Thermal and mechanical behavior of casting copper alloy wheel during wheel and belt continuous casting process

To investigate the thermal and mechanical behavior of casting wheel,a two-dimensional thermoelastic-plastic finite element model was used to predict the temperature,stress and distortion distribution of the casting wheel during the wheel and belt continuous casting process.The effects of grinding thickness and casting speed on the thermal and mechanical behaviors of the center of the hot face of the casting wheel were discussed in detail.In each rotation,the casting wheel passes through four different spray zones.The results show that the temperature distribution of the casting wheel in different spray zones is similar,the temperature of the hot face is the highest and the temperature reaches the peak in the spray zoneⅢ.The stress and distortion depend on the temperature distribution,and the maximum stress and distortion of the hot face are 358.2 MPa and 1.82 mm,respectively.The temperature at the center of the hot face decreases with increasing grinding thickness and increases with increasing casting speed.

Estimation of Vehicle Speed Based on Wheel Speeds from ASR System in Four-Wheel Drive Vehicles

Three major methods currently in the use of determining vehicle speed based on wheel speeds, the minimum wheel speed, minimum wheel speed corrected by slope method and the Kalman filter method, are analyzed, with merits and defects of each approach stated. Through simulations, the Kalman filter method based on minimum wheel speed shows improved accuracy, in addition to better adaptivity to vehicle reference speed. It also can be used to acceleration ship regulation （ASR） in part-time four-wheel drive vehicles.

MECHANICAL-ELECTRIC COUPLING DYNAMICAL CHARACTERISTICS OF AN ULTRA-HIGH SPEED GRINDING MOTORIZED SPINDLE SYSTEM

On the basis of the traditional mechanical model of a grinding wheel rotor and the mechanical-electric coupling model with ideal sinusoidal supply, taking high-frequency converting current of inverter power switches into further consideration, a modified mechanical-electric coupling model is created. The created model consists of an inverter, a motorized spindle, a grinding wheel and grinding loads. Some typical non-stationary processes of the grinding system with two different supplies, including the starting, the speed rising and the break in grinding loads, are compared by making use of the created model. One supply is an ideal sinusoidal voltage source, the other is an inverter. The theoretical analysis of the high-order harmonic is also compared with the experimental result. The material strategy of suppressing high-order harmonic mechanical-electric coupling vibration by optimizing inverter operating parameters is proposed.

Controllable and high-throughput preparation of microdroplet using an ultra-high speed rotating packed bed

Microdroplets and their dispersion,with a large specific surface area and a short diffusion distance,have been applied in various unit operations and reaction processes.However,it is still a challenge to control the size and size distribution of microdroplets,especially for high-throughput generation.In this work,a novel ultra-high speed rotating packed bed(UHS-RPB)was invented,in which rotating foam packing with a speed of 4000-12000 r·min^(-1) provides microfluidic channels to disperse liquid into microdroplets with high throughput.Then generated microdroplets can be directly dispersed into a continuous falling film for obtaining a mixture of microdroplet dispersion.In this UHS-RPB,the effects of rotational speed,liquid initial velocity,liquid viscosity,liquid surface tension and packing pore size on the average size(d_(32))and size distribution of microdroplets were systematically investigated.Results showed that the UHS-RPB could produce microdroplets with a d_(32) of 25-63μm at a liquid flow rate of 1025 L·h^(-1),and the size distribution of the microdroplets accords well with Rosin-Rammler distribution model.In addi-tion,a correlation was established for the prediction of d_(32),and the predicted d_(32) was in good agreement with the experimental data with a deviation within±15%.These results demonstrated that UHS-RPB could be a promising candidate for controllable preparation of uniform microdroplets.

Analysis of torque transmitting behavior and wheel slip prevention control during regenerative braking for high speed EMU trains

The wheel-rail adhesion control for regenerative braking systems of high speed electric multiple unit trains is crucial to maintaining the stability,improving the adhesion utilization,and achieving deep energy recovery.There remain technical challenges mainly because of the nonlinear,uncertain,and varying features of wheel-rail contact conditions.This research analyzes the torque transmitting behavior during regenerative braking,and proposes a novel methodology to detect the wheel-rail adhesion stability.Then,applications to the wheel slip prevention during braking are investigated,and the optimal slip ratio control scheme is proposed,which is based on a novel optimal reference generation of the slip ratio and a robust sliding mode control.The proposed methodology achieves the optimal braking performancewithoutthewheel-railcontactinformation.Numerical simulation results for uncertain slippery rails verify the effectiveness of the proposed methodology.

