Fracture Mechanism of Cologne-Egg Fastener Clips in Rail Corrugation Sections
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摘要:
钢轨波磨作为地铁线路的典型钢轨损伤形式，其高发区段常伴随着扣件弹条断裂问题，严重影响列车的运营安全. 其中，科隆蛋扣件小半径区段是钢轨波磨的高发区段. 为探究科隆蛋扣件弹条的断裂机理，首先结合现场调研，构建包含完整科隆蛋扣件的轮对-钢轨-扣件系统有限元模型；然后，从共振响应的角度探究轮轨摩擦耦合振动激励下科隆蛋扣件弹条的共振响应；最后，从疲劳寿命角度，对比有无波磨区段科隆蛋扣件弹条的疲劳寿命情况，并以此量化不同弹条的疲劳损伤情况. 研究结果表明：在钢轨波磨高发区段，轮轨摩擦耦合振动主频与科隆蛋扣件弹条一阶约束模态一致，轮轨摩擦耦合振动引起的弹条共振是科隆蛋扣件断裂的主要原因；钢轨波磨加剧了轮轨摩擦耦合振动，使得科隆蛋扣件弹条寿命相较无波磨区段下降99.04%，仅为设计寿命的3.11%；此外，科隆蛋扣件小半径曲线区段低轨工作边一侧的弹条更容易发生疲劳失效，失效位置位于其弹条后拱端内侧.
Abstract:As typical rail damage of the railway, rail corrugation is often accompanied by the fastener clip fracture, which seriously affects the operation safety of the train. Moreover, the small-radius section of the Cologne-egg fastener experiences frequent rail corrugation. To explre the fracture mechanism of Cologne-egg fastener clips, firstly, the finite element model of the wheel set-rail-fastener system, including the complete Cologne-egg fastener model, was established baesd on the field investigation. Then, the resonant response of the Cologne-egg fastener clip was explored, considering the frictional coupling vibration of the wheel-rail system. Finally, the fatigue life of the Cologne-egg fastener clip was compared in the cases of with and without rail corrugation sections, and the fatigue damage of different clips was quantified. The results show that the dominant frequency of the frictional coupling vibration of the wheel-rail system is consistent with the first-mode constraint mode of the Cologne-egg fastener clip in the frequent rail corrugation sections, which indicates that the clip resonance induced by the frictional coupling vibration of the wheel-rail system is the main reason for the Cologne-egg fastener fracture. The frictional coupling vibration of the wheel-rail system is aggravated by the rail corrugation, which makes the clip life of the Cologne-egg fastener in the rail corrugation section decrease by 99.04% compared with that in the absence of rail corrugation section. The clip life is thus only 3.11% of the design clip life. Besides, the Cologne-egg fastener clip on the low gauge side is more prone to fatigue failure in the small-radius curved section, and the failure position is located on the inner side of the rear arch end of the clip.
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图 1 科隆蛋扣件区段钢轨波磨及扣件断裂特征
Figure 1. Rail corrugation and fastener fracture characteristics of Cologne-egg fastener section
图 3 科隆蛋扣件弹条扣压过程模拟
Figure 3. Simulation of Cologne-egg fastener clip compression process
图 5 轮对-钢轨-扣件系统的瞬时动态分析结果
Figure 5. Instantaneous dynamic analysis results of wheel set-rail-fastener system
图 6 科隆蛋扣件弹条10～
2000 Hz约束模态频率及振型Figure 6. Constraint modal frequency and vibration mode of Cologne-egg fastener clip at 10–
2000 Hz
图 8 科隆蛋扣件弹条最大应力时程图
Figure 8. Maximum stress time history diagram of Cologne-egg fastener clips
图 9 科隆蛋扣件弹条雨流计数分布图
Figure 9. Rain flow count distribution of Cologne-egg fastener clips
表 1 轮对-钢轨-扣件系统有限元模型的材料属性[9,18,19]
Table 1. Material properties of finite element model of wheel set-rail-fastener system [9,18,19]
部件 弹性模量/MPa 泊松比 密度/
（kg•m−3）轮对 210.00×103 0.30 7800 钢轨 206.00×103 0.30 7800 DI弹条 206.00×103 0.30 7800 轨距垫 6.20×103 0.35 1400 调高垫板 6.00 0.45 1190 承轨座/底座 170.00×103 0.30 7900 减振橡胶 5.58 0.49 1190 
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