Wheel-rail contact model for railway vehicle-structure interaction applications:development and validation

An enhancement in the wheel-rail contact model used in a nonlinear vehicle-structure interaction(VSI)methodology for railway applications is presented,in which the detection of the contact points between wheel and rail in the concave region of the thread-flange transition is implemented in a simplified way.After presenting the enhanced formulation,the model is validated with two numerical applications(namely,the Manchester Benchmarks and a hunting stability problem of a sus-pended wheelset),and one experimental test performed in a test rig from the Railway Technical Research Institute(RTRI)in Japan.Given its finite element(FE)nature,and contrary to most of the vehicle multibody dynamic commercial software that cannot account for the infrastructure flexibility,the proposed VSI model can be easily used in the study of train-bridge systems with any degree of complexity.The validation presented in this work proves the accuracy of the proposed model,making it a suitable tool for dealing with different railway dynamic applications,such as the study of bridge dynamics,train running safety under different scenarios(namely,earthquakes and crosswinds,among others),and passenger riding comfort.

Influence of railway wheel tread damage on wheel-rail impact loads and the durability of wheelsets

Dynamic wheel-rail contact forces induced by a severe form of wheel tread damage have been measured by a wheel impact load detector during full-scale field tests at different vehicle speeds.Based on laser scanning,the measured three-dimensional damage geometry is employed in simulations of dynamic vehicle-track interaction to calibrate and verify a simulation model.The relation between the magnitude of the impact load and various operational parameters,such as vehicle speed,lateral position of wheel-rail contact,track stiffness and position of impact within a sleeper bay,is investigated.The calibrated model is later employed in simulations featuring other forms of tread damage;their effects on impact load and subsequent fatigue impact on bearings,wheel webs and subsurface initiated rolling contact fatigue of the wheel tread are assessed.The results quantify the effects of wheel tread defects and are valuable in a shift towards condition-based maintenance of running gear,and for general assessment of the severity of different types of railway wheel tread damage.

State-of-Arts of Mechanics of Rolling Contact and Its Application to Analysis of the Interactions between Wheel and Rail

A few typical models of theory on rolling contact of bodies are reviewed, and the advantages and disadvantages in the applications to the dynamics of railway vehicles and the wheel/rail rolling contact are discussed in detail in the present paper.

Effect of rail corrugation on vertical dynamics of railway vehicle coupled with a track

The effect of rail corrugation on the vertical dynamics of railway vehicle coupled with a curved track is investigated in detail with a numerical method when a wheelset is steadily curving. In the calculation of rail corrugation we consider the combination of Kalkers rolling contact theory modified, a model of material loss on rail running surface, and a dynamics model of railway vehicle coupled with a curved track. In the establishment of the dynamic model, for simplicity, one fourth of the freight car without lateral motions, namely a wheelset and the equivalent one fourth freight car body above it, is considered. The Euler beam is used to model the rails and the track structure under the rails is replaced with equivalent springs, dampers and mass bodies. The numerical results show the great influence of the rail corrugation on the vibration of the parts of the vehicle and the track, and the some characters of rail corrugation in development.

Simulation on derailment base on a new wheel-rail contact method

The simulation package for special research on derailment of high speed vehicle is established.The process of derailment is different from other behaviors of vehicle dynamics because of large lateral displacement of wheelsets.To get correct results,a new fast algorithm to computing contact force is adopted and the exact geometry analysis is necessary to judge derailment happened.Variation of contact condition and coefficient of friction with speeds are also considered into vehicle-track coupled model.The structure of the package is presented in detail.The results are particular emphasis on investigation influence of maximum track defect,critical vehicle speed and various contact condition on derailment.The simulation can also be used to define the most risk factor leading to derailment.

精密轴系低温动态摩擦力矩波动分析及优化策略

精密轴系作为机械设备旋转支承核心,其动态摩擦力矩及平稳性直接影响整机功耗及运转精度,尤其在低温环境下,由于温度对润滑油黏度、零件尺寸和配合关系的影响,精密轴系更易出现动态摩擦力矩异常波动。针对某精密轴系低温环境下批次性动态摩擦力矩异常波动现象进行了主因素分析,通过ADAMS平台建立仿真模型,分析了引导间隙、兜孔间隙对保持架动态特性的影响。结合拆解数据,指出兜孔间隙不合理引发的兜孔磨损是造成精密轴系动态摩擦力矩异常波动的原因,通过数理统计对保持架参数进行优化,兜孔间隙与引导间隙之比为0.70~0.85时,该精密轴系低温下运转稳定。

