Quantitative Prediction of Tread Profile Variations during Emergency Braking of Heavy Duty Trains

doi:10.3969/j.issn.1004-132X.2025.02.020

Abstract

Abstract: In order to quantitatively predict the changes of wheel tread profile, ABAQUS software was used to complete thermal-mechanical coupling finite element simulation to solve the transient temperature distribution, hardness distribution, thermoelastic and plastic strain of tread during braking. Based on Archard wear model, the ABAQUS subprogram was developed using Fortran language. Then, ALE technology and Umeshmotion subprogram were used to solve the dynamic change of wheel tread wear depth in the finite element model. Finally, the influences of plastic deformations and wear were combined to obtain the changes of tread morphology after cooling to room temperature. The results show that the contact states of wheel and rail are affected by the plastic deformations of tread and wheel and rail wear. Under the combined actions of wheel and rail wear, the wear area is like a step. Under the conditions of axle load of 25 t, initial speed of 100 km/h and braking distance of 600 m, the maximum depression depth of wheel-rail contact spot center is about 16 μm and the edge of wheel-rail contact spot is as about 5 μm due to the comprehensive effects of plastic deformation and wheel-rail wear.

Key words: tread braking, thermal-mechanical coupling, plastic deformation, wear depth

摘要： 为了定量预测车轮踏面轮廓形貌变化，利用ABAQUS软件完成热机械耦合有限元仿真，求解制动过程中的踏面瞬态温度分布、硬度分布以及热弹、塑性应变；基于Archard磨损模型，利用Fortran语言对ABAQUS子程序进行二次开发，在此基础上采用ALE技术和Umeshmotion子程序求解有限元模型中车轮踏面的磨损深度动态变化。最后综合塑性变形和磨耗的影响，得到冷却至室温后踏面形貌的变化。结果表明：由于踏面塑性变形和轮轨磨损影响轮瓦接触状态，轮瓦磨损和轮轨磨损综合作用下磨损区域呈台阶状；在轴重25 t、初速度100 km/h、制动距离600 m的工况下，由于塑性变形和轮轨磨损的综合作用，轮轨接触斑中心最大凹陷深度约16 μm，轮轨接触斑边缘凸起约5 μm。

关键词: 紧急制动, 热机械耦合, 塑性变形, 磨损深度

CLC Number:

U270.35

SONG Jianfeng1, SHI Yinggang2, 3, HUANG Weijian3, ZHAO Yansong3, DONG Yonggang1. Quantitative Prediction of Tread Profile Variations during Emergency Braking of Heavy Duty Trains[J]. China Mechanical Engineering, 2025, 36(02): 369-379.

宋剑锋1, 时迎港2, 3, 黄伟建3, 赵琰淞3, 董永刚1. 重载列车紧急制动过程踏面轮廓变化定量预测[J]. 中国机械工程, 2025, 36(02): 369-379.

