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摘要: 从滚动接触理论、试验与数值模拟三方面概述了轮轨关系研究现状,强调了轮轨滚动接触行为中轮轨材料动态力学性能的影响;总结了轮轨材料静动态力学性能与本构关系的相关成果;介绍了由车轮扁疤、踏面剥离/剥落、车轮多边形等典型踏面缺陷引起的轮轨动态响应研究,分析了车轮踏面缺陷对轮轨滚动接触行为和列车系统动力学性能的影响,以及车轮踏面缺陷的形成原因、影响规律与演变机理,重点关注了轮轨动态效应对高速轮轨滚动接触行为的影响;概括了车轮踏面缺陷的检测技术与减缓和防治措施。研究结果表明:车轮踏面缺陷致使轮轨冲击力显著增大,导致轮轨部件损伤和车体异常振动,严重影响车辆-轨道系统部件的使用寿命和列车动力学性能,甚至威胁列车运行安全;车轮踏面缺陷的成因与机理仍需进一步探究,车辆异常制动、轮轨低黏着状态均会导致车轮扁疤的产生,轮轨材料特性、轮轨间接触载荷、轮对共振、列车制动系统性能与线路运行条件/环境等均是导致车轮踏面发生剥离的主要影响因素,轮轴共振、轮轨摩擦振动、车轮制造镟修工艺等均与车轮多边形的形成有密切联系;改善轮轨材料的性能,控制轨道系统的支撑刚度/阻尼及轮轨间摩擦因数等均是抑制车轮踏面缺陷产生的有效途径。Abstract: The current research on wheel-rail relationship was summarized in three aspects, including rolling contact theories, experiments, and numerical simulations. The influence of dynamics mechanical properties of wheel/rail materials on wheel-rail rolling contact behavior was emphasized. The related results on the static and dynamic mechanical properties of wheel/rail materials and constitutive relationship were summarized. A systematical introduction was presented on the progress of research on wheel-rail dynamic responses caused by wheel flat, tread spalling, wheel polygonization, and other typical tread influences, mainly including the influence of wheel tread defects on wheel-rail rolling contact behavior and vehicle system dynamics, and the causation, influence rules and evolution mechanism of wheel tread defect. The influences of dynamic effects on high-speed wheel-rail rolling contact behavior was emphasized and the detection technologies and prevention measures of wheel tread defects were summarized. Analysis results suggest that the wheel tread defects significantly increase the wheel-rail impact force, resulting in damages of wheel-rail components and abnormal vibration of car body, which seriously affect the service life of vehicle-track components and vehicle dynamics performance, and even threaten the safety of train operation. The causes and mechanisms of wheel tread defects still need to be further explored, abnormal braking of vehicle and low adhesion state between wheel and rail will lead to wheel flat, characteristics of wheel/rail materials, wheel-rail contact load, wheelset resonance, performance of braking system and operation conditions/environment are the main factors leading to wheel tread spalling, wheel-axle resonance, wheel-rail friction vibration, wheel manufacturing and re-profiling are closely related to the formation of wheel polygonization. Improving the performance of wheel/rail materials, controlling the support stiffness/damping of track system and friction coefficients between wheel and rail are all effective measures to restrain wheel tread defects. 3 tabs, 19 figs, 209 refs.