联合载荷作用下精密轴系角接触球轴承钢球与保持架动力学行为分析

针对联合载荷作用下精密轴系角接触球轴承钢球与保持架的相互作用行为,基于滚动轴承动力学理论建立了精密轴系动力学分析模型,分析了转速、载荷、轴承结构参数对钢球与保持架动力学行为的影响,并通过保持架转速试验验证了模型的准确性,结果表明:力矩载荷对钢球与保持架动力学行为的影响程度较径向载荷明显;在径向载荷作用下,当转速小于40000 r/min时钢球与保持架的作用力随轴向预紧力增大而增大,当转速大于40000 r/min时钢球与保持架的作用力随轴向预紧力增大先减小后增大;在力矩载荷作用下,钢球与保持架的作用力随着力矩载荷的增大先增大再减小而后急剧增大;增大保持架兜孔间隙与外沟曲率半径系数有利于减小钢球与保持架的作用力。

Mechanical model for double side self-propelled rolling machine based on rigid and flexible contact dynamics

The objective of the present research was to establish a mechanical model to study the performance of double side self-propelled rolling machine.There are two key models in the modeling process.The first model is the soft cover dynamics model,which is an important innovation in this study.And the insulation quilt was established based on the Macro-modeling technology.The second model is the double side self-propelled rolling machine virtual prototype model.By specifying multiple contact constraints and loadings between the soft cover dynamics model and the rigid component,the virtual prototype model was built successfully and the double side self-propelled rolling process was completely simulated.Moreover,the interaction mechanisms of the rigid and flexible coupling mechanics were investigated.The virtual rolling processes of different insulation quilt lengths were analyzed under different thickness treatments.The simulated results showed a good agreement with the experimental measurements,which suggested that the established model is an effective approach to evaluating and optimizing the rolling machine.The successful establishment of the mechanical model can facilitate the study of the performance of the product and further optimization,and also is of great significance to shorten the development cycle and reduce costs.

重载铁路小半径曲线内轨滚动接触疲劳机理研究

国内某重载铁路小半径曲线内轨发生严重的滚动接触疲劳及其所致剥离损伤,主要集中在内侧轨肩处。为揭示其萌生机理,在轮轨现场观测和列车参数调研的基础上,建立典型重载列车的动力学模型,并利用损伤函数与表面滚动接触疲劳指数,数值分析内轨滚动接触疲劳的主要影响因素。所预测的疲劳区位置、严重程度及裂纹扩展方向等均与现场观测吻合,并发现钢轨磨耗失形是滚动接触疲劳在内轨两侧轨肩处发生的根本原因。内轨内侧轨肩处疲劳由机车曲线通过行为主导,“Co-Co”式转向架中间轮对的贡献最显著,机车导向轮对与货车共同决定了内轨外侧轨肩疲劳。随着曲线半径R增大,轮轨间作用强度减弱,使得内轨疲劳的严重程度逐渐降低,两轨肩疲劳区向轨顶中心靠拢,并最终在R为1000 m左右时合为1个疲劳区,轨面剥离现象也趋于消失。

变载荷作用下的角接触球轴承动力学分析

为研究球轴承在变载荷作用下的动力学行为,建立了角接触球轴承的动力学模型,并在不同的载荷谱下进行了角接触球轴承的动力学计算,对比了不同载荷谱作用下球与内外圈的接触角和接触载荷以及球的自转角速度和公转角速度随时间的变化。结果表明:载荷瞬时变化产生的冲击会导致球与内外圈的接触载荷和接触角发生突变,且变化幅度与冲击载荷大小相关;在受载荷冲击后,球的自转角速度和公转角速度也会发生突变,并且随轴承的转动,球的自转角速度和公转角速度会最终达到一个稳定值;载荷变化幅度越大,变化频率越快,轴承运动的变化幅度就越大。

机车车轮滚动接触疲劳特性及减缓方法

针对某E型大功率机车在复杂环境下运行时出现的车轮裂纹,通过现场监测试验和数值模拟,分析了E型机车的滚动接触疲劳(RCF)特性。分析表明环境干湿条件和运行工况条件将影响机车RCF裂纹的产生,机车的2L轴和5L轴车轮RCF发生率较低,3L和4L轴上的车轮RCF发生率较高。牵引杆倾斜和电气的不当补偿将加剧机车的轴重转移,使得3L和4L轴车轮更易发生RCF裂纹。最后通过对E型机车的电气补偿进行了仿真优化,结果表明可以显著降低机车4L轴和3L轴车轮的最大RCF损伤,提升机车运行安全性能。

