A critical review of wheel/rail high frequency vibration-induced vibration fatigue of railway bogie in China

Purpose–This review aims to give a critical view of the wheel/rail high frequency vibration-induced vibration fatigue in railway bogie.Design/methodology/approach–Vibration fatigue of railway bogie arising from the wheel/rail high frequency vibration has become the main concern of railway operators.Previous reviews usually focused on the formation mechanism of wheel/rail high frequency vibration.This paper thus gives a critical review of the vibration fatigue of railway bogie owing to the short-pitch irregularities-induced high frequency vibration,including a brief introduction of short-pitch irregularities,associated high frequency vibration in railway bogie,typical vibration fatigue failure cases of railway bogie and methodologies used for the assessment of vibration fatigue and research gaps.Findings–The results showed that the resulting excitation frequencies of short-pitch irregularity vary substantially due to different track types and formation mechanisms.The axle box-mounted components are much more vulnerable to vibration fatigue compared with other components.The wheel polygonal wear and rail corrugation-induced high frequency vibration is the main driving force of fatigue failure,and the fatigue crack usually initiates from the defect of the weld seam.Vibration spectrum for attachments of railway bogie defined in the standard underestimates the vibration level arising from the short-pitch irregularities.The current investigations on vibration fatigue mainly focus on the methods to improve the accuracy of fatigue damage assessment,and a systematical design method for vibration fatigue remains a huge gap to improve the survival probability when the rail vehicle is subjected to vibration fatigue.Originality/value–The research can facilitate the development of a new methodology to improve the fatigue life of railway vehicles when subjected to wheel/rail high frequency vibration.

Investigation into rail corrugation in high-speed railway tracks from the viewpoint of the frictional self-excited vibration of a wheel–rail system

A finite element vibration model of a multiple wheel-rail system which consists of four wheels, one rail, and a series of sleepers is established to address the problem of rail corrugation in high-speed tracks. In the model, the creep forces between the wheels and rail are considered to be saturated and equal to the normal contact forces times the friction coefficient. The oscillation of the rail is coupled with that of wheels in the action of the saturated creep forces. When the coupling is strong, self- excited oscillation of the wheel-rail system occurs. The self-excited vibration propensity of the model is analyzed using the complex eigenvalue method. Results show that there are strong propensities of unstable self-excited vibrations whose frequencies are less than 1,200 Hz under some conditions. Preventing wheels from slipping on rails is an effective method for suppressing rail corrugation in high-speed tracks.

Characteristics of wheel-rail vibration of the vertical section in high-speed railways

In order to analyze the characteristics of wheel-rail vibration of the vertical section in a high-speed railway, a vehicle-line dynamics model is established using the dynamics software SIMPACK. Through this model, the paper analyzes the influence of vertical section parameters, including vertical section slope and vertical curve radius, on wheel-rail dynamics interaction and the acting region of wheel-rail vibration. In addition, the characteristics of wheel- rail vibration of the vertical section under different velocities are investigated. The results show that the variation of wheel load is not sensitive to the vertical section slope but is greatly affected by the vertical curve radius. It was also observed that the smaller the vertical curve radius is, the more severe the interaction between the wheel and rail be- comes. Furthermore, the acting region of wheel-rail vibration expands with the vertical curve radius increasing. On another note, it is necessary to match the slope and vertical curve radius reasonably, on account of the influence of operation speed on the characteristics of wheel-rail vibration. This is especially important at the design stage of vertical sec- tions for lines of different grades.

Slip-Stick Vibrations of Wheelsets and Rail Corrugations

A dynamic space coupling model is developed for simulating the vibrations of wheel/rail systems as well as the torsion and bending vibrations of wheelsets. It is found that the slip stick vibrations of wheelsets are mainly caused and controlled by the crossing excitation or self excitation of the vertical vibrations of the whole system and by the bending vibrations and torsion vibrations of the wheelsets. It is found for the first time that the slip stick vibrations may occur in more than one forms, and one or another of the three kinds of vibrations is excited more strongly. Four typical kinds of slip stick vibrations are enumerated and described. The field investigation on rail corrugations shows that the four kinds of slip stick vibrations are most likely to exist and related with different corrugated features.

