimens were calculated using finite element software ANSYS according to the simulation experimental parameters.
Main conclusions are drawn as follows.
1. The water medium obviously decrease rolling friction coefficient and wear volume of wheel/rail specimens. Sanding can increase rolling friction coefficient and wear volume of wheel/rail specimens under the water condition. Furthermore, sanding can aggravate the surface damage of wheel/rail specimens. Rolling friction coefficient can come to the normal level during the dry condition after sanding. With the conditions changing from water, dry and water sanding, the surface damage of wheel specimen transforms from slight delamination to serious spalling damage. The delamination damage is dominant for the rail specimen. However, the spalling damage of rail specimen is slighter than that of wheel specimen.
2. With an increase of axle load, rolling friction coefficient and wear volume of wheel/rail materials decrease. With the increase from110N to170N, the surface damage of wheel specimen transforms from slight delamination to serious spalling damage. However, the spalling damage of rail specimen is slighter than that of wheel specimen.
3. Finite element simulation results show that the friction coefficient of wheel/rail has no obvious effect on the maximal contact stress and the contact zone of the wheel/rail interface under the same loading condition. With an increase of axle load, the contact radius and area of wheel/rail contact zone increase under the same friction coefficient condition. The maximal contact stress of contact zone presents a nonlinear growth with an increase of axle load. Furthermore, the increase of contact stress becomes flat with an increase of axle load.
利用MMS-2A型摩擦磨损试验机进行不同工况下轮轨材料的摩擦磨损实验,分析了同一加载情况下,干态、水态以及水砂态对轮轨材料摩擦磨损性能的影响,研究了水态下不同的加载情况对轮轨材料摩擦磨损性能的影响；结合前述模拟试验部分,利用有限元软件ANSYS得到轮轨静接触工况下的应力、接触斑等特征数值。
论文通过研究得到以下几个结论：
1.相比于干态,水会使轮轨材料的摩擦因数、磨损量明显下降；水介质下撒砂可增加轮轨材料滚动摩擦因数和磨损量,且加重轮轨表面的损伤,撒砂后续的干摩擦会使摩擦因数恢复到干态下的正常水平；随水态、干态到水砂态工况的变化,车轮试样表面从粗糙凸起并伴有轻微剥落向严重剥落损伤转变,钢轨材料的表面损伤主要表现为片层状剥离并伴有剥落现象,但较车轮材料的剥落损伤程度轻微。
2.随着载荷的增加,轮轨材料的磨损程度降低,其中摩擦因数、磨损量有所下降；载荷从110N到170N的增加过程中,车轮材料表面从多处分布点蚀及剥离到仅极少的呈现出点蚀的情况,钢轨材料表面也呈现同样的变化趋势,且车轮材料损伤程度重于钢轨材料。
3.有限元模拟结果表明：在相同的载荷条件下,轮轨材料静接触面间代入不同的摩擦因数计算时,对接触面间的最大接触应力及接触斑的影响不大；当代入相同的摩擦因数时,随着载荷的增加,轮轨材料接触面的接触半径呈平缓的上升趋势,接触区域面积渐增。接触面的最大接触应力随载荷的增加呈现非线性增长趋势,且随着载荷的不断增大,接触应力变化趋于平缓。
The wheel/rail contact is the most basic and complex problem in the operation of the railway system. In today's world of railway transport network has there are several primary characteristics of railway-transportation network, which concluding increased amount of carriage,axle load on rail and rate, high density of transportation. Thus it comes to the results that contact surface of wheel/rail material wearing aggravated, the servicing life of wheel/rail material shorten, the impact of using tackifier on the wheel/rail materials and so on. Such problems have a profound influence on railway transportation system.
The friction and wear experiments of wheel/rail materials were carried out using MMS-2A friction and wear tester under different working conditions. Furthermore, the effect of dry, water and sanding conditions on friction and wear behaviors of wheel/rail materials was explored in detail. The effect of axle load on friction and wear behaviors of wheel/rail materials was investigated and analyzed under the water condition. The contact stress and contact zone of wheel/rail specimens were calculated using finite element software ANSYS according to the simulation experimental parameters.
