Temperature Distribution of Treads and Wear Prediction during Train Emergency Braking

doi:10.3969/j.issn.1004-132X.2021.04.007

Abstract

Abstract: The rapid increases of tread temperature during the emergency braking processes of the trains caused the friction and wear mechanism of the wheel tread to be significantly different from that during steady state operations. In order to accurately predict the wear of the trains emergency braking tread, the wheel tread contact with the rail and the brake shoe was also considered during the tread braking processes, the thermal-mechanical coupling finite element model of tread braking processes was established based on ABAQUS finite element software, the impacts of braking temperature rise on the mechanical properties, hardness and friction coefficient of the wheel treads were comprehensively considered, the temperature distribution, hardness distribution and contact stress distribution on the wheel tread during emergency braking were obtained by simulation, the wheel-rail dynamics software UM was used to obtain the wheel-rail contact spot shapes and the wheel-rail creep area relative slip distribution during the emergency braking processes. Then, the Archard wear model wass used to determine the tread wear depth after a single emergency braking with quantitative predictions. The results show that for the two working conditions of the initial braking speed of 130 km/h and 160 km/h, the highest tread temperature reach 397.0 ℃ and 4859 ℃ respectively, the cumulative maximum wear depthes of the tread are 590 μm and 7.43 μm, respectively. Compared with the tread braking experiments, it is found that the wear position and topography distribution trend are consistent.

Key words: tread, emergency braking, thermal-mechanical coupling, temperature field, tread wear

摘要： 列车紧急制动过程中踏面温度急剧升高导致车轮踏面的摩擦磨损机理与稳态运行时有显著差异。为了准确预测列车紧急制动过程中踏面磨耗，同时考虑踏面制动过程中车轮踏面与钢轨及闸瓦接触，基于有限元软件ABAQUS建立了踏面制动过程热机械耦合有限元模型，综合考虑制动温升对车轮踏面力学性能、硬度及摩擦因数的影响，仿真得到了紧急制动过程中车轮踏面上温度分布、硬度分布以及接触应力分布，并利用轮轨动力学软件UM得到了紧急制动过程中轮轨接触斑形状以及轮轨蠕滑区相对滑移分布，在此基础上结合Archard磨耗模型对单次紧急制动结束后的踏面磨损深度进行了定量预测。结果表明：对于制动初速度为130 km/h、160 km/h两种工况，踏面最高温度分别达到了397.0 ℃和485.9 ℃，踏面最大累积磨损深度分别为5.90 μm和7.43 μm，与踏面制动实验对比发现,预测结果与实验结果磨损位置及形貌分布趋势一致。

关键词: 踏面, 紧急制动, 热机械耦合, 温度场, 踏面磨耗

CLC Number:

U270.35

DONG Yonggang, YI Shuai, HUANG Xinlei, SONG Jianfeng, DU Xiaozhong. Temperature Distribution of Treads and Wear Prediction during Train Emergency Braking[J]. China Mechanical Engineering, DOI: 10.3969/j.issn.1004-132X.2021.04.007.

董永刚, 仪帅, 黄鑫磊, 宋剑锋, 杜晓钟. [轮轨磨耗及预测]列车紧急制动过程中踏面温度分布及磨耗预测[J]. 中国机械工程, DOI: 10.3969/j.issn.1004-132X.2021.04.007.

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