Experimental study of the wheel/rail impact caused by wheel flat within 400 km/h using full-scale roller rig

Purpose–In service,the periodic clashes of wheel flat against the rail result in large wheel/rail impact force and high-frequency vibration,leading to severe damage on the wheelset,rail and track structure.This study aims to analyze characteristics and dynamic impact law of wheel and rail caused by wheel flat of high-speed trains.Design/methodology/approach–A full-scale high-speed wheel/rail interface test rig was used for the test of the dynamic impact of wheel/rail caused by wheel flat of high-speed train.With wheel flats of different lengths,widths and depths manually set around the rolling circle of the wheel tread,and wheel/rail dynamic impact tests to the flats in the speed range of 0–400 km/h on the rig were conducted.Findings–As the speed goes up,the flat induced the maximum of the wheel/rail dynamic impact force increases rapidly before it reaches its limit at the speed of around 35 km/h.It then goes down gradually as the speed continues to grow.The impact of flat wheel on rail leads to 100–500 Hz middle-frequency vibration,and around 2,000 Hz and 6,000 Hz high-frequency vibration.In case of any wheel flat found during operation,the train speed shall be controlled according to the status of the flat and avoid the running speed of 20 km/h–80 km/h as much as possible.Originality/value–The research can provide a new method to obtain the dynamic impact of wheel/rail caused by wheel flat by a full-scale high-speed wheel/rail interface test rig.The relations among the flat size,the running speed and the dynamic impact are hopefully of reference to the building of speed limits for HSR wheel flat of different degrees.

小半径曲线上P75钢轨打磨廓形设计及应用研究

以国内某重载铁路R400 m曲线P75钢轨为研究对象,建立了轮轨接触模型和轮径差曲线描述模型,选取代表性车轮踏面和钢轨廓形,采用轮径差曲线逆向求解法优化了轮轨接触区域钢轨廓形,并依据打磨量最小化原则设计得到了曲线钢轨打磨廓形。建立了实测参数下的车辆-轨道多体动力学仿真模型,对比分析了实测廓形和设计廓形匹配下的动力学指标。按钢轨廓形设计要求,在该R400 m曲线上实施了钢轨打磨试验和轮轨动力学测试。研究结果表明,优化后轮径差曲线趋于平滑,车辆曲线通过能力得到提高,抗脱轨能力得到保持;轮轨关系得到显著改善、轮轨接触点交叉跳跃和集中问题得到缓解;轮轨横向力减小20%以上,脱轨系数减小16%以上,钢轨法向接触应力减小32%以上,轮轨蠕滑力减小26%以上;实施打磨后,轮轨横向力减小34%以上,脱轨系数减小35%以上,钢轨振动加速度减小35%以上;打磨后3个月轨面疲劳伤损未见明显发展,钢轨使用寿命由前一换轨周期的8个月延长至13.5个月。仿真分析和打磨试验验证了钢轨廓形设计方法在重载铁路小半径曲线的应用效果。

基于多目标函数的钢轨打磨廓形优选研究

针对CR400BF和CRH5动车组6~8 Hz主频车体抖动问题,从改善轮轨关系角度出发,分别建立车轮踏面和钢轨廓形样本库,通过确定目标函数和设置边界条件求解得到优选钢轨廓形。建立实参数车辆-轨道刚柔耦合动力学模型和轮轨接触弹塑性有限元模型,通过仿真分析对比优选钢轨廓形和60N廓形的等效锥度、动力学指标和轮轨接触应力。按优选钢轨廓形进行钢轨打磨试验,结果表明:优选钢轨廓形与磨耗车轮踏面匹配时轮轨关系改善,等效锥度小于上限值0.4;与不同磨耗车轮踏面匹配时,优选钢轨廓形动力学指标优于60N,且轮轨接触应力和打磨量均更小;按优选钢轨廓形进行钢轨打磨后,CR400BF、CRH5动车组舒适度、平稳性指标分别减小15.7%、13.1%以上,车体振动加速度主频消除。优选钢轨廓形可有效缓解CR400BF和CRH5动车组车体抖动,优选方法和实施流程可为相关问题研究提供参考。

