动车组车轮疲劳性能估算研究
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摘要
以某型动车组广泛使用的ER8C车轮为例,采用车轮辐板光滑试样测试常温以及-20℃,-40℃低温下车轮材料的疲劳极限,并定量分析尺寸系数和表面加工系数对车轮疲劳性能的影响。其中,在计算尺寸系数时基于车轮辐板厚度方向与其光滑试样径向受力状态相似的特点,取车轮疲劳强度最薄弱部位的辐板厚度为截面特征尺寸;在计算表面加工系数时基于Frost裂纹试样疲劳极限理论,不考虑表层应力状态对车轮疲劳性能的影响,仅考虑表面加工粗糙度对疲劳性能的影响。在此基础上,可估算出99%可靠度以及常温、低温条件下动车组车轮的疲劳极限。考虑到车轮钢与风电塔筒、轮毂等都属于碳素钢材料体系,借鉴风电行业广泛使用的结构寿命评估国际标准,可得到动车组车轮的应力—寿命曲线。
Taking ER8 C wheels widely used for some types of EMUs for examples, the fatigue limits of wheel materials under normal temperature,-20 and-40 ℃ were tested by using smooth specimens of wheel webs. The influence of size factor and surface machining factor on the fatigue performance of wheel was quantitatively analyzed. In calculating the size factor, based on the characteristics that the thickness direction of wheel web was similar to the radial stress state of smooth specimen, the web thickness of the weakest part of wheel fatigue strength was taken as the characteristic size of the cross section. In calculating the surface machining factor, based on the Frost's fatigue limits theory of crack specimen, the effect of surface stress state on the fatigue performance of wheel was not considered, but only the effect of surface roughness on the fatigue performance was considered. On this basis, the fatigue limits of EMU wheels with 99% reliability under normal and low temperature conditions could be estimated. Considering that wheel steel and wind power tower and wheel hub all belonged to carbon steel material system, the stress-life curve of EMU wheel could be obtained by referring to the international standard of structural life assessment widely used in wind power industry.
Taking ER8 C wheels widely used for some types of EMUs for examples, the fatigue limits of wheel materials under normal temperature,-20 and-40 ℃ were tested by using smooth specimens of wheel webs. The influence of size factor and surface machining factor on the fatigue performance of wheel was quantitatively analyzed. In calculating the size factor, based on the characteristics that the thickness direction of wheel web was similar to the radial stress state of smooth specimen, the web thickness of the weakest part of wheel fatigue strength was taken as the characteristic size of the cross section. In calculating the surface machining factor, based on the Frost's fatigue limits theory of crack specimen, the effect of surface stress state on the fatigue performance of wheel was not considered, but only the effect of surface roughness on the fatigue performance was considered. On this basis, the fatigue limits of EMU wheels with 99% reliability under normal and low temperature conditions could be estimated. Considering that wheel steel and wind power tower and wheel hub all belonged to carbon steel material system, the stress-life curve of EMU wheel could be obtained by referring to the international standard of structural life assessment widely used in wind power industry.
引文
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[7] FROST N E,MARSH K J,POOK L P.Metal Fatigue[M].London:Oxford University Press,1974.
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[9] 张关震.高速、重载轮轨系统金属材料与服役安全基础研究中期总结报告[R].北京:中国铁道科学研究院,2016:8-10.
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[11] 张澎湃.动车组车轮疲劳性能数值仿真和评定方法研究[D].北京:中国铁道科学研究院,2014.(ZHANG Pengpai.Research of EMU Wheel's Fatigue Performance Simulation and Assessment Method [D].Beijing:China Academy of Railway Sciences,2014.in Chinese)
[12] 丛韬,韩建民,张关震,等.铁路车轮轮辋疲劳裂纹和踏面剥离掉块的微观伤损因素分析[J].中国铁道科学,2017,38(5):93-99.(CONG Tao,HAN Jianmin,ZHANG Guanzhen,et al.Analysis of Micro Damage Factors of Shattered Rim and Tread Shelling of Railway Wheel[J].China Railway Science,2017,38(5):93-99.in Chinese)
[2] 付秀琴,张斌,张弘,等.贝氏体车轮钢性能分析[J].中国铁道科学,2008,29(5):83-86.(FU Xiuqin,ZHANG Bin,ZHANG Hong,et al.Performance Analysis of Bainite Wheel Steel [J].China Railway Science,2008,29(5):83-86.in Chinese)
[3] 刘敬辉,谢基龙,习年生,等.840D车轮辐板孔裂纹成因的强度及疲劳分析[J].中国铁道科学,2005,26(6):33-37.(LIU Jinghui,XIE Jilong,XI Niansheng,et al.Strength and Fatigue Analysis on Crack Initiation of 840D Wheel Plate Hole [J].China Railway Science,2005,26(6):33-37.in Chinese)
[4] 张关震.高速动车组车轮低温服役失效机理及可靠性年度进展情况报告[R].北京:中国铁道科学研究院,2016:20-44.
[5] 赵少汴,王忠保.疲劳设计[M].北京:机械工业出版社,1992.
[6] 张澎湃,刘金朝,张斌,等.基于主应力法和修正的Crossland疲劳准则的动车组车轮疲劳强度评定方法研究[J].中国铁道科学,2014,35(2):52-57.(ZHANG Pengpai,LIU Jinzhao,ZHANG Bin,et al.Assessment Method for Fatigue Strength of EMU Wheel Based on Principal Stress Method and Amendatory Crossland Method [J].China Railway Science,2014,35(2):52-57.in Chinese)
[7] FROST N E,MARSH K J,POOK L P.Metal Fatigue[M].London:Oxford University Press,1974.
[8] 胡志忠,曹淑珍.表面粗糙度对构件疲劳强度影响的预测[J].西安交通大学学报,1995,29(6):90-95.(HU Zhizhong,CAO Shuzhen.The Prediction of Fatigue Strength for Component Surface Roughness [J].Journal of Xi'an Jiaotong University,1995,29(6):90-95.in Chinese)
[9] 张关震.高速、重载轮轨系统金属材料与服役安全基础研究中期总结报告[R].北京:中国铁道科学研究院,2016:8-10.
[10] Germanischer Lloyd in Cooperation with the Wind Energy Committee.GL Guideline for the Certification of Wind Turbines Edition 2010[S].Brooktorkai 18,20457 Hamburg,Germany:Germanischer Lloyd Industrial Services GmbH,2010.
[11] 张澎湃.动车组车轮疲劳性能数值仿真和评定方法研究[D].北京:中国铁道科学研究院,2014.(ZHANG Pengpai.Research of EMU Wheel's Fatigue Performance Simulation and Assessment Method [D].Beijing:China Academy of Railway Sciences,2014.in Chinese)
[12] 丛韬,韩建民,张关震,等.铁路车轮轮辋疲劳裂纹和踏面剥离掉块的微观伤损因素分析[J].中国铁道科学,2017,38(5):93-99.(CONG Tao,HAN Jianmin,ZHANG Guanzhen,et al.Analysis of Micro Damage Factors of Shattered Rim and Tread Shelling of Railway Wheel[J].China Railway Science,2017,38(5):93-99.in Chinese)