二级齿轮减速器高速级轴承动态特性分析

为探究减速器轴承在动载荷作用下的动态特性变化规律,以高速级轴承为研究对象,采用广义有限元法建立了计入轴柔性、齿轮与轴承时变刚度的二级齿轮传动系统动力学模型,求解并获得轴承动载荷。基于显示动力学法建立了轴承有限元模型,计算在动载荷作用下轴承外圈的应变时域历程,并通过试验验证仿真结果的正确性。最后分析了轴承在动载荷和恒定载荷下接触特性以及打滑特性的变化规律,结果表明:在动载荷作用下,动应力波动幅值增加且内圈运动轨迹呈不稳定态势;外圈动态接触力呈余弦分布形式且波动周期与动载荷保持一致;保持架和滚子的打滑率增加,滚子运动轨迹椭圆率减小且出现“滞后承载,提前退出”的承载形式。

FeCr合金波纹形貌对滚滑摩擦性能影响的原子分析

目的研究FeCr合金不同表面波纹形貌对滚滑摩擦力学特性的影响,旨在指导高精密零件表面加工。方法采用分子动力学方法构建了光滑表面、一维和二维正弦波纹表面。综合分析了不同形貌特征对纳米压痕和滚滑摩擦过程中FeCr合金的变形、亚表面损伤以及摩擦性能的影响。结果在纳米压痕试验中,光滑表面接触面积最大,受压后变形最大,且压痕力与接触面积呈正相关。不同表面形貌的塑性变形临界压深存在显著差异,其中二维正弦波纹表面的临界压深最大。在纳米滚滑摩擦试验中,原子相互作用占主导作用,在3种表面中,光滑表面摩擦力和摩擦因数最高。在纯滑动或高速滚动时,一维正弦波纹表面的摩擦因数最小。此外,在摩擦试验中,磨损原子堆积高度、分布与界面形貌特征、滚动速度相关。磨屑原子堆积的体积和高度与接触面积呈正相关,与滚动速度呈负相关。二维正弦波纹表面磨屑原子堆积高度最低,亚表面最为稳定。结论波纹形貌表面能够减小实际接触面积,密集的波峰和波谷能够减小材料的变形,提高亚表面稳定性。

热力耦合作用的双半内圈角接触球轴承热特性

针对航空发动机高速重载双半内圈角接触球轴承运行中生热问题,基于滚动轴承动力学以及传热学理论,考虑轴承热变形以及润滑油的作用,建立热力耦合作用的双半内圈角接触球轴承动力学分析模型。采用预估-校正的GSTIFF变步长积分算法求解动力学方程组,分析了工况参数和结构参数对轴承热特性的影响,结果表明:考虑热力耦合的轴承动力学模型更接近试验结果;内、外圈温度受转速以及轴向力的影响较大,轴向力对内、外圈温差的影响较大;内圈沟曲率半径系数对轴承温度的影响较大,当内圈沟曲率半径系数为0.532时内、外圈温差最小,外圈沟曲率半径系数和垫片厚度对轴承温度的影响较小。

基于Fluent的高速角接触球轴承润滑脂动态分布

以脂润滑高速角接触球轴承为研究对象,建立润滑脂流动仿真模型,根据轴承实际运转工况设置模型速度、温度等边界条件,通过拟合常温至高温条件下的润滑脂黏度模型参数,建立全温域范围赫-巴黏度模型来描述润滑脂非牛顿流体特性,采用CFD软件Fluent进行仿真试验,并分析轴承在不同转速、温度和填脂量下的润滑脂分布。结果表明:在一定的填脂量下,随着转速提高润滑脂在轴承腔内分布更均匀,且在保持架转动方向的两侧分布更多,而内圈润滑脂量逐渐减少,转移到保持架和外圈;相对于常温,在高温下润滑脂流动性更高,向离心方向扩散的特征更为明显,这是内圈更易磨损的原因之一;在润滑脂填充比例为19.8%~29.7%的范围内,随着填脂量提高,润滑脂分布状态更好。

考虑内圈中心偏移和钢球均匀磨损的深沟球轴承振动特性分析

为研究轴承内圈中心偏移和钢球磨损对滚动轴承振动特性的影响,以深沟球轴承为例提出一种计算钢球接触变形的方法,建立了考虑钢球均匀磨损的滚动轴承动力学模型,分析钢球不同磨损程度对轴承系统振动特性的影响。结果表明:与传统模型相比,考虑轴承内圈中心偏移影响模型的振动位移偏大,结果更接近实际情况;钢球磨损后内圈振动位移的幅值变大,同时会导致保持架转动频率及其倍频的出现,并在钢球通过频率两侧出现明显的边频带;随着钢球磨损程度增大,内圈振动位移的幅值也随之增大,当钢球磨损量达到一定程度时钢球将不与内圈接触并承载。