Main conclusions are drawn as follows.
1. The water medium obviously decrease rolling friction coefficient and wear volume of wheel/rail specimens. Sanding can increase rolling friction coefficient and wear volume of wheel/rail specimens under the water condition. Furthermore, sanding can aggravate the surface damage of wheel/rail specimens. Rolling friction coefficient can come to the normal level during the dry condition after sanding. With the conditions changing from water, dry and water sanding, the surface damage of wheel specimen transforms from slight delamination to serious spalling damage. The delamination damage is dominant for the rail specimen. However, the spalling damage of rail specimen is slighter than that of wheel specimen.
2. With an increase of axle load, rolling friction coefficient and wear volume of wheel/rail materials decrease. With the increase from110N to170N, the surface damage of wheel specimen transforms from slight delamination to serious spalling damage. However, the spalling damage of rail specimen is slighter than that of wheel specimen.
3. Finite element simulation results show that the friction coefficient of wheel/rail has no obvious effect on the maximal contact stress and the contact zone of the wheel/rail interface under the same loading condition. With an increase of axle load, the contact radius and area of wheel/rail contact zone increase under the same friction coefficient condition. The maximal contact stress of contact zone presents a nonlinear growth with an increase of axle load. Furthermore, the increase of contact stress becomes flat with an increase of axle load.
引文
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[3]沈志云.关于高速铁路及高速列车的研究[J].振动、测试与诊断.1998,18(1)：1-7.
[4]失名.世界铁路发展的共同趋势[J].工业设计.2011(1)：14-17.
[5]李世斌.世界高速铁路发展的动向[J].铁道技术监督.2007,35(1)：35-37.
[6]何邦模.高速铁路的技术经济优势[C].世界轨道交通.2004,(8).
[7]赵映莲,淑梅.国外高速铁路区间渡线设置状况分析及对我国的启示[J].中国铁路.2002,(8).
[8]马超,郭军利,张晓东,等.美国铁路发展历史及现状[J].铁道运输与经济.2011,33(9)：58-61.
[9]肖朝福.简论我国铁路发展现状及趋势[J].福建广播电视大学学报.2007,65：72-75.
[10]张聪.高速铁路发展若干问题探析[J]. China Collective Economy. 2010.02(上):170-171.
[11]强志.中国铁路发展面临机遇和挑战[J].铁道知识.2009,1：11-13.
[12]覃为刚,唐怀平.轮轨水介质粘着分析[J].西南交通大学学报.2000,35(5)：509-512.
[13]杨翊仁,张继业,金学松.轮轨水介质接触的完全数值分析方法[JJ].铁道学报,1998,20(4)：31-36.
[14]邓建华,译著.计算机辅助优化法[M].西安：西北工业大学出版社,1988：50-100.
[15]金学松,沈志云.轮轨滚动接触疲劳问题研究的最新进展[J].铁道学报.2001,23(2)：92-108.
[16]宋建华,申鹏,王文健,等.水介质条件下轮轨黏着特性试验研究[J].中国铁道科学.2010,31(3)：52-56.
[17]熊嘉阳,金学松.铁路曲线钢轨初始波磨演化分析[J].机械工程学报.2006,42(6)：60-66.
[18]JINY,ISHIDA M,NAMURA A. Experimental simulation and prediction of wear of wheel flange and rail gauge corner[J]. Wear.2011,271:259-267.
[19]SHUR E A,BYCHKOVA N Y,TRUSHEVSKY. Physical metallurgy aspects of rolling contact fatigue of rail steels [J]. Wear.2005,258:1165-1171.
[20]ARIAS-CUEVASA O,LIA Z,LEWISB R. A laboratory investigation on the influence of the particle size and slip during sanding on the adhesion and wear in the wheel-rail contact[J]. Wear.2011,271:14-24.
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