季冻区无砟轨道损伤变形及其对车轨动力响应的影响研究

为探究季冻区无砟轨道损伤变形对行车安全性和轨道服役性能的影响规律,以我国季冻区典型无砟轨道结构为研究对象,基于有限元方法和混凝土塑性损伤本构理论,建立考虑结构配筋的CRTS III型板式无砟轨道精细化非线性分析模型,研究路基冻胀作用下轨道结构的变形和损伤规律;结合多体动力学方法,建立高速车辆-轨道-路基耦合系统动力学模型,分析路基冻胀变形作用下高速铁路车-线-路基耦合系统动力响应。结果表明:冻胀位置对轨道结构伤损变形和离缝的产生和发展影响显著;当冻胀发生在底座板凹槽中间位置时,离缝值最大,当冻胀发生在底座板凹槽位置时,钢轨位移最大;当冻胀发生在底座板伸缩缝位置时,底座板最早产生宏观裂纹;轨道结构的变形损伤和层间离缝随着冻胀幅值增加、冻胀波长减小而增加;底座板相较于其他轨道结构更容易产生损伤,建议将底座板底面波脚产生裂纹的冻胀量作为控制标准;路基不均匀冻胀会加剧轮轨动态相互作用,进而对行车安全性和轨道服役性能产生不良影响;高速铁路的轮轨垂向动力响应随着路基冻胀幅值的增加而增大;20 m冻胀波长以下的冻胀变形及其幅值增大对车轨动力响应影响尤为严重,应予以重视。研究结论以期为季冻区高速铁路路基段基础结构动态性能演变及服役安全提供理论基础和工程指导。

随机轮轨动态激励对钢弹簧浮置板轨道减振性能影响分析

为分析随机轮轨不平顺对钢弹簧浮置板轨道减振性能影响,该文采用随机模拟的方法,研究了不同轨道不平顺状态下随机车轮不圆顺在浮置板轨道插入损失评估结果方面的随机特性,以及轨道不平顺发展对插入损失评价结果的影响。研究结果表明:不同轨道不平顺状态下,随机车轮不圆顺作用下隧道壁最大Z振级的插入损失离散超过10 dB,且随着轨道不平顺的发展,插入损失的样本均值和标准差均明显减小;分频插入损失统计结果显示,轨道不平顺的发展对频率低于6.3 Hz的插入损失影响更加显著,对于20 Hz以上频段的统计均值的影响并不明显。

轮轨激扰下轨道车辆轴箱轴承振动与润滑特性分析

基于赫兹接触和弹流润滑理论建立了考虑轴箱轴承的轨道车辆模型,研究了轮轨激扰对轴箱轴承的振动特性和油膜刚度特性的影响规律。分别采用MATLAB/Simulink和UM软件建立了轴承动力学模型和轨道车辆模型,通过相互作用力实现二者的耦合关系。模拟了轴承和轮对的典型故障形式,并详细分析了这些故障对轴承的振动特性和润滑特性的影响。研究结果表明:润滑可以有效减小轴承的振动;轴承的局部故障将导致油膜刚度的增大,轴承故障和车轮扁疤都对润滑的影响较为显著;此外,轮轨激扰会降低轴承外圈的振动比率,但是会增大车辆其他部件的振动,对车体的振动几乎无影响。