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表 1 国内外轮轨试验台及其主要技术参数
Table 1. Wheel-rail test rigs and main technical parameters at home and abroad
设备名称 最高模拟速度/(km·h-1) 模拟工况 轨道轮直径/mm 模拟方式 德国慕尼黑滚振试验台 500 测试机车车辆转向架、减振器、悬挂装置等参数对列车走行性能及运行品质的影响 1 400.0 轮-轮 美国IIT-GMEMD轮轨模拟试验机 76 牵引、制动、蛇行运动与冲角模拟 914.4 轮-轮 日本轮轨实物环形疲劳试验台 260 轮轨疲劳伤损与磨耗机理测试 轮-轨 日本轮轨滚动试验台 250 不同载荷、润滑介质下,测试轮轨蠕滑特性/蠕滑力随蠕滑率的变化关系 860.0 轮-轮 日本双筒式滚动试验台 70 模拟轮轨间的摩擦和磨耗 350.0 轮-轮 日本新型轮轨蠕滑率测试装置 测试不同介质、摇头角对轮轨蠕滑力的影响 轮-轨 英国Amsler蠕滑-磨耗试验机 测试轮轨磨耗率、轮轨蠕滑率与接触应力的关系 50.0 轮-轮 德国RASP轮轨系统试验台 300 模拟不同材料下的轮轨磨耗与滚振 2 100.0 轮-轮 德国道岔通过试验台 测试不同车轮和道岔材料匹配时轮轨磨损情况 轮-轨 中国西南交通大学整车滚振试验台 600 车辆运行平稳性、稳定性、曲线通过能力、轮轨黏着利用、踏面磨损等试验测试 1 800.0 轮-轮 中国铁科院高速轮轨关系试验台 500 高速、重载轮轨黏着/蠕滑、磨耗、疲劳等测试 3 000.0 轮-轮 表 2 轮轨接触仿真方法
Table 2. Simulation methods of wheel-rail contact
仿真方法 优点 缺点 多体动力学法 便于建立完整的列车-轨道耦合模型,方便考虑列车悬挂和动力学性能参数的影响,计算效率高 忽略了动态效应和材料力学性能;求解高频响应时精度降低;不能直接求解轮轨接触应力/应变状态 静态有限元法 可以分析轮轨局部接触状态和应力/应变分布 不能反映轮轨间滚动接触状态 多体动力学和有限元联合仿真法 兼具多体动力学法的主要优点,可以考虑轮轨系统及重要部件的柔性特征,计算效率降低 仍无法克服多体动力学法的局限性 动态有限元法 能够很好地计及轮轨接触非线性和动态效应,可以反映材料力学性能(包括动态力学性能)的影响,能够直接求解轮轨接触应力/应变状态,且求解高频响应精度较高 建模较复杂,计算时间较长 表 3 车轮扁疤引起的轮轨冲击力变化趋势与动态增大系数
Table 3. Changing trends and DAFs of wheel-rail impact force caused by wheel flat
文献 研究方法 扁疤类型 速度范围/(km·h-1) 冲击力随速度的变化趋势 DAF [60]、[61] 仿真 新扁疤 100~300 在150 km·h-1时有最大值 3.7 [89] 仿真 新/旧扁疤 200~350 新扁疤:单调递减;旧扁疤:深度小于0.1 mm时单调递增,深度大于0.1 mm时单调递减 6.0 [92] 理论/试验 旧扁疤 5~100 在40 km·h-1时出现峰值,在75 km·h-1时出现谷值 7.0 [93] 理论/试验 旧扁疤 0~120 在20~30 km·h-1时出现峰值,在60 km·h-1时出现谷值 5.5 [94] 试验 旧扁疤 0~130 在20~30 km·h-1时出现峰值,在40~60 km·h-1时出现谷值 2.7 [103] 理论 旧扁疤 0~180 在25~40 km·h-1时出现峰值,在40 km·h-1时出现谷值 2.5 [104] 理论 新/旧扁疤 0~150 新扁疤:在30~50km·h-1时有最大值;旧扁疤:单调递增 4.3 [105] 理论 新扁疤 5~120 在20 km·h-1时出现峰值,在30 km·h-1时出现谷值 4.0 [107] 理论 旧扁疤 0~140 在28 km·h-1时出现峰值,在60 km·h-1时出现谷值 5.0 [109] 理论 旧扁疤 10~160 在30~50 km·h-1时出现峰值,但随扁疤深度增加近似呈线性变化 6.0 [110] 理论 新/旧扁疤 10~200 近似单调递增 4.5 [111] 理论 旧扁疤 10~150 在30~60 km·h-1时有最大值 2.7 [112] 理论 新/旧扁疤 20~300 在35 km·h-1时出现峰值,旧扁疤在85 km·h-1时出现谷值,而新扁疤在55 km·h-1时出现谷值 3.4 [114] 仿真 旧扁疤 0~160 在30和150 km·h-1时出现峰值,在50 km·h-1时出现谷值 5.4 [118] 仿真 新/旧扁疤 20~300 新扁疤:在50~100 km·h-1时有最大值;旧扁疤:单调递增 7.5 [120] 仿真 新扁疤 100~350 在175~250 km·h-1时有最大值 5.6 [121] 仿真 新扁疤 60~160 在100km·h-1时有最大值 5.0 [125] 仿真 旧扁疤 10~400 在20和140 km·h-1时出现峰值;在60 km·h-1时出现谷值 3.8 [127] 仿真 旧扁疤 20~400 在30 km·h-1时有最大值 3.6 -
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