Study on Crack Propagation of Freight Train Wheel Treads under Ramp Emergency Braking Conditions

doi:10.3969/j.issn.1004-132X.2025.12.001

Abstract

Abstract:

The fatigue crack propagation of freight train wheel treads under ramp emergency braking conditions was studied based on the extended finite element method， taking into account the frictional heat generation， conduction heat dissipation， and the variation of material parameters with temperature. By analyzing the temperature fields and stress fields during the rolling contact processes under ramp emergency braking conditions， the results indicate that the existence of tread cracks affects the wheel-rail contact stress distribution， the high contact stress regions are divided into two sub-regions by the tread cracks， and stress concentration occurs at the crack front， and the tread crack propagation behavior is closely related to the relative positions of cracks and contact regions. During the braking processes， the circumferential compressive stress generated by high temperature will inhibit the tread crack growth， but the residual tensile stress after cooling will promote the tread crack propagation. During the stages of tread temperature rising， the tread crack propagation mode is a mixed Ⅱ-Ⅲ multiaxial propagation mode， dominated by mode Ⅱ propagation. During the stages of cooling， the tread crack propagation mode is mixed Ⅰ-Ⅱ-Ⅲ multiaxial propagation mode， dominated by mode Ⅰ and mode Ⅱ.

Key words: tread crack, freight train, thermo-mechanical coupling, extended finite element, stress intensity factor, emergency braking

摘要：

基于扩展有限元法，考虑摩擦生热、传导散热、材料参数随温度的变化，研究了坡道紧急制动工况下货运列车车轮踏面疲劳裂纹扩展问题。通过分析坡道紧急制动工况下车轮滚动过程中的温度场及应力场，发现踏面裂纹的存在会影响轮轨接触应力分布，使高接触应力区一分为二，并在裂纹前沿出现应力集中，踏面裂纹扩展行为与裂纹和接触斑的相对位置密切相关。在制动过程中，高温产生的周向压应力会抑制踏面裂纹扩展，但冷却后的残余拉应力会促进踏面裂纹扩展。在踏面温度上升阶段，踏面裂纹扩展模式是以Ⅱ型滑开裂纹为主导的Ⅱ-Ⅲ型多轴复合扩展，在冷却阶段踏面裂纹扩展模式是以Ⅰ型张开裂纹和Ⅱ型滑开裂纹为主导的三种扩展类型兼具的多轴复合扩展。

关键词: 踏面裂纹, 货运列车, 热机耦合, 扩展有限元, 应力强度因子, 紧急制动

CLC Number:

U270

Jie ZHAO, Chun LU, Jiahuan HE, Tinghai MA, Zhang YE. Study on Crack Propagation of Freight Train Wheel Treads under Ramp Emergency Braking Conditions[J]. China Mechanical Engineering, 2025, 36(12): 2811-2819.

赵杰, 卢纯, 何家欢, 马亭海, 叶张. 坡道紧急制动工况下货车车轮踏面裂纹扩展行为研究[J]. 中国机械工程, 2025, 36(12): 2811-2819.

Figures/Tables 15

Fig.1 Research roadmap

Fig.2 Loads and boundary conditions

Tab.1 Material parameters of the wheel［5］

温度/ ℃	弹性模量 E/GPa	屈服强度 E_s/MPa	质量热容/（J·kg $- 1$ ·K $- 1$ ）	热膨胀系数/10 $- 5$	热导率/ （W·K $- 1$ ·m $- 1$ ）
26	225	605.4	470	1.033	51
100	203	556.6	490	1.112	49
200	176	507.8	530	1.207	45
300	152	465.6	570	1.226	42
400	132	437.8	620	1.331	38
500	97	390.3	680	1.392	35
600	77	276.0	790	1.428	32

Tab.1 Material parameters of the wheel［5］

温度/ ℃	弹性模量 E/GPa	屈服强度 E_s/MPa	质量热容/（J·kg $- 1$ ·K $- 1$ ）	热膨胀系数/10 $- 5$	热导率/ （W·K $- 1$ ·m $- 1$ ）
26	225	605.4	470	1.033	51
100	203	556.6	490	1.112	49
200	176	507.8	530	1.207	45
300	152	465.6	570	1.226	42
400	132	437.8	620	1.331	38
500	97	390.3	680	1.392	35
600	77	276.0	790	1.428	32

Tab.2 Ramp emergency braking parameters

轴重

M/t

初速度

v₀/（km·h $- 1$ ）

制动距离

S/m

制动时间

t/s

Tab.2 Ramp emergency braking parameters

轴重

M/t

初速度

v₀/（km·h $- 1$ ）

制动距离

S/m

制动时间

t/s

闸瓦宽度/m

100

830

0.085

Fig.3 XFEM mesh

Fig.4 Tread crack location and mesh division

Fig.5 Plane model

Fig.6 Model validation

Fig.7 Temperature and stress time history curves of wheel tread

Fig.8 Result of thermo-mechanical simulation analysis

Fig.9 Stress field distribution when cracks are not in the wheel-rail contact influence area

Fig.10 Effect of crack on wheel-rail contact stress

Fig.11 Effect of cracks on stress field distribution during rolling

Fig.12 Time history of crack stress intensity factor in three states

Fig.13 Distribution of stress intensity factor along crack front in three states

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