References

［1］王雪萍, 张军, 马贺. 高速列车车轮踏面磨耗预测方法的研究［J］. 摩擦学学报, 2018, 38(4):462-467.
WANG Xueping, ZHANG Jun, MA He. Prediction Method of Wheel Wear of High Speed Train［J］. Tribology, 2018, 38(4):462-467.
［2］周亮, 郭立昌, 丁昊昊, 等. 低温环境下列车车轮材料磨损与损伤演变行为研究［J］. 摩擦学学报, 2022, 42(4):844-853.
ZHOU Liang, GUO Lichang, DING Haohao, et al. Wear and Damage Evolution Behaviours of Railway Wheel Steel in the Low Temperature Environment［J］. Tribology, 2022, 42(4):844-853.
［3］王延朋, 丁昊昊, 邹强, 等. 列车车轮踏面滚动接触疲劳研究进展［J］. 表面技术, 2020, 49(5):120-128.
WANG Yanpeng, DING Haohao, ZOU Qiang, et al. Research Progress on Rolling Contact Fatigue of Railway Wheel Treads［J］. Surface Technology, 2020, 49(5):120-128.
［4］YE Yunguang, SUN Yu, SHI Dachuan, et al. A Wheel Wear Prediction Model of Non-Hertzian Wheel-rail Contact Considering Wheelset Yaw:Comparison between Simulated and Field Test Results［J］. Wear, 2021, 474/475:203715.
［5］沈明学, 容彬, 李圣鑫, 等. 车轮踏面不圆顺对高速列车轮轨界面黏着与车轮表面损伤的影响［J］. 中国机械工程, 2022, 33(22):2664-2672.
SHEN Mingxue, RONG Bin, LI Shengxin, et al. Effects of Wheel Tread Out-of-roundness on Wheel-rail Interface Adhesions and Wheel Surface Damages of High-speed Trains［J］. China Mechanical Engineering, 2022, 33(22):2664-2672.
［6］王群娣. 重载车轮轮辋不同深度对磨损与损伤行为的影响［J］. 铁道车辆, 2016, 54(9):6-9.
WANG Qundi. Effects of Different Depths of Heavy Haul Wheel Rims on Wear and Damage［J］. Rolling Stock, 2016, 54(9):6-9.
［7］陈帅, 吴磊, 张合吉, 等. 踏面制动温升对重载铁路车轮磨耗的影响［J］. 机械工程学报, 2017, 53(2):92-98.
CHEN Shuai, WU Lei, ZHANG Heji, et al. Influence of Temperature Rising of Tread Braking on Wheel Wear for Heavy Haul Freight Car［J］. Journal of Mechanical Engineering, 2017, 53(2):92-98.
［8］郭涛, 王宁, 刘永强. 车轮踏面常规磨耗对高速列车动力学性能的影响［J］. 石家庄铁道大学学报(自然科学版), 2020, 33(4):44-49.
GUO Tao, WANG Ning, LIU Yongqiang. Influence of Wheel Wear on Dynamic Performance of High-speed Train［J］. Journal of Shijiazhuang Tiedao University (Natural Science Edition), 2020, 33(4):44-49.
［9］董永刚, 仪帅, 黄鑫磊, 等. 重载列车紧急制动过程车轮踏面疲劳裂纹萌生寿命预测［J］. 中国铁道科学, 2021, 42(5):123-131.
DONG Yonggang, YI Shuai, HUANG Xinlei, et al. Prediction of Fatigue Crack Initiation Life of Wheel Tread during Emergency Braking of Heavy Haul Train［J］. China Railway Science, 2021, 42(5):123-131.
［10］董永刚, 仪帅, 黄鑫磊, 等. 列车紧急制动过程中踏面温度分布及磨耗预测［J］. 中国机械工程, 2021, 32(4):431-438.
DONG Yonggang, YI Shuai, HUANG Xinlei, et al. Temperature Distribution of Treads and Wear Prediction during Train Emergency Braking［J］. China Mechanical Engineering, 2021, 32(4):431-438.
［11］宋剑锋, 黄鑫磊, 仪帅, 等. 列车制动过程踏面温度场及应力-应变分布特性［J］. 吉林大学学报(工学版), 2023, 53(10):2773-2784.
SONG Jianfeng, HUANG Xinlei, YI Shuai, et al. Temperature Field and Stress-strain Distribution of Tread during Train Braking［J］. Journal of Jilin University (Engineering and Technology Edition), 2023, 53(10):2773-2784.
