复杂工况下高速列车轴箱轴承摩擦动力学特性及磨损致性能退化机理研究

As a critical component of the high-speed train travel device, the axle box bearing is subjected to the complex dynamic load and the harsh operating condition, which faces severe challenges in terms of service performance, reliability and life. In recent years, over-temperature alarm accidents of the axle box bearings frequently occur, which seriously affects driving safety and operational quality. The service performance is reflected in the tribo-dynamics characteristics，whereas the reliability and life are greatly affected by the wear. Therefore, this project intends to study the tribo-dynamics of axle box bearings under complex conditions and the performance degradation mechanism caused by wear. Firstly, the grease lubrication and the multi-body dynamics modeling theory for the high-speed train axle box bearings will be studied. The corresponding numerical simulation model and the efficient algorithm will be proposed. Then, the tribo-dynamics of the axle box bearings will be analyzed considering the complex working conditions and design parameters, which might provide a theoretical basis for the optimal design of the bearing. Finally, the wear prediction method and wear-induced degradation mechanisms for the axle box bearings under complex working conditions will be explored. It would be able to provide effective ways to improve the fault diagnosis quality and life prediction accuracy for the axle box bearings. This project will provide the theoretical basis and technical support for the design and manufacture of the axle box bearings for the high-speed train.

轴箱轴承作为高速列车走行装置的关键部件，由于承受复杂的动载冲击及运行环境，在服役性能，可靠性与寿命等方面面临严峻挑战。近年来，轴箱轴承超温报警事故频发，严重影响行车安全与运营质量。轴箱轴承的摩擦动力学特性是其服役性能的重要标志，而磨损则是影响其可靠性与寿命的关键性因素。为此本项目将围绕复杂工况下轴箱轴承的摩擦动力学特性及磨损导致的性能退化机理展开研究。首先对脂润滑理论及滚动轴承的多体动力学建模方法进行研究，提出高速列车轴箱轴承的摩擦动力学数值仿真模型及高效求解方法。然后，基于该模型对高速列车复杂工况环境及多因素影响下轴箱轴承的摩擦动力学特性展开研究，为该轴承的全工况包络优化设计提供理论依据。最后，对轴箱轴承磨损预测方法及复杂工况下磨损导致的性能退化机理进行探究，为提高轴箱轴承的故障诊断水平及寿命预测精度提供有效途径。通过本项目的研究，将为高速列车轴箱轴承的设计与制造提供理论基础与技术支持。

轴箱轴承作为高速动车组走行部的关键零部件，决定着整车运行的安全性与可靠性。由于苛刻的工况与复杂的运行环境，其摩擦学与动力学性能一直是行业关注的重点。然而，轴箱轴承是高自由度、力-流-热耦合的多体多场系统，针对该系统的准确高效的数值分析与预测模型仍比较匮乏，导致学术界与工业界对其复杂工况下的摩擦动力学特性认识不够深入。项目以某型轴箱轴承为研究对象，在滚子-滚道的弹流润滑快速计算方法、滚子轴承的摩擦动力学分析方法与轴箱轴承的磨损故障特征方面开展了系统性工作。在滚子轴承滚子-滚道热弹流建模与快速计算方法方面，构建了线接触摩擦副热弹流润滑接触刚度与阻尼的代理模型，为滚子-滚道的润滑与动力学耦合分析提供了参考。基于弹流润滑中心膜厚经验公式与表面微凸体接触模型的隐式求解，建立了线接触摩擦副的混合弹流润滑快速分析方法；在轴箱轴承的摩擦动力学建模与分析方面，结合增广拉格朗日多体动力学理论与滚子-滚道混合弹流润滑快速分析方法，建立了滚子轴承摩擦动力学高效分析模型，并验证了模型的准确性；在轴箱轴承的磨损故障特性分析方面，根据拆车的轴箱轴承故障件，建立了滚道表面磨损与保持架破裂的故障分析模型，对滚道表面磨损引起的动力学响应特征进行了计算与分析。通过上述三方面的研究，建立了轴箱轴承的摩擦动力学高效分析方法，揭示了滚子-滚道界面的混合弹流润滑机理。该模型进一步开发形成了自主分析软件，在中车企业项目中得到应用。相关成果正拓展至某型盾构机主轴承润滑分析软件的开发中。本项目的研究为滚子轴承的摩擦动力学高效分析提供了新方法，相关的分析结果为轴箱轴承等滚子轴承的可靠性设计与智能运维提供了理论支撑。