车轴表层残余应力模拟及其对裂纹扩展行为的影响

doi:10.3901/JME.2025.18.230

机械工程学报 ›› 2025, Vol. 61 ›› Issue (18): 230-239.doi: 10.3901/JME.2025.18.230

• 运载工程 • 上一篇

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车轴表层残余应力模拟及其对裂纹扩展行为的影响

杨冰¹, 吕培锦^1,2, 黄勉¹, 徐艳晖³, 肖守讷¹, 阳光武¹, 朱涛¹

1. 西南交通大学轨道交通运载系统全国重点实验室成都 610031;
2. 比亚迪股份有限公司汽车新技术研究院深圳 518118;
3. 中车大同电力机车有限公司研究院大同 037038

收稿日期:2024-10-20 修回日期:2025-01-15 发布日期:2025-11-08
作者简介:杨冰(通信作者)，男，1979年出生，博士，研究员，博士研究生导师。主要研究方向为材料疲劳与断裂、结构可靠性与安全性。E-mail：yb@swjtu.edu.cn
基金资助:
国家自然科学基金(52375159)和四川省科技计划(2024NSFTD0011)资助项目

Simulation of Surface Residual Stress in Railway Axles and Its Influence on Crack Propagation Behavior

YANG Bing¹, Lü Peijin^1,2, HUANG Mian¹, XU Yanhui³, XIAO Shoune¹, YANG Guangwu¹, ZHU Tao¹

1. State Key Laboratory of Rail Transit Vehicle System, Southwest Jiao Tong University, Chengdu 610031;
2. BYD Company Limited, Automotive New Technology, Research Institute, Shenzhen 518118;
3. Technology Center, CRRC Datong Co., Ltd., Datong 037038

Received:2024-10-20 Revised:2025-01-15 Published:2025-11-08

摘要/Abstract

摘要： 车轴是轨道交通车辆走行部的重要组成部件，其疲劳与断裂性能事关铁路运营安全。为提高车轴强度，特别是疲劳强度，通常会对车轴进行淬火、滚压、喷丸等表面强化处理，引入表层残余压应力，以提高车轴抗疲劳断裂性能。为探究表层残余应力对车轴裂纹扩展行为及疲劳寿命的影响，利用ABAQUS及其关联子程序，模拟强化工艺处理后引入的残余应力，并在轮轴过盈配合、旋转弯曲载荷共同作用下，通过扩展有限元法对裂纹萌生后的扩展行为进行表征，揭示过盈配合和残余应力对裂尖前缘应力强度因子、裂纹形貌演化、扩展速度变化的影响。同时，通过子程序模拟了车轴服役过程中主要承受的旋转弯曲载荷作用，裂纹扩展形貌演化过程与实际试验更加接近。对实际经过表面强化处理，受残余压应力影响的车轴截面，若仿真分析评估时不考虑残余应力影响，得到的结果可能偏离实际，过度保守。

关键词: 残余应力, 车轴, 裂纹扩展, 旋转弯曲载荷, 扩展有限元

Abstract: The axle is a crucial component in the running gear of rail vehicles, and its fatigue and fracture performance are critical for the safety of railway operations. To enhance the strength of the axle, especially its fatigue strength, surface strengthening treatments such as quenching, rolling, and shot peening are commonly applied to introduce residual compressive stresses, thereby improving the axle's resistance to fatigue fracture. To investigate the influence of residual stresses on the crack propagation behavior and fatigue life of the axle, ABAQUS and its associated subroutines are utilized to simulate the residual stresses introduced after the strengthening process. Under the combined action of interference fit and the rotating bending load experienced during the service of the wheelset, the Extended Finite Element Method is employed to characterize the crack propagation behavior after crack initiation. This aims to reveal the effects of interference fit and residual stresses on the stress intensity factor at the crack tip, the evolution of crack morphology, and changes in crack propagation velocity. Additionally, the subroutine is used to simulate the effect of the rotating bending load primarily experienced by the axle during service, making the simulated crack propagation process more closely aligned with actual experiments. For axles that have undergone surface strengthening treatments and are influenced by residual stresses, failure to consider the effects of residual stresses in simulation analyses may lead to results that deviate from reality and are over conservative.

Key words: residual stress, railway axles, crack growth, rotating bending load, extended finite element method

中图分类号:

U266

杨冰, 吕培锦, 黄勉, 徐艳晖, 肖守讷, 阳光武, 朱涛. 车轴表层残余应力模拟及其对裂纹扩展行为的影响[J]. 机械工程学报, 2025, 61(18): 230-239.

YANG Bing, Lü Peijin, HUANG Mian, XU Yanhui, XIAO Shoune, YANG Guangwu, ZHU Tao. Simulation of Surface Residual Stress in Railway Axles and Its Influence on Crack Propagation Behavior[J]. Journal of Mechanical Engineering, 2025, 61(18): 230-239.

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车轴表层残余应力模拟及其对裂纹扩展行为的影响

Simulation of Surface Residual Stress in Railway Axles and Its Influence on Crack Propagation Behavior

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