制动工况对高速列车制动盘残余应力及翘曲变形的影响

李志强; 郑轶男; 张晓康; 李杰; 杨智勇

doi:10.3969/j.issn.0258-2724.20230691

制动工况对高速列车制动盘残余应力及翘曲变形的影响

doi: 10.3969/j.issn.0258-2724.20230691

北京交通大学机械与电子控制工程学院，北京 100044

基金项目: 中央高校基本科研业务费专项资金（2021JBM023）；国家自然科学基金项目（52002018）

详细信息

作者简介:
李志强（1987—），男，副教授，研究方向为轨道车辆结构可靠性设计，E-mail：lizhq@bjtu.edu.cn

中图分类号: U270.1
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- 被引次数: 0
出版历程
- 收稿日期: 2023-12-26
- 修回日期: 2024-04-03
- 网络出版日期: 2024-07-18

Influence of Braking Conditions on Residual Stress and Warping Deformation of Brake Discs of High-Speed Trains

School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University, Beijing 100044, China

摘要

摘要:
动车组制动盘在长期服役过程中会形成复杂的残余应力，进而使盘体在拆解后形成不可回复的翘曲变形，为探究残余应力与翘曲变形对制动盘后续维修和重复利用可行性的影响，首先，通过测试动车组轮装铸钢制动盘材料不同温度下的拉伸应力-应变数据，构建了对应的材料Ramberg-Osgood本构模型，在有限元软件中建立制动盘循环对称三维瞬态仿真模型；其次，针对列车不同制动初速度、不同平均减速度等制动工况，采用间接耦合方法分析了制动盘表层与心部残余应力的形成与平衡过程，研究了制动盘结构约束释放后的翘曲变形量变化，采用分段函数与多项式拟合了制动盘变形量与制动能量、热输入功率的函数关系；最后，通过对服役后的制动盘进行翘曲变形量测量与X射线残余应力测试，对比分析了对应仿真条件时制动盘摩擦面残余应力分布规律，发现仿真结果与实测数据具有较好的数据和趋势一致性. 研究表明：制动盘翘曲变形量与制动能量、制动减速度呈正相关关系，制动工况越严苛制动盘翘曲变形量越大；仿真与实测均表明高残余拉应力位于摩擦面中部螺栓孔附近，且制动工况越严苛高残余拉应力值越大.
- 制动盘 /
- 残余应力 /
- 翘曲变形 /
- 数值模拟 /
- 试验验证
Abstract:
The brake disc of electric multiple units (EMUs) will form complex residual stress during long-term service, which will lead to irreversible warping deformation after disassembly. In order to investigate the influence of residual stress and warping deformation on the feasibility of subsequent maintenance and reuse of brake discs, firstly, the Ramberg-Osgood constitutive model of corresponding materials was constructed by testing the tensile stress-strain data of cast steel for wheel-mounted brake discs of EMUs at different temperatures. A cyclically symmetric three-dimensional transient numerical simulation model of brake discs was established in finite element software. Secondly, the formation and balance process of residual stress in the surface and center of the brake disc were analyzed by indirect coupling method for different braking conditions considering different initial braking speeds and different average decelerations of the train. The change in warping deformation of the brake disc after structural constraint release was studied. The functional relationship between brake disc deformation and braking energy and heat input power was fitted by piecewise function and polynomial. Finally, by measuring the warping deformation and testing the X-ray residual stress of the brake disc after service, the residual stress distribution law on the friction surface of the brake disc under the corresponding simulation condition was compared. The simulation results had good data and trend consistency with the measured data. The study reveals that the warping deformation of the brake disc is positively correlated with braking energy and braking deceleration. More severe braking condition indicates greater warping deformation of the brake disc. The simulation and measurement show that the high residual tensile stress is located in the middle of the friction surface and close to the bolt holes. The high residual tensile stress value is higher when the braking condition becomes more severe.
- brake disc /
- residual stress /
- warping deformation /
- numerical simulation /
- test verification

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图 1 棒状拉伸试样尺寸

Figure 1. Tensile size of rod specimen

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图 2 制动盘材料不同温度下的单调拉伸应力-应变

Figure 2. Monotonic tensile stress-strain curves of brake disc materials at different temperatures

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图 3 热机耦合仿真分析模型

Figure 3. Analysis model for thermal-mechanical coupling simulation

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图 4 热分析边界条件

Figure 4. Boundary conditions for thermal analysis

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图 5 应力分析边界条件

Figure 5. Boundary conditions for stress analysis

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图 6 不同制动初速度下制动结束拆除螺栓后等效应力分布

Figure 6. Equivalent stress distribution after bolt removal at the end of braking with different initial braking speeds

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图 7 制动盘螺栓孔边应力分析节点位置及编号

Figure 7. Node position and number of bolt hole in brake disc for stress analysis

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图 8 不同制动初速度下摩擦面不同方向应力-时间曲线

Figure 8. Stress-time curves in different directions on friction surface under different initial braking speeds

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图 9 距摩擦面不同深度取点位置及周向应力变化曲线

Figure 9. Circumferential stress changes at different depths from friction surface

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图 10 不同制动初速度下摩擦面周向塑性应变

Figure 10. Circumferential plastic strain of friction surface at different initial braking speeds

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图 11 翘曲变形随制动能量变化

Figure 11. Variation of warping deformation with braking energy

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图 12 翘曲变形随制动减速度变化

Figure 12. Variation of warping deformation with braking deceleration

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图 13 制动盘翘曲变形量测试方法

Figure 13. Test method of warping deformation of brake disc

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图 14 X射线法测试摩擦面残余应力

Figure 14. Residual stress of friction surface measured by X-ray method

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图 15 测试与仿真残余应力值对比

Figure 15. Comparison of tested and simulated residual stress values

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表 1 制动盘材料不同温度下的力学性能参数

Table 1. Mechanical properties of brake disc material at different temperatures

温度/（℃） σ_0.2/MPa σ_b/MPa E /GPa n

25 1055 1142 214 37.893

100 1007 1095 202 33.306

400 843 948 191 19.766

600 547 568 159 13.252

800 77 102 59 12.593

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表 2 制动盘翘曲变形量测试结果

Table 2. Test results of warping deformation of brake disc

螺栓孔编号 1 2 3 4 5 6 7 8 9 10 11 12 平均

变形量/mm 1.20 1.24 1.18 1.20 1.16 1.20 1.16 1.20 1.16 1.20 1.18 1.18 1.18

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