织构化表面处理降低高速列车制动尖叫噪声的研究

As a major part of running noise of high speed trains, brake squeal has become the key problem influencing the normal operations and development of high speed railway that need to be solved. Up to present, the mechanism causing squeal is not yet fully understood, and there is still no general solutions exist to reduce the squeal tendencies. Friction noise is caused by the interface friction action, however; there are very few reports on controlling friction noise by using surface treatment until now. Therefore, controlling and reducing the brake squeal propensity of high speed train at the source by using surface texturing treatment will have both significant theoretical innovation and application value. In this work, textured-surface configurations are introduced on the surface of brake disc/pad, and high speed disc brake squeal tests and nonlinear explicit dynamic finite element analysis are performed. The influence of the pattern and dimension parameters of surface texture on the brake squeal tendencies is studied, and the mechanism of textured-surface reducing brake squeal is investigated through the piont of energy feedback of friction-induced vibration. The design and process optimization of surface texture is conducted, and full-scale high speed disc brake simulation tests are performed to validate the effects of the optimized surface texture. Finally, design criteria of surface texture which can significantly reduce the brake squeal propensity of high speed train is established. The achievements of this project will add knowledge to our understanding of friction noise, and provide theoretical basis and engineering guidance for reducing the brake squeal propensity of high speed train.

高速列车制动噪声作为高速列车运行噪声的重要组成部分，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。目前国内外对制动摩擦噪声产生机理尚无统一认识，要控制此类噪声很困难。摩擦噪声的根源是摩擦界面的摩擦，而迄今通过改变界面特性来主动控制摩擦噪声的研究鲜见报道。因此开展表面织构化处理降低高速列车制动尖叫噪声的研究，从根源上主动控制高速列车制动噪声，具有重要的理论创新意义和工程应用价值。本项目拟在高速列车制动盘/片表面进行织构化处理，通过高速盘形制动噪声试验并结合非线性动力学分析，系统研究织构图案和尺寸参数对制动噪声的影响，从摩擦自激振动能量反馈的角度揭示织构降低制动尖叫噪声的作用机理，优化织构设计及工艺并进行全尺寸高速列车盘形制动噪声验证试验，最终建立能长效降低高速列车制动尖叫噪声的表面织构的设计准则。相关成果可丰富摩擦噪声的理论基础，并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，拟在高速列车制动盘、片表面进行织构化处理，结合试验和有限元计算分析手段，研究表面织构对制动噪声的影响及作用机理，尝试从根源上主动控制高速列车制动噪声。项目资助期间取得了一些重要的研究成果：1）成功的在高速列车制动盘、片材料表面设计并加工出各种不同形状、尺寸及分布的表面织构；2）在不同接触模式和试验工况参数下，对各种织构化的高速列车制动盘、片材料样品开展了摩擦噪声试验，系统研究了织构图案和尺寸分布参数对摩擦尖叫噪声及摩擦磨损特性的影响；3）深入分析了影响制动摩擦尖叫噪声触发和演变规律的关键界面因素，揭示了织构化表面降低制动尖叫噪声的作用机理；4）成功研制了高速列车盘型制动摩擦噪声缩比试验台，该试验台能模拟高速列车盘形制动的制动工况，可以对制动盘、片的材料、结构、界面特性、列车速度、载重等因素与制动噪声的关系进行试验和分析；5）建立了织构表面摩擦制动有限元模型，并对各种织构化表面条件下的制动摩擦振动噪声特性进行了非线性显式动力学分析，进一步验证和认识了织构化表面对制动尖叫噪声的影响机理，并实现了织构化表面制动尖叫噪声的预测；6）分析和评估了织构磨损失效机理和作用寿命，并综合各方面因素对降噪表面织构进行了优化，初步建立了能长效降低高速列车盘形制动尖叫噪声且易于加工的表面织构的设计准则。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8篇、EI检索论文5篇、核心期刊论文6篇；培养博士研究生2人、顺利答辩获硕士学位10人；获授权国家发明专利2项、实用新型专利1项。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的理论基础，还为降低高速列车制动噪声提供了理论依据和工程指导。