铁路轨道加强部件弹性轨撑研发与应用

Research and Applications of Elastic Rail Braces in Railway Track Reinforcement

轨撑是铁路曲线和长大坡度地段的重要轨道加强部件之一。经现场调研,既有轨撑结构存在局部刚度不均匀、调整性差、类型多等问题。既有结构的刚度不均匀会导致部分扣件不起横向支撑作用,给轨道带来较大的冲击,造成轨道状态恶劣,而调整性差则引起轨撑与轨腰间离缝、不密贴,长期使用会对轨枕和钢轨带来伤损,不利于工务运营维修。结合重载铁路、客货共线及其他铁路现场使用的需求,研制了50,60,75 kg/m专线系列钢轨用弹性轨撑,采用整体式结构,轨撑与轨腰完全贴合,增大接触面,提升抗横向性能。轨撑侧面镶嵌(硫化)弹性橡胶或聚氨酯材料,避免和钢轨硬接触,适当释放位移保证弹性,减轻轨撑抵靠钢轨轨腰带来的磨耗和伤损问题。采用有限元方法建立弹性轨撑实体模型,理论分析弹性轨撑方案受力规律,确定合理的技术参数。另制定弹性轨撑组装试验测试方法和技术要求,相同条件下与国铁弹条Ⅱ型扣件进行室内对比试验,经测试各项指标均达到预期效果,性能安全可靠。为验证弹性轨撑的实际应用效果,选取曲线半径为400 m的小半径曲线段进行现场试铺并进行观测,相关数据表明弹性轨撑能有效抵抗钢轨承受的异常横向荷载,轨距变化率小,达到设计要求,可保证列车安全运行,具有良好的推广应用价值。

Rail braces are important components for reinforcing tracks in railway curves and steep slope sections.Field surveys have identified several issues with existing rail brace structures,such as uneven local stiffness,poor adjustability,and multiple types.The uneven stiffness in existing structures causes some fasteners to fail in providing adequate lateral support,leading to significant impacts on tracks and resulting in poor track conditions.Furthermore,poor adjustability leads to gaps between the rail braces and the rail web,causing improper contact.Over time,this can damage both the sleepers and the rails,complicating track maintenance and operations.To meet the demands of heavy-load railways,mixed passenger-freight lines,and other railway applications,a series of elastic rail braces for 50 kg/m,60 kg/m,and 75 kg/m specialized rails were developed.These braces featured a one-piece design that ensured full contact between the rail braces and the web,increasing the contact area and improving lateral resistance.Elastic rubber or polyurethane materials were embedded(vulcanized)into the sides of the rail brace,preventing hard contact with the rail.The design allowed for slight displacement,maintaining elasticity and reducing the abrasion and damage caused by rail braces pressing against the web.A solid model of elastic rail brace was established using the finite element method to theoretically analyze its stress distribution and determine reasonable technical parameters.In addition,testing methods and technical requirements for assembling the elastic rail braces were developed.Indoor comparative tests were carried out under identical conditions with the type Ⅱ elastic fastener used in Chinas railway.The results showed that all indicators met expectations,demonstrating the designs safety and reliability.To further validate its practical applications,field trials were conducted on a small-radius curved track with a radius of 400 m.Observation data indicated that the elastic rail brace effectively resisted the abnormal lateral load on the rails,with minimal track gauge variation rate.The design meets the required standards,ensuring safe train operations,and has significant potential for widespread applications.