考虑三维纵向不均匀磨耗的钢轨滚动接触疲劳裂纹萌生预测

Prediction of the initiation of rail rolling contact fatigue cracks considering three-dimensional longitudinal uneven wear

  • 摘要: 为探究小半径曲线钢轨纵向不均匀磨耗对滚动接触疲劳(RCF)裂纹萌生的影响,基于Archard材料磨损理论与损伤函数理论分别建立钢轨三维磨耗预测模型及RCF裂纹萌生预测模型,结合型面迭代更新策略及损伤累积方法,提出了一种考虑三维纵向不均匀磨耗的钢轨RCF裂纹萌生预测方法,并对U75V淬火钢钢轨进行了分析。研究表明:随着车辆通过次数增加,外轨纵向磨耗深度分布差异随磨耗发展先增大后逐渐减小,内轨纵向磨耗深度分布差异随磨耗发展逐渐减小;这种钢轨三维纵向不均匀磨耗导致的短波不平顺会对RCF损伤分布产生较大波动,使得钢轨纵向RCF裂纹最早萌生位置随磨耗发展发生改变。轨头型面变化引发的轮轨多点接触导致RCF萌生位置发生改变,外轨在轨距角23 mm及轨侧30 mm临近区域形成两条主萌生光带,内轨轨顶偏外11 mm临近区域形成一条主萌生光带,在这些光带内最早萌生RCF裂纹。考虑三维纵向不均匀磨耗的RCF裂纹萌生寿命更接近于实际,钢轨服役初期至单节车辆通过约15万次时,该阶段钢轨磨耗与损伤累积速率较缓,此后因磨耗加剧导致损伤累积显著加快,外轨纵向108.5 m处和内轨纵向83.25 m处累积损伤值先达到裂纹萌生门阀值1,该区段最早裂纹萌生。该研究方法可为小半径曲线钢轨纵向RCF裂纹萌生位置及寿命预测提供参考。

     

    Abstract: To investigate the effect of longitudinal uneven wear on small-radius curve rails on the initiation of rolling contact fatigue (RCF) cracks, a three-dimensional rail wear prediction model and an RCF crack initiation prediction model were respectively established based on Archard's material wear theory and damage function theory. By combining a profile iterative update strategy and a damage accumulation method, a prediction method for RCF crack initiation in rails considering three-dimensional longitudinal uneven wear was proposed, and analyzed for U75V quenched steel rails. The study shows that: as the number of vehicle passes increases, the difference in longitudinal wear depth distribution of the outer rail first increases and then gradually decreases with wear development, while the difference in the inner rail's longitudinal wear depth distribution gradually decreases; the short-wavelength irregularities caused by such three-dimensional longitudinal uneven rail wear lead to significant fluctuations in RCF damage distribution, causing the earliest initiation position of longitudinal RCF cracks in rails to change with wear development. The multi-point wheel-rail contact induced by rail head profile changes leads to changes in RCF initiation positions: two main initiation bands form in the outer rail near the regions 23 mm from the gage corner and 30 mm from the rail side, while a single main initiation band forms in the inner rail near the region 11mm outside the rail crown. RCF cracks first initiate within these bands. The predicted RCF crack initiation life considering three-dimensional longitudinal uneven wear is closer to reality. From the early service stage of the rail to approximately 150,000 passes of a single vehicle, the rates of rail wear and damage accumulation are relatively slow. Thereafter, accelerated wear leads to a significant increase in damage accumulation. The cumulative damage values at the longitudinal positions of 108.5 m on the outer rail and 83.25 m on the inner rail first reach the crack initiation threshold of 1, where cracks first initiate in these sections. This research method provides a reference for predicting the initiation positions and service life of longitudinal RCF cracks in small-radius curve rails.

     

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