机体杆端轴承-密封单元的动力学特性

机体杆端轴承在往复摆动的过程中,密封圈磨损严重,导致润滑脂保持率低和轴承寿命短,影响飞机的飞行安全。针对这一问题,建立机体杆端轴承-密封单元系统的动力学模型,分析工况条件(摆动频率、摆动振幅及轴承腔内温度)对系统密封性能的影响以及密封单元参数(密封圈内径、密封圈厚度、橡胶材料硬度、金属骨架轴向尺寸、金属骨架内径)对轴承摩擦力矩的影响规律,结果表明:密封圈与轴承内圈的最大接触应力随轴承腔内温度升高而减小,随轴承摆动频率和摆动振幅增大而线性增大;机体杆端轴承的摩擦力矩随橡胶密封圈厚度和橡胶材料硬度的增大而增大,随金属骨架轴向尺寸和内径的增大而减小,随密封圈内径增大而产生波动,密封圈内径应小于9.5 mm以避免摩擦力矩急剧增大。结合分析结果对密封单元进行增效设计,密封特性及摩擦特性试验结果表明,增效设计后,密封单元的润滑脂保持率提升了17.3%,轴承启动力矩下降了21.6%。

Influence of white etching layer on rolling contact behavior at wheel-rail interface

The existence of narrow and brittle white etching layers(WELs)on the rail surface is often linked with the formation of rail defects such as squats and studs,which play the key roles in rail surface degradation and tribological performance.In the present study,a systematic investigation on stress/strain distribution and fatigue life of the WEL during wheel-rail rolling contact was conducted based on a numerical model considering the realistic wheel geometry.This is the first study considering the influence of rail materials,loading pressure,frictional condition,WEL geometry(a/b),and slip ratio(Sr)in the practical service conditions at the same time.The results revealed much higher residual stress in WEL than in rail matrix.Stress changes along the rail depth matched with the previously reported microstructure evolutions.The current work revealed that the maximum difference in contact stress between the wheel passages of rail matrix and the WEL region(noted as stress variation)rises with the increase of loading pressure,the value of a/b,and Sr;but drops with the friction coefficient(μ).In addition,a critical length–depth ratio of 5 for a/b has been found.The fatigue parameter,FP,of the WEL decreased quickly with the length–depth ratio when it was less than 5 and then increased slightly when it was larger than 5.This study also revealed that the fatigue life of the WEL was reduced for high strength head hardened(HH)rail compared with standard carbon(SC)rail.

Dynamic performance of six-axle locomotive subjected to asymmetric brake shoe forces

To research the influence of asymmetric brake shoe forces(ABSF)induced by braking failure on the dynamic performance of six-axle locomotive,the static equilibrium model of three-axle bogie and dynamic model for locomotive are established.The coupling vibration equations of axle hung motor and wheelset are derived.For the air braking,the influence mechanism of ABSF on the wheel-rail asymmetric motion and force characteristics are discussed.It can be found that if the ABSF is applied in the front wheelset,all the wheelsets move laterally in the same direction.Once the ABSF occurs in the middle or rear one,other wheelsets may move laterally towards the opposite direction.The motion amplitude and direction of all wheelsets strictly depend on the resultant moment of suspension yawing moment and brake shoe asymmetric moment.For the asymmetric braking,the free lateral gap of axle-box could increase the wheelset motion amplitude,but could not change the moving direction.In both the straight line and curve,the ABSF may lead to wheelset misaligning motion,intensify the wheel-rail lateral dynamic interaction and deteriorate wheel-rail contact state.Especially for the steering wheelsets,the asymmetric braking increases the wheelset attack angle significantly,which forms the worst braking condition.

Effects of solid friction modifier on friction and rolling contact fatigue damage of wheel-rail surfaces

In railway network,friction is an important factor to consider in terms of the service behaviors of wheel-rail system.The objective of this study was to investigate the effect of a solid friction modifier(FM)in a railway environment.This was achieved by studying the friction,wear,and rolling contact fatigue(RCF)damage on the wheel-rail materials at different slip ratios.The results showed that when a solid FM was applied,the friction coefficient decreased.After the solid FM was separated from the wheel-rail interface,the friction coefficient gradually increased to its original level.With the application of the solid FM,the wear rates of the wheel-rail decreased.In addition,the thickness and hardness of the plastic deformation layers of the wheel-rail materials were reduced.The worn surfaces of the wheel-rail were dominated by pits and RCF cracks.Without the FM,RCF cracks ranged from 84 to 120μm,and subsurface cracks were generated.However,with the FM,RCF cracks ranged from 17 to 97μm and no subsurface cracks were generated.These findings indicate possible methods of improving the performance of railway rolling stock by managing friction,and reducing wear and permanent RCF damage affecting both the wheels and rails.