［12］KATO T, FUJIMURA T, YAMAMOTO Y, et al. Effect of Wheel Size and Tread Braking on Subsurface Crack Initiation in Heavy Haul Car Wheels［J］. Procedia Structural Integrity, 2019, 19:238-248.
［13］李英奇, 张银花, 刘佳朋, 等. 重载铁路钢轨磨损与损伤行为试验研究［J］. 中国铁道科学, 2022, 43(6):152-160.
LI Yingqi, ZHANG Yinhua, LIU Jiapeng, et al. Experimental Study on Wear and Damage Behavior of Rail for Heavy Haul Railway［J］. China Railway Science, 2022, 43(6):152-160.
［14］黄焱, 阳涛, 张志勇. 列车运行阻力试验研究［J］. 科技视界, 2019(11):52-53.
HUANG Yan, YANG Tao, ZHANG Zhiyong. Research on Test of Resistance to Motion of Trian［J］. Science & Technology Vision, 2019(11):52-53.
［15］曹世豪, 李煦, 张四放, 等. Hertz理论与有限元法分析轮轨接触疲劳的差异性研究［J］. 机械工程学报, 2015, 51(6):126-134.
CAO Shihao, LI Xu, ZHANG Sifang, et al. Research of the Differences between Hertz Theory and Finite Element Method to Analyze the Fatigue of Wheel/Rail Contact［J］. Journal of Mechanical Engineering, 2015, 51(6):126-134.
［16］黄鑫磊. 货运列车大长下坡周期制动踏面热疲劳及热摩擦损伤研究［D］.秦皇岛:燕山大学,2022.
HUANG Xinlei. Study on Thermal Fatigue and Thermal Friction Damage of Brake Tread of Freight Train with Long Downhill Cycle［D］. Qinhuangdao:Yanshan University, 2022.
［17］雷国军. 重载列车车轮表面对流传热特性的数值研究［D］. 兰州:兰州交通大学, 2020.
LEI Guojun. Numerical Study on Convective Heat Transfer Characteristics on Wheel Surface of Heavy-haul Train［D］.Lanzhou:Lanzhou Jiatong University, 2020.
［18］张金煜, 虞大联, 李海涛, 等. 列车运行过程中车轮车轴对流换热系数的等效值算法［J］. 铁道车辆, 2022, 60(6):57-63.
ZHANG Jinyu, YU Dalian, LI Haitao, et al. An Equivalent Value Algorithm for Convective Heat Transfer Coefficient of Wheel and Axle during Train Operation［J］. Rolling Stock, 2022, 60(6):57-63.
［19］雷国军, 林志敏, 张永恒, 等. 重载列车车轮表面对流传热特性数值研究［J］. 工程热物理学报, 2022, 43(7):1902-1910.
LEI Guojun, LIN Zhimin, ZHANG Yongheng, et al. Numerical Study on Convective Heat Transfer Characteristics on the Wheel Surface of Heavy-duty Train［J］. Journal of Engineering Thermophysics, 2022, 43(7):1902-1910.
［20］朱衡. 高速重载列车踏面制动过程热-机械-组织耦合仿真［D］. 秦皇岛:燕山大学, 2019.
ZHU Heng. Thermal-mechanical-tissue Coupling Simulation of High-speed and Heavy-haul Train Tread Braking Process［D］.Qinhuangdao:Yanshan University, 2019.
［21］仪帅. 重载列车踏面制动过程车轮热摩擦损伤及热疲劳寿命研究［D］. 秦皇岛:燕山大学, 2021.
YI Shuai. Study on Thermal Friction Damage and Thermal Fatigue Life of Wheels during Tread Braking of Heavy-duty Trains［D］.Qinhuangdao:Yanshan University, 2021.
［22］丁军君.基于蠕滑机理的重载货车车轮磨耗研究［D］.成都:西南交通大学,2008:46-47.
DING Junjun. Research on Wheel Wear of Heavy Duty Truck Based on Creep Mechanism［D］. Chengdu:Southwest Jiaotong University, 2008:46-47.
［23］胡军海. 重载铁路货车轮对磨耗及其对动力学的影响研究［D］. 成都:西南交通大学, 2021:20-21.
HU Junhai. Study on Wheelset Wear of Heavy-haul Railway Freight Cars and Its Influence on Dynamics［D］. Chengdu:Southwest Jiaotong University, 2021:20-21.
［24］IKEUCHI K, HANDA K, LUNDN R, et al. Wheel Tread Profile Evolution for Combined Block Braking and Wheel-rail Contact:Results from Dynamometer Experiments［J］. Wear, 2016, 366/367:310-315.

