Residual stress measurement and lifetime evaluation of railway axles by neutron scattering technology
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摘要: 为准确预测表面强化铁路车轴剩余寿命，提出了考虑三维残余应力的损伤容限分析方法；以感应淬火碳钢S38C车轴为例，综合利用中子布拉格边透射成像与角度分散中子衍射试验，开展残余应变二维分布表征以及三维残余应力测试；采用数值方法，将三维残余应力植入车轴模型，研究了在实测载荷谱、压装载荷以及残余应力耦合作用下全尺寸车轴的剩余寿命。试验结果表明：轴向和切向均呈现约3 mm的压缩残余应变梯度层，表层最大压缩残余应变达-4.5×10-3，但芯部的最大应变为1.0×10-3；车轴最大轴向和切向压缩残余应力分别约为-500、-303 MPa，而径向应力整体保持在零平均应力范围波动，距表层4.5 mm深度以后，3个分量均为拉伸应力；车轴表层受压缩残余应力影响，深度小于4.5 mm时不会发生裂纹扩展，当深度大于4.5 mm以后裂纹扩展加速；裂纹扩展深度阈值不同，导致无残余应力条件下的剩余寿命计算结果大于考虑三维残余应力情形，但在最保守条件下车轴的剩余服役里程22.7万公里超过3.5个探伤周期，有较大安全裕度。试验结果可以为表面强化铁路车轴的无损探伤周期制定和优化提供科学参考。Abstract: To accurately predict the remaining lifetime of surface-strengthed railway axles, a damage tolerance analysis method considering three-dimensional (3D) residual stresses was proposed. By taking the induction-hardened carbon steel S38C axle as an example, two-dimensional (2D) distribution characterization of residual strain and 3D residual stress measurement were performed through comprehensive application of the neutron Bragg-edge transmission imaging and angle-dispersive neutron diffraction experiments. A numerical method was employed to implant the 3D residual stress into the axle model, and the remaining lifetime of the full-scale axle was studied by coupling the measured load spectrum, press-fit loads, and residual stresses. Experimental results show that, both axial and hoop directions present a compressive residual strain gradient layer of about 3 mm, with a maximum compressive residual strain of up to -4.5×10-3 in the surface layer, yet a maximum strain of up to 1.0×10-3 in the core. The maximum axial and hoop compressive residual stresses of the axle are about -500 and -303 MPa, respectively, while radial stresses overall fluctuate in the zero mean stress range. At depths beyond 4.5 mm from the surface layer, all three components are tensile stresses. The axle surface layer is subjected to compressive residual stresses, and crack propagation does not occur if the crack depth is less than 4.5 mm. Nevertheless, cracks propagate accelerates when the crack depth is greater than 4.5 mm. Different crack propagation depth thresholds lead to a larger calculated remaining lifetime for the residual stress-free condition than for the case where 3D residual stresses are taken into account. However, the axle remaining service mileage of the axle of 227 000 km under the most conservative conditions exceeds 3.5 non-destructive inspection (NDI) cycles, with a large safety margin. The experimental results can provide a scientific reference for the development and optimization of NDI cycles for surface-strengthed railway axles.
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图 1 感应淬火S38C车轴光镜检查结果
Figure 1. Optical examination results of induction-hardened S38C axles
图 2 中子散射试验试样制备方法及试样尺寸
Figure 2. Neutron scattering experimental samples preparation method and sample dimension
图 3 两类试样的中子散射试验现场
Figure 3. Neutron scattering experimental sites for two types of samples
图 5 角度分散中子衍射原理及数据处理方法
Figure 5. Principle of angle-dispersive neutron diffraction and data processing method
图 6 利用标准铁试样校准中子飞行距离
Figure 6. Calibration of neutron flight distance using standard iron sample
图 7 d0, 110随径向深度的梯度变化规律
Figure 7. Gradient variation law of d0, 110 with radial depths
图 8 车轴圆柱、长条试样残余应变二维分布(单位：mm)
Figure 8. Two-dimensional distributions of residual strains for axle cylindrical and long strip samples (unit: mm)
图 9 长条试样三维残余应力表征结果
Figure 9. Characterization results of three-dimensional residual stresses for long strip sample
图 10 感应淬火S38C车轴残余应力数值重构结果
Figure 10. Numerical reconstruction results of residual stresses for induction-hardened S38C axle
图 11 残余应力试验数据与仿真结果对比
Figure 11. Comparison of experimental data and simulation results of residual stresses
图 13 考虑压装载荷的轮对有限元模型
Figure 13. Wheelsets finite element model considering press-fitted loads
图 14 含裂纹车轴有限元模型横截面的轴向应力响应
Figure 14. Axial stress response of cross-section of axle finite element model containing cracks
图 15 实测载荷谱下ΔK随a的变化规律
Figure 15. Variation rule of ΔK with a under measured load spectrum
图 16 基于实测载荷谱的车轴剩余服役里程预测结果
Figure 16. Axle remaining service mileage prediction results based on measured load spectrum
表 1 实测载荷谱(测试里程848 km)
Table 1. Measured load spectrum (848 km tested mileage)
载荷级数 1 2 3 4 5 6 7 8 幅值/kN 67.93 72.55 77.16 81.78 86.40 91.02 95.64 100.26 频数 5 155 4 967 4 400 3 036 1 136 435 115 15 
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