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.

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.

Wear characteristics and prediction of wheel profiles in high-speed trains

Wheel/rail relationship is a fundamental problem of railway system. Wear of wheel profiles has great effect on vehicle performance. Thus, it is important not just for the analysis of wear characteristics but for its prediction. Actual wheel profiles of the high-speed trains on service were measured in the high-speed line and the wear characteristics were analyzed which came to the following results. The wear location was centralized from-15 mm to 25 mm. The maximum wear value appeared at the area of 5 mm from tread center far from wheel flange and it was less than 1.5 mm. Then, wheel wear was fitted to get the polynomial functions on different locations and operation mileages. A binary numerical prediction model was raised to predict wheel wear. The prediction model was proved by vehicle system dynamics and wheel/rail contact geometry. The results show that the prediction model can reflect wear characteristics of measured profiles and vehicle performances.

Typical wheel–rail profile change rules and matching characteristics of high speed railway in China

Purpose–In order to systematically grasp the changes and matching characteristics of wheel and rail profiles of high speed railway(HSR)in China,172 rail profile measurement points and 384 wheels of 6 high-speed electric motive unites(EMUs)were selected on 6 typical HSR lines,including Beijing–Shanghai,Wuhan–Guangzhou,Harbin–Dalian,Lanzhou–Xinjiang,Guiyang–Guangzhou and Dandong–Dalian for a two-year field test.Design/methodology/approach–Based on the measured data,the characteristics of rail and wheel wear were analyzed by mathematical statistics method.The equivalent conicity of wheel and rail matching in a wheel reprofiling cycle was analyzed by using the measured rail profile.Findings–Results showed that when the curve radius of HSR was larger than 2,495 m,the wear rate of straight line and curve rail was almost the same.For the line with annual traffic gross weight less than 11 Mt,the vertical wear of rail was less than 0.01 mm.The wear rate of the rail with the curve radius less than 800 m increased obviously.The wheel tread wear of EMUs on Harbin–Dalian line,Lanzhou–Xinjiang line and Dandong–Dalian line was relatively large,and the average wear rate of tread was about 0.05–0.06 mm$(10,000 km)
1,while that of Beijing–Shanghai line,Wuhan–Guangzhou line and Guiyang–Guangzhou line was about 0.03–0.035 mm$(10,000 km)
1.When the wear range was small,the equivalent conicity increased with the increase of wheel tread wear.When the wear range of wheel was wide,the wheel–rail contact points were evenly distributed,and the equivalent conicity did not increase obviously.Originality/value–This research proposes the distribution range of the equivalent conicity in one reprofiling cycle of various EMU trains,which provides guidance for the condition-based wheel reprofiling.

Minimum Curve Radii for High-Speed Trains, Including the Gyroscopic Moments of the Wheels

This paper studies the title problem including an analysis of the gyroscopic effects of the wheels of a rail-car travelling at high-speed around a level, horizontal curve. The analysis is based upon the fundamental principles of dynamics. The result is a design formula for the minimum curve radius needed to prevent derailment. Aside from the rail car geometric and physical properties, the minimum curve radius depends upon the square the train speed. An illustrative example shows that the wheel gyroscopic effect is destabilizing and additive to the centrifugal force derailment tendency. From a track design perspective, however, the gyroscopic effect is relatively small compared with the centrifugal force effect.

Parametric analysis of wheel wear in high-speed vehicles

In order to reduce the wheel profile wear of highspeed trains and extend the service life of wheels, a dynamic model for a high-speed vehicle was set up, in which the wheelset was regarded as flexible body, and the actual measured track irregularities and line conditions were considered. The wear depth of the wheel profile was calculated by the well-known Archard wear law. Through this model, the influence of the wheel profile, primary suspension stiffness, track gage, and rail cant on the wear of wheel profile were studied through multiple iterafive calculations. Numerical simulation results show that the type XP55 wheel profile has the smallest cumulative wear depth, and the type LM wheel profile has the largest wear depth. To reduce the wear of the wheel profile, the equivalent conicity of the wheel should not be too large or too small. On the other hand, a small primary vertical stiffness, a track gage around 1,435-1,438 mm, and a rail cant around 1：35-1：40 are beneficial for dynamic performance improvement and wheel wear alleviation.