[1]	SHEN Mingxue, RONG Bin, LI Shengxin, ZHAO Huoping, JI Dehui, XIONG Guangyao. Effects of Wheel Tread Out-of-roundness on Wheel-rail Interface Adhesions and Wheel Surface Damages of High-speed Trains#br# [J]. China Mechanical Engineering, 2022, 33(22): 2664-2672,2683.
[2]	LI Huan, HUANG Chaowang, ZHOU Kang, ZHANG Changxin, ZENG Caiyou. Numerical Simulation and Experimental Verification of High-power Ultrasonic Welding of Al/Steel Joints [J]. China Mechanical Engineering, 2022, 33(02): 226-233.
[3]	PAN Chengyi, TONG Yuanqi, CAO Guanqun, ZHAO Yanling. Research on Friction and Wear Characteristics and Simulation of Microstructures Surface Unfolding Wheels [J]. China Mechanical Engineering, 2021, 32(22): 2689-2696.
[4]	LIN Qiyin, ZHANG Yuhan, HONG Jun, WANG Chen, ZHANG Ningjing, . Influences of Grain Sizes on Contact Mechanics Properties of Polycrystalline Coppers [J]. China Mechanical Engineering, 2021, 32(19): 2312-2320.
[5]	DONG Yonggang, YI Shuai, HUANG Xinlei, SONG Jianfeng, DU Xiaozhong. Temperature Distribution of Treads and Wear Prediction during Train Emergency Braking [J]. China Mechanical Engineering, 2021, 32(04): 431-438,445.
[6]	NIE Xin1;XIAO Bingbing1;SHEN Danfeng2;GUO Wenfeng1. Research on Thermal-mechanical Stamping Forming Considering Deformation Heat and Friction Heat Effects [J]. China Mechanical Engineering, 2020, 31(16): 2005-2015.
[7]	LIU Shihao, LIN Mao. Research on Status and Prospects of Optimization Design Method of High-speed CNC Turntables [J]. China Mechanical Engineering, 2020, 31(13): 1629-1637.
[8]	CHEN Minghe;WANG Ning. Current Research and Development Trends in Constitutive Relation for High Strength Aluminum Alloys in Hot Plastic Deformation [J]. China Mechanical Engineering, 2020, 31(08): 997-1007.
[9]	SHU Weicai1;QIU Baoxiang2;YANG Jianguo1;GAO Zengliang1. Influences of Rotation Speed and Feed Speed in Shaft Riveting on Properties of Hub Bearings [J]. China Mechanical Engineering, 2020, 31(06): 688-694.
[10]	TANG Kai1;ZHOU Liucheng2;HE Weifeng2;WANG Wenjian1;GUO Jun1;LIU Qiyue1. Experimental Study on Influences of Laser Shock Processing on Fatigue Performance of LZ50 Axle Steels [J]. China Mechanical Engineering, 2020, 31(03): 267-273.
[11]	LI Lijuan1，2，3;XIE Shejuan1，2;CHEN Hong'en1，2;CHEN Lingli1，2;HE Manru1，2;CHEN Zhenmao1，2. Influence of Plastic Deformation on Signals of Magnetic Incremental Permeability for Carbon Steel [J]. China Mechanical Engineering, 2018, 29(14): 1653-1660.
[12]	YIN Aijun, YAO Wenquan, REN Hongji, DAI Zongxian. Evaluation of Metal Plastic Deformation Using Radio-frequency Reflection Features [J]. China Mechanical Engineering, 2017, 28(02): 135-138.
[13]	Xie Guilan, Yu Chao, Gong Shuguang, Tian Jie, Hu Jundi. Simulation of Metal Bulk Forming Based on MPM [J]. China Mechanical Engineering, 2016, 27(22): 3093-3097,3102.
[14]	Wang Shijun, Yang Chao, Wang Shiyi, Yang Huixin, Zhao Jinjuan, Li Shujuan, Li Pengyang. Normal Contact Model of Rough Surfaces Based on True Stress-Strain Relationship [J]. China Mechanical Engineering, 2016, 27(16): 2148-2154.
[15]	Guo Huoming, Wang Wenjian, Liu Tengfei, Liu Jihua, Guo Jun, Liu Qiyue. Analysis of Damage Behavior of Heavy-haul Railway Rails [J]. China Mechanical Engineering, 2014, 25(2): 267-272.