动车组轮装制动盘整形修复技术研究

Research of the redressing and repair techniques for wheel-mounted brake discs on EMUs

为节约动车组运营维护成本,实现制动盘的重复利用,开展某型动车组轮装制动盘修复技术研究。结合国内外动车组制动盘整形修复技术,同时开展了冷整形、热整形和冷热结合整形工艺验证,研究得出冷整形能显著降低制动盘的翘曲变形,但无法消除波浪变形;热整形能有效控制制动盘的波浪变形,但不能完全消除制动盘的翘曲变形;冷热结合整形工艺可有效控制制动盘的翘曲变形和波浪变形,整形后的制动盘变形量均能达到规定要求。通过多次验证最后开发出制动盘冷热结合的整形修复技术及修复工艺参数,试验结果显示,冷热结合整形修复工艺不影响制动盘的各项性能指标,修复后的制动盘满足修复技术条件的要求。

In order to save the operation and maintenance cost of EMUs and realize the reuse of brake discs,research is being conducted on the repair technology of wheel-mounted brake discs on an EMU.Combining domestic and overseas techniques for redressing and repairing brake discs on EMUs,cold redressing,hot redressing,and integrated cold and hot redressing processes have been validated.The study shows that cold redressing can significantly reduce the warping deformation of brake discs,but cannot eliminate the corrugated deformation,while the hot redressing can effectively control the wave deformation of the brake discs,but cannot completely eliminate their warping deformation.The warping deformation and corrugated deformation of the brake discs can be controlled effectively by integrating the cold and hot redressing techniques,and the deformation of the brake discs after redressing can meet the specified requirements.Finally,the integrated cold-hot repair techniques and process parameters of the brake discs are developed through several validations.Test results show that the cold-hot combined repair technology doesn’t affect the performance indicators of the brake discs,and the restored brake discs meet the requirements of the recovery technical conditions.