基于摩擦界面优化的低噪声高速列车盘形制动闸片的设计

Brake noise emanating from high speed train has become a key issue in affecting the normal operation and restricting the development of high speed railways, which need to be solved. Brake noise is originated from the friction action between the interface of brake disc and pad, and thus it should be solved from the interface, by designing a reasonable and effective contact interface to suppress the generation of squeal. However, there are very few reports on controlling brake noise by modification of interface features until now. Therefore, it is of considerable theoretical innovation and engineering application value to design a new brake pad surface with low brake noise, which may consequently help to explore a new path to suppress the generation of brake noise of high speed train. In this work, brake pads with different interface features are designed, and the effect of brake pad interface features on the brake noise is systematically studied and the mechanism is consequently revealed. And on this basis, both the ‘directly’ and ‘indirectly’ methods: modifying the interface features and designing and using damping pad with new structures, are included to regulate the brake pad interface and make sure a good interface matching between the brake disc and pad. Finally, the design principles of bake friction interface related to the reduction of the brake noise of high speed train is established, which will provide theoretical basis and engineering guidance for reducing the brake noise of high speed train.

高速列车制动噪声已成为影响高速铁路正常运营并制约其发展的关键问题，亟待解决。制动噪声源于制动盘/片间界面的相互摩擦作用，要解决制动噪声问题需从界面角度入手，设计合理有效的摩擦界面从根源上抑制制动噪声，但目前通过改变界面特性来主动控制制动噪声的报道极少。因此开展基于摩擦界面优化的低噪声高速列车盘形制动闸片的设计，探索从根源上主动控制高速列车制动噪声的新途径，具有重要的理论创新意义和工程应用价值。本项目拟通过设计具有不同界面特征的制动闸片摩擦块，系统研究并揭示摩擦块界面特征对制动噪声的影响及作用机理，在此基础上采用修改界面特征和设计使用新型阻尼垫片对摩擦界面进行 “直接”和“间接”调控相结合的方式，实现摩擦块界面有效调控及盘/片间良好的界面匹配，建立能有效降低制动噪声的制动摩擦界面设计准则，为降低高速列车制动噪声提供理论依据和工程指导。

本项目针对高速列车制动噪声已成为影响和制约高速铁路正常运营及发展的问题，通过设计具有不同界面特征的制动闸片摩擦块，系统研究并揭示了摩擦块界面特征对制动噪声的影响及作用机理，在此基础上采用修改界面特征和设计使用新型阻尼垫片对摩擦界面进行 “直接”和“间接”调控，实现摩擦块界面有效调控及盘/片间良好的界面匹配，建立了能有效降低制动噪声的制动摩擦界面设计准则，为降低高速列车制动噪声提供理论依据和工程指导。项目资助期间取得了一些重要的研究成果：1）深入揭示了高速列车制动噪声触发及演变规律，建立了制动过程中制动界面各种因素与制动噪声的动态关联性，成功找出控制制动噪声的关键界面因素；2）通过改变摩擦块安装方向、形状等界面特征，成功实现高速列车制动噪声及界面摩擦学行为的“直接”调控；3）分析了摩擦块形状对高速列车制动系统不稳定性及振动特性的影响，阐明了摩擦块界面特征对高速列车制动噪声的影响机理；4）成功设计具有特殊结构的新型金属阻尼垫片用于摩擦块背后的方式对摩擦界面进行“间接”调控；5）对弹性阻尼垫片进行织构化设计，结合试验和有限元计算分析手段，揭示了织构化设计的弹性阻尼垫片对摩擦自激振动的影响机制；6）揭示了不同阻尼元件作用下摩擦系统的粘滑振动特性及相应的界面摩擦学行为，阐明了含阻尼元件摩擦系统的强非线性动力学问题；7）阐明了高速列车盘形制动摩擦块界面调控及匹配机制，初步建立了低噪声高速列车盘型制动闸片摩擦块界面设计准则。.截止目前，直接相关研究成果已发表标注基金资助的SCI检索论文25篇、EI检索论文6篇、核心期刊论文3篇；培养博士3人、硕士14人顺利答辩获学位；获授权中国发明专利6件、实用新型专利10件。研究成果具有重要的理论创新意义和工程应用价值，不仅丰富了摩擦噪声产生机制及其调控的理论基础，还为低噪声高速列车盘型制动闸片设计提供了理论依据和工程指导。