Mechanism and Control Method of Rail Corrugation-Induced Clip Fracture in Sections with Double-Layer Nonlinear Vibration Damping Fastener
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摘要:
为研究地铁双层非线性减振扣件区段由钢轨波磨诱导的弹条断裂问题，以典型的GJ-Ⅲ型双层非线性减振扣件为研究对象，结合现场调研和数值仿真对该区段扣件弹条的断裂诱因及其影响因素进行分析. 首先，构建了含有钢轨波磨的轮对-钢轨-扣件系统有限元模型；然后，采用瞬时动态分析方法从共振响应角度探究了钢轨波磨区段扣件弹条的断裂诱因；接着，通过疲劳累计损伤理论从疲劳特性角度对比研究了低轨两侧弹条在有无波磨情况下的疲劳寿命；最后，进行参数化分析，探究了钢轨波磨外在激励和扣件部件内在特性对弹条疲劳寿命的影响规律. 结果表明：钢轨波磨诱导的高频激励导致了GJ-Ⅲ型扣件弹条共振，是弹条断裂的主要诱因；钢轨波磨加剧了轮轨系统的振动响应，降低了弹条的使用寿命且对低轨外侧弹条影响更为严重，使其疲劳寿命降低至2.18 × 105次，仅为弹条设计寿命的4.36%；钢轨波磨外在激励方面，波磨波深减小和波磨波长增大会使弹条疲劳寿命有所增加，且当波磨波长在40 mm以上时，其疲劳寿命提升较大；扣件部件内在特性方面，减小弹条弹性模量，增加弹条泊松比、橡胶垫板泊松比及其弹性模量，能一定程度上减少弹条的疲劳损伤，进而缓解钢轨波磨区段扣件弹条的断裂.
Abstract:To study the problem of rail corrugation-induced clip fracture in metro sections with double-layer nonlinear vibration damping fasteners, by taking the typical GJ-Ⅲ type fastener as the research object, field investigation and numerical simulation were combined to analyze the causes and influencing factors of fastener clip fracture in this section. Firstly, a finite element model of the wheel–rail–fastener system incorporating rail corrugation was constructed. Subsequently, the instantaneous dynamic analysis method was employed to investigate the causes of fastener clip failure in the rail corrugation section from the perspective of resonance response. Then, based on cumulative fatigue damage theory, the fatigue life of the fastener clips on both sides of the low rail was compared under conditions with and without rail corrugation from the perspective of fatigue characteristics. Finally, a parametric analysis was conducted to explore the influence of external rail corrugation excitation and internal characteristics of fastening components on the fatigue life of the fastener clip. The results show that the high-frequency excitation induced by rail corrugation leads to the resonance in the GJ-III type fastener clip, which is the main cause of the clip fracture. Rail corrugation aggravates the vibration responses of the wheel–rail system, reduces the clip’s service life, and has a more serious impact on the outer clip of the low rail. It cuts the fatigue life to 2.18 × 105 cycles, which is only 4.36% of the design life. In terms of external excitation from rail corrugation, reducing the corrugation depth and increasing the corrugation wavelength can extend the fatigue life of the clip; moreover, when the corrugation wavelength exceeds 40 mm, the fatigue life improves significantly. In terms of the internal characteristics of fastener components, reducing the elastic modulus of the clip, increasing the Poisson’s ratio of both the clip and the rubber pad, and increasing the rubber pad’s elastic modulus can reduce the fatigue damage of the clip to some extent, thereby mitigating clip fracture in the rail corrugation section.
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Key words:
- rail corrugation /
- clip fracture /
- GJ-Ⅲ fastener /
- resonance response /
- fatigue failure
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图 1 GJ-Ⅲ型扣件区段钢轨波磨及弹条断裂特征
Figure 1. Rail corrugation and clip fracture characteristics in GJ-Ⅲ fastener section
图 5 轮轨瞬时动态分析与GJ-Ⅲ型扣件弹条的约束模态
Figure 5. Instantaneous dynamic analysis of wheels and rails and restraint modes of GJ-III fastener clip
图 7 GJ-Ⅲ型扣件弹条最大应力时程图
Figure 7. Time history diagram of maximum stress in GJ-Ⅲ fastener clip
图 9 钢轨波磨特征对弹条疲劳寿命的影响
Figure 9. Effect of rail corrugation characteristics on fatigue life of fastener clip
图 10 弹条材料参数对弹条疲劳寿命的影响
Figure 10. Effect of clip material parameters on fatigue life of fastener clip
图 11 橡胶垫板材料参数对弹条疲劳寿命影响
Figure 11. Effect of material parameters of rubber pad on fatigue life of fastener clip
表 1 轮对-钢轨-扣件系统有限元模型材料属性[17-19]
Table 1. Material properties of finite element model of wheelset–rail–fastener system [17–19]
部件 弹性模量/
MPa泊松比 密度/
（kg·m−3）轮对 210000 0.30 7800 钢轨 206000 0.30 7800 DI 弹条 206000 0.30 7800 螺旋道钉 206000 0.30 7800 轨距垫 6200 0.35 1400 轨下橡胶垫板 5 0.49 1200 中间橡胶垫板 5 0.49 1200 上、下层铁垫板 174000 0.28 7200 扣件 纵向 垂向 横向 扣件刚度/（MN·m−1） 10 16 22 扣件阻尼/（kN·s·m−1） 2 20 2 
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