钢轨焊接接头的静弯试验有限元建模及受力分析
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摘要
钢轨焊接接头的静弯试验是评定焊接工艺和接头性能的重要方法。基于静弯试验系统的结构特征,建立了包含双接触对的钢轨焊接接头静弯接触有限元模型,分析了单元尺寸和接触刚度等接触对参数对计算时间及计算结果精度的影响,优化确定出合适的单元尺寸和接触对模型参数,并通过对比已有文献数据,证明了模型的适用性。然后根据钢轨闪光焊接头的静弯检验标准,对钢轨轨头受压(正弯)和轨头受拉(反弯)时的应力分布进行了模拟计算,获得了钢轨静弯时的应力分布特征、最大等效应力及其位置。通过对计算结果进行分析,对钢轨窄间隙电弧焊接头的强度、残余应力等提出了控制要求,可为后续钢轨窄间隙电弧焊接的工艺改进、接头质量控制和性能改善提供有价值的参考。
The static bending test of rail welded joint is an important way to evaluate the welding process and joint quality. Based on the structural features of static bending test system,the contact finite element model including two contact pairs for the static bending test of rail welded joint was established. The influences of parameters of contact pairs,including element size,contact stiffness and so on,on the calculation time and result accuracy were analyzed,and the appropriate element size,contact pair parameters for FE model were determined by optimizing se-lection. Moreover,the applicability of the FE model for stress analysis was confirmed by comparing the calculated results with the experimental results presented in related literature. After that,according to the standard concerning the static bending test of rail joint welded by flash butt welding,the simulating computation of the stress distribution was conducted for both rail head being pressed( forward bending) and rail head in tension( reverse bending) respectively by using the established contact FE model,and the stress distribution characteristics as well as the value and location of the maximum von Mises stress was discovered accordingly. Through analysis on the computational results,the control requirements was put forward on the strength and residual stress of rail joint welded by narrow gap arc welding. These conclusions can offer valuable reference for the subsequent process modification,joint quality control and performance improvement of rail narrow gap arc welding.
The static bending test of rail welded joint is an important way to evaluate the welding process and joint quality. Based on the structural features of static bending test system,the contact finite element model including two contact pairs for the static bending test of rail welded joint was established. The influences of parameters of contact pairs,including element size,contact stiffness and so on,on the calculation time and result accuracy were analyzed,and the appropriate element size,contact pair parameters for FE model were determined by optimizing se-lection. Moreover,the applicability of the FE model for stress analysis was confirmed by comparing the calculated results with the experimental results presented in related literature. After that,according to the standard concerning the static bending test of rail joint welded by flash butt welding,the simulating computation of the stress distribution was conducted for both rail head being pressed( forward bending) and rail head in tension( reverse bending) respectively by using the established contact FE model,and the stress distribution characteristics as well as the value and location of the maximum von Mises stress was discovered accordingly. Through analysis on the computational results,the control requirements was put forward on the strength and residual stress of rail joint welded by narrow gap arc welding. These conclusions can offer valuable reference for the subsequent process modification,joint quality control and performance improvement of rail narrow gap arc welding.
引文
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[16]童宝宏,刘颖,苏荭.滚动轴承动态接触特性数值模拟中若干问题[J].机械工程学报,2012,48(21):116-123.
[17]叶庆佟.钢轨焊头静弯破断荷载标准的研究[J].铁道建筑,1988(10):3-7.
[2]丁韦,刘艳红,黄辰奎,等.国内外铁路钢轨焊接标准接头力学性能检验方法对比分析[J].铁道技术监督,2006,34(7):4-6.
[3]高文会,李力,丁韦.我国与英国的钢轨焊接接头技术条件的比较与分析[J].铁道建筑,2003(10):12-14.
[4]王东,高文会,代韬,等.钢轨固定式闪光焊接头静弯试验及与落锤试验相关性分析[J].铁道建筑,2018(2):129-133.
[5]朱志明,范开果,潘际銮.高速铁路钢轨焊接技术的发展与应用[J].焊接,2013(5):5-10.
[6]宋宏图,李力,丁韦,等.钢轨自保护药芯焊丝自动窄间隙电弧焊工艺及装备研究[J].电焊机,2011,41(3):91-94.
[7]朱志明,范开果,刘晗,等.低气压对自保护药芯焊丝电弧特性的影响[J].清华大学学报:自然科学版,2015(7):734-738.
[8]朱志明,范开果,王永东,等.低气压对自保护药芯焊丝焊缝成形的影响[J].焊接学报,2015,36(2):1-5.
[9]刘正文.高速无缝线路钢轨窄间隙自动化电弧焊接关键技术研究[D].北京:清华大学博士学位论文,2010.
[10]朱志明,范开果,刘晗,等.残余应力对钢轨焊接接头落锤试验性能的影响[J].焊接学报,2017,38(4):55-58.
[11]范开果.钢轨窄间隙自动电弧焊接工艺优化与低气压环境工程应用[D].北京:清华大学博士学位论文,2015.
[12]崔瀚钰.高速铁路钢轨力学模型的应用与合理性分析[J].上海铁道科技,2014(1):44-45.
[13]宁明哲,刘长文.钢轨接头强度的有限元分析[J].铁道科学与工程学报,2003,21(2):45-49.
[14]王珍君,侯炳麟.钢轨轨头三维应力有限元分析[J].中国铁道科学,2000,21(4):66-72.
[15]曾意军.60TY钢轨弯折有限元仿真模拟分析[J].铁道建筑技术,2012(10):35-36.
[16]童宝宏,刘颖,苏荭.滚动轴承动态接触特性数值模拟中若干问题[J].机械工程学报,2012,48(21):116-123.
[17]叶庆佟.钢轨焊头静弯破断荷载标准的研究[J].铁道建筑,1988(10):3-7.