基于多尺度有限元建模技术的GJ-III型扣件轨道动力特性分析

GJ-III型扣件轨道作为地铁线路一种中等减振轨道,服役后出现钢轨短波长波磨,导致高频轮轨振动噪声问题。为探明该轨道的动力特性,利用ABAQUS软件建立减振扣件轨道的三维有限元模型。为减小有限长轨道边界反射波影响并同时保证计算效率,采用多尺度建模技术将轨道简化为梁-壳-实体模型。利用该模型探究了轮轨耦合作用下的轨道垂向动力特性,分析了扣件垂向刚度和阻尼对轨道垂向频响特性的影响。结果表明:(1)将50.0 m实体轨道模型简化为12.5 m实体和37.5 m梁-壳模型,可节约65.3%的计算时间,同时仿真与现场测试结果基本一致。(2)钢轨垂向一阶弯曲和pinned-pinned共振模态在轨道垂向位移导纳上表征明显,其频带分别为100~150 Hz和1022~1101 Hz。(3)减振扣件轨道在100 Hz以下振动响应表现为钢轨和道床板的整体弯曲和扭转振动;车辆静载集中力引起的钢轨预应力会诱发400~800 Hz轮对间轨道垂向频响峰值。(4)考虑柔性轮对作用后,轨道垂向位移导纳在分别在43 Hz、381 Hz和641 Hz处出现新的明显峰值,分别对应于轮轨耦合的P2共振模态、轮对间钢轨垂向二、三阶弯曲模态。柔性车轮在180 Hz、341 Hz和504 Hz处的振动模态也会引起钢轨垂向导纳出现新峰值。轮对质量效应对减振扣件轨道50~250 Hz内垂向振动有抑制作用,钢轨不易萌生该频段波磨。(5)钢轨垂向一阶弯曲、P2共振和轮对间钢轨垂向弯曲频率均随扣件垂向刚度增加而增加,扣件垂向阻尼仅对轨道导纳波动幅值有抑制作用。

嵌入式轨道三维滚动接触模型冲击特性研究

嵌入式轨道在城市轨道交通领域得到广泛运用,在高速铁路方面,国内外也有少量的相关报道和理论研究。嵌入式轨道对减缓轮轨冲击有显著效果,其中焊接接头是引起轮轨冲击的重要原因之一,对于时速400公里以及更高运行速度的列车,焊接接头冲击激励引起的轮轨力变化十分显著,目前对于高速工况下嵌入式轨道的研究尚不充分。基于显式动力学有限元方法,采用三维高速轮轨瞬态滚动接触模型对轮轨冲击过程进行数值模拟,并探究时速400公里速度下的嵌入式轨道的冲击特性。得出以下结论:嵌入式轨道与扣件式轨道在受到不同波长冲击时均能够减小垂向轮轨力变化幅值,焊接接头波长越长,垂向轮轨冲击力越能快速趋于平缓;车轮在受到焊接接头长波冲击时,嵌入式轨道能明显降低纵向轮轨力。研究结果可为嵌入式轨道在高速铁路的运用提供参考。

轮轨摩擦自激振动导致曲线啸叫研究

在地铁车辆通过狭窄的曲线轨道时,往往伴随着啸叫噪声的产生。为深入研究这一现象,该研究考虑了列车在曲线轨道行驶时的轮轨接触状态,进而建立了轮对-轨道系统的摩擦耦合有限元模型。随后,通过复特征值分析对该模型进行深入研究,并探讨了不同摩擦因数以及钢轨吸振器的类型及其参数对曲线啸叫产生趋势的影响。研究结果表明,轮对-轨道系统由于摩擦自激振动而引起的曲线啸叫噪声频率为482.4 Hz、1 205.1 Hz和2 153.9 Hz,这与现场测试结果相一致。此外,当摩擦因数大于或等于0.25时,轮对-轨道系统才会出现2 153.9 Hz的曲线啸叫噪声频率;而安装钢轨侧面吸振器及增大其连接阻尼或者选择合适的轨底吸振器结构均能有效地缓解轮对-轨道系统的摩擦自激振动。

