考虑曲率匹配因素的钢轨砂带打磨宏观接触压力建模与仿真

doi:10.3901/JME.2020.02.154

摘要/Abstract

摘要： 钢轨砂带打磨过程本质上表现为接触轮、砂带和钢轨之间的复杂非线性接触作用，其接触应力计算是材料去除、磨削温升及砂带磨损建模研究的基础，然而现有面向内凹接触轮的接触模型并未考虑Hertz接触理论的适用性问题和"轮"轨曲率匹配所带来的影响。基于内凹接触轮曲率半径与钢轨廓形曲率半径的几何匹配特性，以及外部接触压力对接触轮橡胶层变形的影响，将钢轨砂带打磨宏观接触分为椭圆形接触、双三角形接触和马鞍形接触三种情况。通过将三维接触问题转化为外包薄层弹性橡胶的圆形刚体与刚性平面间的二维平面接触问题，建立考虑曲率匹配因素的钢轨砂带打磨接触区域边界和应力分布理论计算模型，并开展有限元仿真对比分析。结果表明，仿真模型和理论模型均可得到形态相吻合的椭圆形接触斑、双三角形接触斑和马鞍形接触斑，并且主要参量误差处于钢轨砂带打磨工况允许阈值内，较好地验证了所建理论模型的有效性。所提出的理论模型对现有模型进行了完善并为内凹接触轮钢轨砂带打磨材料去除建模奠定了理论基础。

关键词: 钢轨打磨, 砂带, 接触, 曲率匹配

Abstract: Rail grinding with abrasive belt essentially appears as the complex nonlinear contact interaction among contact wheel, abrasive belt and rail surface, the contact stresses calculation in which is the basis of modeling of material removal, grinding temperature and abrasive belt wear. However, the existing contact model for the concave contact wheel falls to consider the applicability of the Hertz theory and the effect of the "wheel" curvature matching. Based on the geometric matching between the radius curvature of concave wheel and that of rail profile, and also the influence of external contact pressure on rubber deformation of contact wheel, the macro contact of abrasive belt rail grinding is divided into three cases, including oval contact, double triangular contact and saddle contact. Then, this 3D contact problem is translated into 2D plane contact problem between the circular rigid body covered with thin elastic rubber layer and the rigid plane. Finally, the theoretical models for boundary curve and contact stress distribution are developed, and the finite element simulations are also implemented. Results show that almost identical contours of oval contact, double triangular contact and saddle contact can be obtained through the theoretical model and the simulation model, and the errors of main parameters are all within the allowable range of grinding condition for the rail grinding with abrasive belt, which verifies the validity of the proposed theoretical model. The proposed theoretical model has improved the existing model and laid a theoretical foundation for the modeling of grinding material removal for abrasive belt rail grinding using concave wheel.

Key words: rail grinding, abrasive belt, contact, curvature match

中图分类号:

TG742

樊文刚, 王文玺, 侯广友, 王煦辉. 考虑曲率匹配因素的钢轨砂带打磨宏观接触压力建模与仿真[J]. 机械工程学报, 2020, 56(2): 154-162.

FAN Wengang, WANG Wenxi, HOU Guangyou, WANG Xuhui. Macro Contact Pressure Modeling and Simulation for Rail Grinding with Abrasive Belt Based on Curvature Match[J]. Journal of Mechanical Engineering, 2020, 56(2): 154-162.

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