Development of rail technology for high speed railway in China

Purpose–The purpose of this paper is to summarize the status and characteristics of rail technology of high-speed railway in China,and point out the development direction of rail technology of high-speed railway.Design/methodology/approach–This study reviews the evolution of high-speed rail standards in China,comparing their chemical composition,mechanical attributes and geometric specifications with EN standards.It delves into the status of rail production technology,shifts in key performance indicators and the quality characteristics of rails.The analysis further examines the interplay between wheels and rails,the implementation of grinding technology and the techniques for inspecting rail service conditions.It encapsulates the salient features of rail operation and maintenance within the high-speed railway ecosystem.The paper concludes with an insightful prognosis of high-speed railway technology development in China.Findings–The rail standards of high-speed railway in China are scientific and advanced,highly operational and in line with international standards.The quality and performance of rail in China have reached the world’s advanced level.The 60N profile guarantees the operation quality of wheel–rail interaction effectively.The rail grinding technology system scientifically guarantees the long-term good service performance of the rail.The rail service state detection technology is scientific and efficient.The rail technology will take“more intelligent”and“higher speed”as the development direction to meet the future needs of high-speed railway in China.Originality/value–The development direction of rail technology for high-speed railway in China is defined,which will promote the continuous innovation and breakthrough of rail technology.

基于轴箱高频振动的车轮不圆辨识方法研究

为实现对高速列车车轮高阶不圆的实时检测,研究了轴箱高频振动与车轮不圆的频谱特征和映射关系,采用频域积分方法对车轮不圆的幅值和阶次进行辨识.首先,通过静态测试和台架试验,研究我国高速铁路车轮多边形、钢轨波磨和轨道模态的表现形式;其次,通过高速列车长期服役性能跟踪试验,掌握转向架轴箱振动的时频特征和演化规律;最后,以现场出现车轮20阶多边形的车辆为研究对象,提出基于频域积分的车轮不圆阶次和幅值辨识方法.研究结果表明:CRTS-Ⅱ型轨道板钢轨三阶弯曲频率为592 Hz;列车以300 km/h运行时,20阶车轮多边形和136 mm波长钢轨波磨的响应频率分别为580 Hz和613 Hz;钢轨模态、车轮多边形以及钢轨波磨的振动主频较为集中,轴箱高频振动幅值随车速和镟后里程的增大而增大;采用加速度频域积分方法,从理论上可实现对车轮不圆幅值和阶次的辨识;基于线路实测轴箱加速度的20阶车轮多边形辨识结果与静态测试值相对误差不超过5%.

400 km/h高速铁路直立式声屏障降噪效果及安全性研究

开展400 km/h高速铁路噪声影响研究是践行“交通强国”战略的有力举措。为研究400 km/h高速铁路噪声特性及辐射源强,获取现有直立式声屏障在速度400 km/h条件下降噪效果及适应性,采用有限元模型进行仿真计算,模拟计算400 km/h高速铁路噪声源强并进行组成分析,对高速铁路通用的直立式声屏障降噪效果、耐久性、安全性等进行分析研究,对目前直立式声屏障适应性提出实施建议。研究表明:高速列车以速度400 km/h运行时,距离铁路外轨中心线25 m、轨上3.5 m处,桥梁段总声级为97.8 dB(A),路基段总声级为96.7 dB(A),气动噪声大于轮轨噪声;提出现有直立式声屏障在速度400 km/h条件下插入损失为2.7~8.9 dB(A);在安全方面,提出立柱底部螺栓养护年限;针对目前铁路直立式声屏障通用图适用性进行分析,提出结构安全优化建议。研究结果可指导400 km/h高速铁路噪声影响分析及直立式声屏障设计工作。

双雷达与轮轴传感器融合的列车高精度测速方法

为在列车运动过程非线性变化、噪声为非高斯的条件下,实现测速传感器的量测误差校准及融合后的速度高精度估计,提出列车测速系统配置双雷达与轮轴传感器,并根据联邦粒子滤波进行融合的测速方法。以CRH3型列车在两车站间从启动到停止的运行全过程为例,将不同速度估计方法在列车产生空转、打滑、振动以及测速传感器存在动态噪声情况下的测速误差进行分析并验证。仿真结果表明:双雷达与轮轴组合进行校准后粒子滤波相对未校准时在空转和打滑阶段均方根误差可分别降低31.52%、47.35%;对比双雷达分离振动速度校准法和双雷达角度偏差估计校准法,双雷达分离振动速度校准法在列车振动速度占比0~1和雷达安装角误差-1°~1°范围内,相对误差最大可降低39.66%。采用联邦粒子滤波融合后的测速结果较融合前双雷达和轮轴传感器滤波测速的结果MAE分别降低34.71%,14.03%,RMSE分别降低26.51%、10.98%。采用联邦粒子滤波融合的方式较联邦扩展卡尔曼滤波融合测速均方根误差降低26.97%,最大绝对误差可降低16.10%。