轮轨冲击振动系统非线性动力学特性分析

当车辆通过轨道的局部不平顺时,轮轨间将产生大小突变且具有随机性的作用力,使车辆垂向系统的动态响应发生较大变化,这会影响车辆与轨道部件的疲劳寿命、影响车辆行驶的平稳性,还会导致车辆振动加剧。为分析当轮轨间发生冲击振动时车辆垂向减振系统的动态特性,通过建立一种垂向轮轨冲击振动系统物理数学模型,将动力学方程处理为无量纲形式,利用定步长四阶R-K数值方法求解该冲击振动系统响应,并将轮轨垂向冲击位置作为系统的Poincaré映射界面,结合分岔图、相图、时域响应对该系统在不同的无量纲激振频率下的分岔形式进行了分析,通过数值仿真,分析了系统通过余维二Hopf-Flip分岔、倍周期分岔向混沌运动转迁的过程,为车辆减振设计中的混沌预测和控制提供参考依据。

轮轨激励对橡胶垫浮置板轨道减振效果的影响

以某一组临近的普通整体道床和橡胶垫浮置板轨道为研究对象,对比测试振源加速度,同步调研上线运营列车的净运营里程,并开展车轮不圆顺测试,分析不同轮轨不平顺状态下橡胶垫浮置板轨道的减振效果。结果表明:在评价减振轨道的振动控制能力时,除了针对插入损失(或对比损失)开展客观评价外,也需要分析随着轮轨动态激励的增强是否会导致减振轨道段振动响应超过振动限值的问题;测试线路列车车轮呈现明显的7—9阶多边形磨耗特征,且随着轮轨激励的增强,Z振级相对插入损失的评价结果逐渐增大;橡胶垫浮置板轨道分频减振能力的评价结果与不同频段的激振原理直接相关,轨道扣件系统的自振频率(63 Hz)处轮轨动态激励的增加导致普通轨道的隧道壁振动响应增幅更大,该中心频率处的对比损失随着净运营里程的增加而变大。

铁路客车车轮失圆故障声振特性研究

应用单轴滚振试验对轮辋故障报警轮对进行振动及噪声测试,测试结果能很好地反映出非圆化对轮对振动噪声的直接影响,轮对几何不圆的主阶次会以基频及其倍频呈现于测试数据中;为充分研究报警轮对在车辆维度的动力学及声辐射特性,建立了车辆-轨道耦合动力学模型及轮对声学仿真模型,并以实测车轮表面粗糙度为输入激励,结合试验和计算结果可知,动力学模型能够反映轮辋故障;在频域对比中,实测和仿真结果中低频带的30 Hz、35 Hz、52 Hz和104 Hz均有波峰对应,即来自主阶次9阶、17阶和中心波长为500 mm的车轮径向缺陷特征频率均能反映在仿真模型上;研究了跟随速度变化的动力冲击和辐射声压幅值,结果指出当前故障轮对的噪声超限。

