基于接触斑内瞬态滚动接触解的钢轨滚动接触疲劳萌生模型研究

doi:10.3901/JME.260060

摘要/Abstract

摘要： 小半径曲线钢轨易发生严重滚动接触疲劳，其萌生机理和疲劳寿命与轮轨接触斑内蠕滑行为直接相关。参照广泛应用的轮轨滚动接触疲劳传统损伤函数模型，以基于显式有限元法的三维轮轨瞬态滚动接触模型为核心分析手段，考虑自旋蠕滑影响，模拟得到随时变化的宏观、斑内细观轮轨滚动接触解，进而提出一种以斑内瞬态局部磨耗数τγ_L为自变量的新损伤函数模型，实现斑内滚动接触疲劳损伤分布的精确预测。以某重载铁路C80货车导向轮对在800 m半径曲线的瞬态通过为例，首先分析宏观与斑内微观蠕滑解的强相关性，确定新损伤函数模型的可行性；其次，基于传统损伤函数，提出一种τγ_L和局部损伤值d_L间关系的确定方法；最后，开展参数变化分析，涵盖可导致滚动接触疲劳的轮轨接触载荷范围，建立重载用U75V淬火轨的新损伤函数模型，0.69 MPa<τγ_L<3.04 MPa时钢轨会发生滚动接触疲劳损伤且τγ_L=2.21 MPa时最严重。传统损伤函数预测接触应力很低的接触斑边缘部分也存在损伤，新损伤函数模型中修正了此不合理现象。应用于重载钢轨滚动接触疲劳预测，发现预测的疲劳区与现场观测结果相符，斑内损伤分布能解释现场裂纹扩展方向在一定范围内波动的事实。如何更精确确定新损伤函数关键参数和“磨耗折减量”，尚待更深入研究。

关键词: 滚动接触疲劳, 损伤函数, 轮轨瞬态滚动接触, 损伤分布, 重载钢轨, 显式有限元法

Abstract: Sharp curved rails are prone to severe rolling contact fatigue（RCF）, the initiation mechanism and fatigue life of which are directly related to the creep behavior within wheel-rail contact patch. With reference to the widely used RCF traditional damage function model, a 3D wheel-rail transient rolling contact model based on explicit finite element method is used as the main analytical tool to obtain the time-varying macroscopic, intra-patch microscopic wheel-rail rolling contact solution, and then a new damage function model is proposed with the intra-patch transient local wear number τγ_L as the independent variable to achieve the prediction of the intra-patch RCF distribution accurately. Taking the transient passage of a C80 wagon guiding wheelset in an 800 m radius curve of a heavy haul railway line as an example, firstly, the strong correlation between the macroscopic and intra-patch microscopic creep solutions is analysed to check the feasibility of the new damage function model. Secondly, a method of determining the relationship between the local wear numberτγ_L and the local damage value d_L is proposed based on the traditional damage function. Finally, the parameter variations are analysed to cover the range of loads that can lead to wheel/rail RCF. And a new damage function model is established for U75V quenched steel in heavy haul railway, in which RCF may occur when 0.69 MPa<τγ_L <3.04 MPa and be the most serious at τγ_L = 2.21 MPa. The traditional damage function predicts that there is also^*damage at the edge of the contact patch where the contact pressure is very low, and this anomaly is corrected by the new damage function model. Applied to the RCF prediction of heavy haul rail, it is found that the predicted fatigue zone is consistent with the field observation results, and the fact that the direction of crack extension fluctuates within a certain range can be explained by the damage distribution in the contact patch. More in-depth studies are needed to determine more precisely the key parameters of the new damage function model and the "wear reduction".

Key words: rolling contact fatigue, damage function, transient rolling contact of wheel/rail, damage distribution, heavily haul rails, explicit finite element method

中图分类号:

TG156

胡彬, 赵鑫, 张昕, 罗易飞, 鲁连涛, 温泽峰. 基于接触斑内瞬态滚动接触解的钢轨滚动接触疲劳萌生模型研究[J]. 机械工程学报, 2026, 62(2): 354-366.

HU Bin, ZHAO Xin, ZHANG Xin, LUO Yifei, LU Liantao, WEN Zefeng. Study on Rail Rolling Contact Fatigue Model in Consideration of Transient Rolling Contact Solutions within Wheel-rail Contact Patch[J]. Journal of Mechanical Engineering, 2026, 62(2): 354-366.

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