Effect of Eccentric Wear of Brake Shoe on Fatigue Crack Propagation Behavior of Wheel Treads
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摘要:
闸瓦横向偏磨是一种货运列车常见且关键的制动故障，会使得车轮出现热损伤. 为研究闸瓦横向偏磨对货运列车车轮热疲劳裂纹扩展的影响机制，支撑车轮状态修与安全预警，首先，通过材料试验获取ZL-C车轮在不同温度下的力学性能参数及疲劳裂纹扩展参数；其次，建立考虑热-机耦合的车轮有限元模型，仿真计算不同闸瓦偏磨程度紧急制动工况下的温度场与应力场；最后，基于断裂力学理论构建热疲劳裂纹扩展寿命预测模型，分析裂纹的扩展路径与寿命. 结果表明：闸瓦偏磨会导致车轮紧急制动过程中出现显著制动温升，并产生较大的循环周向应力，两者共同作用导致车轮轮辋倒角处“刻度状”裂纹的萌生；热疲劳裂纹主要沿车轮轴向扩展，沿径向方向扩展较慢，随着裂纹尺寸的增加，热疲劳裂纹的深长比不断减小；在闸瓦偏磨的影响下，热裂纹的扩展寿命大幅下降，在闸瓦偏磨25 mm的紧急制动工况下，当裂纹扩展至50.0 mm时发生失稳断裂，与未发生闸瓦偏磨相比，闸瓦偏磨25 mm时热疲劳裂纹从0.2 mm扩展至50.0 mm的扩展寿命降低了90.1%. 对于出现热疲劳裂纹的车轮，要进一步加强监测，避免因裂纹失稳扩展导致的车轮提前失效.
Abstract:Transverse eccentric wear of the brake shoe is a co mmon and critical braking fault in freight trains, which can lead to thermal damage in wheels. The mechanism of transverse eccentric wear of the brake shoe influencing thermal fatigue crack propagation in freight train wheels was investigated to support wheel condition-based maintenance and safety early warning. First, material tests were carried out to obtain the mechanical property parameters and fatigue crack propagation parameters of ZL-C wheels at various temperatures. Second, a thermo-mechanically coupled finite element model of the wheel was developed to simulate the temperature and stress fields under emergency braking conditions with different degrees of eccentric wear of the brake shoe. Finally, based on fracture mechanics theory, a predictive model for thermal fatigue crack propagation service life was established to analyze the crack propagation path and its service life. The results show that the eccentric wear of the brake shoe will lead to a significant braking temperature rise during the emergency braking of the wheel, and a large cyclic circumferential stress will be generated. The combined effect of the two will lead to the initiation of “scale-like” cracks at the chamfer of the wheel rim. The thermal fatigue crack mainly propagates along the axial direction of the wheel and propagates slowly along the radial direction. With the increase of crack size, the depth-to-length ratio of thermal fatigue crack decreases continuously. Under the influence of the eccentric wear of the brake shoe, the propagation service life of the thermal crack is greatly reduced. Under the emergency braking condition of the eccentric wear of the brake shoe of 25 mm, the unstable fracture occurs when the crack extends to 50.0 mm. Compared with that in the condition without the eccentric wear of the brake shoe, the thermal fatigue crack is extended from 0.2 mm to 50.0 mm when the eccentric wear of the brake shoe is 25 mm. The propagation service life of the crack is reduced by 90.1%. For the wheels with thermal fatigue cracks, it is necessary to further strengthen the monitoring, avoiding the early failure of the wheels caused by the unstable propagation of the cracks.
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图 3 车轮材料不同温度下力学性能
Figure 3. Mechanical properties of wheel materials at different temperatures
图 4 断裂韧度试验试样尺寸
Figure 4. Schematic diagram and physical diagram of specimen size for fracture toughness test
图 5 裂纹扩展速率试验试样尺寸
Figure 5. Schematic diagram and physical diagram of specimen size for crack propagation rate test
图 6 不同试样疲劳裂纹扩展的a-N曲线
Figure 6. a-N curves of fatigue crack propagation in different specimens
图 9 车轮制动热负荷仿真分析模型
Figure 9. Simulation analysis model of thermal load of wheel braking
图 12 不同偏磨程度下轮辋倒角处温度-时间历程曲线
Figure 12. Temperature–time history curves at rim chamfers under different degrees of eccentric wear
图 13 不同偏磨程度下轮辋倒角处应力-时间曲线
Figure 13. Stress–time curves at rim chamfers under different degrees of eccentric wear
图 14 不同偏磨程度下轮辋倒角处不同方向应力-时间曲线
Figure 14. Stress–time curves in different directions at rim chamfer under different degrees of eccentric wear
图 15 车轮断裂面形貌及初始裂纹形状
Figure 15. Wheel fracture surface morphology and initial crack shape
图 19 不同闸瓦偏磨工况下热疲劳裂纹应力强度因子分布
Figure 19. Distribution of stress intensity factors of thermal fatigue cracks under different conditions of eccentric wear of brake shoe
图 20 不同闸瓦偏磨工况下热疲劳裂纹扩展路径
Figure 20. Thermal fatigue crack propagation path under different conditions of eccentric wear of brake shoe
图 21 热疲劳裂纹长度随制动次数的变化
Figure 21. Change in thermal fatigue crack length with number of braking cycles
表 1 铸钢车轮材料主要化学成分（质量分数%）
Table 1. Main chemical composition of cast steel wheel material （mass fraction %）
元素 C Si Mn P S Cr Mo Ni 含量 0.67～0.77 ≥0.15 ≤1.2 ≤0.03 ≤0.04 ≤0.25 ≤0.1 ≤0.25 
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表 2 断裂韧度测试结果
Table 2. Fracture toughness test results
$\sqrt{\text{MPa}{{•}}\text{m}} $ 试样材料 韧度 1#试样 46.5 2#试样 45.7 平均值 46.1
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表 3 疲劳裂纹扩展速率测试条件
Table 3. Fatigue crack propagation rate test conditions
试验
温度/℃试验
频率/Hz切口
长度/mm载荷比 最大
载荷/kN20 25 11.98 0.1 9
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