运营期普速铁路曲线区段异常晃车影响因素研究

为分析某运营期普速铁路160 km/h速度等级曲线区段的异常晃车问题,对晃车区段的轮轨廓形进行测量,分析了晃车区段的实测车体加速度与轨道几何不平顺数据的时频特征,进一步建立了车辆-有砟轨道耦合动力学仿真模型,采用试验研究和仿真计算相结合的方式研究了轮轨匹配特性和欠过超高状态对曲线区段车辆横向稳定性的影响。结果表明:异常晃车曲线区段车体横向加速度较大,存在明显周期性振动,车体横向加速度振动空间频率为0.024 m^(-1),对应波长为42 m;晃车曲线区段内外股钢轨廓形对称性差,外股钢轨轨顶面和轨距角处磨耗更严重,与实测车轮廓形匹配时轮轨接触点在轨顶面上更为集中;与采用LM&CHN60廓形相比,采用实测轮轨廓形通过曲线时的轮对横移量更大,轮对和转向架周期性振动更明显,周期性振动空间频率为0.024 m^(-1),与异常晃车频率相同;运行速度为60 km/h时的轮轴横向力显著增加,运行速度为160 km/h时的脱轨系数和轮重减载率显著增加;在曲线半径为5000 m,超高为25 mm条件下,车辆以60 km/h和160 km/h的运行速度通过曲线时分别属于严重过超高和欠超高状态,车体横向加速度振动频率与转向架蛇行运动和车轮蛇行运动频率接近,显著影响了车辆通过曲线时的动力响应;运行速度为120 km/h时曲线区段车辆动力响应整体较小,由此可见适当的欠超高有助于提升车辆曲线通过能力;由于曲线参数的限制,建议优先采用降速通过的方式减小车辆通过该段曲线时的车辆动力响应,同时通过改善轮轨匹配关系进一步提升车辆曲线通过能力。

高速铁路声屏障气动荷载及结构振动响应特性

高速铁路声屏障是铁路噪声控制的常用措施,但声屏障距离线路中心较近,在列车动力作用下会产生振动响应。列车风作用在声屏障表面形成的气动荷载和轮轨接触力产生的钢轨振动会传递到声屏障基础,是导致声屏障结构产生风致振动与轮轨激励振动的主要振源。通过开展声屏障列车气动荷载及振动响应的测试及仿真计算,获得不同工况下声屏障气动荷载及振动响应特性。结果表明:动车组以350 km/h运行时,比300 km/h运行时声屏障气动荷载和振动响应大40%;同一速度级下,路基声屏障立柱的顶端位移比桥梁声屏障顶端大40%~50%,而桥梁声屏障单元板动位移比路基声屏障大20%~30%;轮轨激励振动直接影响了声屏障振动响应,在传递过程中呈有规律衰减的趋势;列车风压与自然横风组合作用时,声屏障立柱的动变形及动应力呈现明显增大的趋势。

复杂多变工况下高铁轮对轴承故障识别研究

为提升复杂多变工况下轴承故障识别精度,研究了高铁轮对轴承故障识别方法。复杂多变工况下的轮对轴承振动信号经集合经验模态分解后,获得多个IMF分量及剩余分量,计算各分量的排列熵,以此为初始特征集,将朴素贝叶斯算法和最大均值差异(FSBD)方法相结合筛选有效特征,进行源域深度迁移自编码器训练,将输出参数作为目标域深度迁移自编码器的初始参数,检测目标域特征子集,输出故障识别结果。实验结果表明:该方法可实现轮对轴承振动信号的分解,完成初始特征FSI值的计算,选取特征数为150时,轮对轴承故障识别效果最突出,识别精度达到98.5%。

轮轨高频激励下高速列车制动盘模态振动及疲劳损伤研究

轴装制动盘是高速列车制动系统最关键的部件,是保证高速列车在紧急情况下安全停车的重要保障。文中基于车轮多边形和钢轨波磨引发的轮轨高频激励对高速列车轴装制动盘振动进行分析,得到轴装制动盘3个方向的振动加速度时域图和频域图。在振动加速度的基础上,对轴装制动盘进行振动模态仿真,分析前6阶振动模态,最后通过疲劳理论分析轴装制动盘在振动加速度影响下的疲劳损伤和寿命。研究结果表明,轮轨高频激励对轴装制动盘的垂向振动加速度影响最大,而对横向振动加速度影响最小;由此产生振动模态从第5阶开始产生严重的变形,因此要避免共振带来的影响;整个紧急制动过程中,轴装制动盘因振动而产生的疲劳应力和疲劳损伤分布趋于一致,最后影响制动盘的疲劳寿命分布,在制动盘的内侧更容易出现振动带来的损伤。