高速列车车轮多边形磨损形成的机理和对策研究

Serious polygonal wear of high-speed train wheels causes the intense vibration and noise of the train/track. The fatigue fracture of some parts occurs and endangers the operation safety. The present project will carry out field tracking test and analysis of relevant high-speed trains and lines. The relationship between wheel polygon wear and vibration characteristics of vehicle/track system is grasped to reveal the formation mechanism of polygonal wear with providing supporting data, and also the results of theoretical model and numerical simulation are verified. The theoretical prediction model of wheel polygon wear of high-speed train is developed. The theoretical model consists of the dynamical model of high- speed train/track rigid-flexible coupling, high-speed wheel/rail rolling contact model and friction wear model of wheel material. Using this theoretical model through numerical simulation studies the relationship between wheel/track excitation, high frequency flexible vibration, operation speed, wheel diameter change and polygonal wear. The mechanism of initiation and development of high-speed wheel polygon wear is revealed completely. The relationship between the development rate of polygonal wear, the operation speed and the change of the wheel diameter, polygonal wear state (depth) and the impact load of the wheel/track is clearly characterized. The present research will have preliminarily worked out the re-profiling limit of polygonal worn wheels and the economic re-profiling strategy in the whole life of wheels. Using laboratory test facilities reproduces the initiation and development of polygonal wear of high-speed wheels and verifies the basic condition of the forming of polygonal wear. Also preliminary measures to suppress the wear of wheel polygon are put forward.

高速列车车轮严重的多边形磨损引发了车辆轨道大系统强烈的振动和噪声，导致一些部件疲劳断裂，危及到行车安全。本项目将对相关的高速列车及线路进行现场跟踪试验分析，掌握车轮多边形磨耗形成与车辆/轨道系统振动特性的关系，为揭示多边形的形成机理提供支撑数据，并验证理论模型和数值仿真的结果。建立高速列车车轮多边形磨损理论预测模型，其模型集高速列车/轨道刚柔耦合动力学模型、高速轮轨滚动接触模型和车轮材料摩擦磨损模型于一体。借助于此理论模型和数值仿真，研究轮轨激励、车辆的高频柔性振动、速度、轮径与多边形磨耗的关系，深入揭示高速车轮多边形磨损发生发展的机理，表征多边形磨损发展速率、运行速度和轮径变化关系、多边形磨损状态（深度）与轮轨冲击载荷关系。初步制定车轮边形波深的镟修限值和车轮全寿命周期内的经济镟策略。利用室内试验装置再现多边形磨损过程，验证多边形磨损形成的基本条件。初步提出抑制轮多边形磨损问题的措施。

高速列车车轮严重的多边形磨损会引发车辆轨道耦合大系统强烈的振动和噪声，也导致一些部件疲劳断裂，危及到行车安全。本项目采用大量的运营现场调查、现场试验数据统计分析、室内1:1台架高速滚动试验研究、理论分析和数值模拟相结合的研究方法，以弄清高速车轮多边形磨耗特征、形成机理和初步确立科学合理经济有效的措施以及车轮多边形磨耗的镟修准则为目的。.完成了任务设置的项目研究计划，实现了预期目标。成功建立考虑转向架系统和轨道系统高频柔性振动特性的车辆轨道刚柔耦合大系统动力学模型及发展相应的数值方法。成功建立车轮多边形磨耗预测模型，并对车轮多边形磨耗机理及多边形磨耗发展的关键条件和影响因素展开了分析讨论。依托全尺寸轮轨滚动试验台，开展轮对的高速纯滚动试验，并在实验室内再现了车轮多边形磨耗产生和发展的整个过程，验证了多边形磨耗形成的基本条件。完成了我国高速列车运营现场已有试验数据统计分析和现场继续跟踪试验分析，现场调查涵盖我国主要高速车型和主要线路，掌握车轮多边形磨耗的特征及规律，探明车轮多边形磨耗的产生与车辆及轨道系统的相干关系。 .关键的结论是列车高速运行时，转向架构架和轮对系统在轮轨不平顺激励下产生系统共振。并传至轮轨滚动接触界面引起了轮轨具有相同频率接触振动。当轮轨界面接触振动的波长(列车速度除以共振频率)能够整除车轮滚动圆周长时, 萌生车轮多边形磨损并快速发展, 这是多边形磨耗发展的基本条件。打破此条件就能有效抑制多边形磨耗的发展。 .初步提出了基于轮轨垂向力限值的车轮多边形磨耗镟修准则。通过理论和试验分析，证明了改变列车运行速度可以有效地抑制车轮多边形磨耗的发展。通过现场跟踪试验分析，评估了车轮踏面修型器对多边形磨耗的抑制效果。对多边形的抑制效果十分理想。.在项目为期四年的执行过程中，共发表论文46篇，其中SCI检索论文14篇，EI检索论文24篇。授权国家发明专利4项。参加国际会议22人次，国内学术交流报告11人次，特邀报告1次。培养博士研究生3名，硕士研究生18名。组织专题研讨会1次，邀请国际专家学术交流6人次。获四川省科学技术进步奖一等奖1项，中国铁道学会科学技术奖二等奖2项。