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。

400 km/h高速铁路轮轨噪声与二次结构噪声预测及分析

为评估400 km/h高速铁路列车通过桥梁时产生的轮轨噪声与二次结构噪声,基于统计能量分析法、有限元-边界元法,建立轮轨噪声和二次结构噪声数值预测模型。在此基础上,从轮轨粗糙度、车速和扣件刚度3个方面,分析轮轨粗糙度变化、车速变化以及扣件刚度变化对高速铁路高架段轮轨噪声和二次结构噪声的影响。研究结果表明:(1)在仅改变轮轨粗糙度情况下,综合噪声的变化趋势一致,随着轮轨粗糙度的增大,综合噪声也呈现增大趋势,并且轮轨粗糙度每增加1 dB,声压级增加1 dB(A);(2)在仅改变车速情况下,综合噪声的变化趋势一致,随着车速的增大,综合噪声也呈现增大趋势,但是噪声增大的速率变缓;(3)在仅改变扣件刚度情况下,扣件刚度变化对综合噪声的影响,主要集中在50~800 Hz频段,在其他频段范围内,综合噪声几乎不受扣件刚度变化的影响。在50~200 Hz频段,随着扣件刚度的增大,综合噪声也相应增大;而在200~800 Hz频段,随着扣件刚度的增大综合噪声数值减小。

路基不均匀沉降对高速车辆-道岔系统动力特性的影响

为了研究路基不均匀沉降对高速列车过岔时轮轨动力响应的影响,结合多体动力学和有限元法,考虑道岔多钢轨的相互作用及柔性变形,建立高速列车-道岔刚柔耦合动力学模型,分析路基不均匀沉降位置、沉降波长、沉降幅值、行车速度等因素对高速列车过岔安全性和平稳性的影响。结果表明:高速道岔区发生路基不均匀沉降会导致轮轨力和车体加速度增加,降低车辆过岔的安全性和平稳性,当路基不均匀沉降最大值位于尖轨顶宽15 mm断面时,对车辆过岔的动力学行为影响最大,轮载过渡段的长度较无路基不均匀沉降条件下延长25.64%;各项动力学指标随路基不均匀沉降波长增大而减小,随沉降幅值增大而增大;相比于区间线路,当道岔区发生路基不均匀沉降时,行车速度的变化对动力学响应的影响更大,尤其是轮轨横向力和车体横向振动加速度。

升力翼高速列车曲线通过时的轮轨黏着性能研究

建立考虑轮轨关系、升力翼及流场耦合特性等因素的车辆系统动力学模型,分析升力翼高速列车曲线通过时的运动姿态和轮轨接触特性响应,研究列车在曲线轨道运行的轮轨黏着性能,探讨轨道不平顺、曲线半径、运行速度及轮轨接触条件对轮轨黏着性能的影响。研究结果表明:气动升力通过改变列车运行动态响应和轮轨接触特性导致内、外侧轮轨垂向力和纵向蠕滑力重新分配,促使内侧轮更易失去黏着;气动升力和运行速度的增大均会劣化轮轨黏着性能,但曲线半径的增大将显著提升轮轨黏着水平;轨道不平顺削弱了轮轨黏着性能,干态、湿态、油态条件下的轮轨黏着性能依次恶化。列车牵引运行时,干态、湿态、油态条件下的轮轨均能满足牵引力安全限值要求,但制动运行时,湿态和油态条件下的轮轨均不能满足制动力安全限值要求。研究结果可为超高速列车的安全运行与节能设计提供技术支持。

珠光体型高铁车轮钢的研究进展

珠光体钢具有高强度和优异的耐磨性,广泛应用于铁路车轮。首先总结了目前我国高速动车组车轮的应用现状、轮辋强韧性水平及主要损伤形式;其次,结合350 km/h自主化高铁车轮钢的研发思路从珠光体组织及夹杂物改性控制方面重点介绍了轮辋材料强韧化机理及超高周疲劳性能的研究进展;最后,从冶金与材料学角度提出了未来更高时速高铁车轮用钢的发展思路。