无缝线路磨损钢轨激光熔覆自动修复方式的研究

doi:10.3901/JME.2017.22.160

机械工程学报 ›› 2017, Vol. 53 ›› Issue (22): 160-165.doi: 10.3901/JME.2017.22.160

扫码分享

无缝线路磨损钢轨激光熔覆自动修复方式的研究

齐海波^1,2, 徐全盖¹, 赵衍庆¹, 郭腾达¹, 任德亮^1,2

1. 石家庄铁道大学材料科学与工程学院石家庄 050043;
2. 河北省交通工程材料重点实验室石家庄 050043

收稿日期:2016-09-22 修回日期:2017-06-20 出版日期:2017-11-20 发布日期:2017-11-20
通讯作者: 齐海波(通信作者),男,1972年出生,博士,教授,硕士研究生导师。主要研究方向为金属增材制造(3D打印)、焊接技术及复合材料制造。E-mail:qhb@stdu.edu.cn
基金资助:
河北省科技支撑计划（14211810D）和河北省高等学校科学技术研究重点（ZH2011232）资助项目。

Study on Realization Method of Automatic Repair Wear Rail by Laser Cladding

QI Haibo^1,2, XU Quangai¹, ZHAO Yanqing¹, GUO Tengda¹, REN Deliang^1,2

1. Institute of Materials Science and Engineering, Shijiazhuang Tiedao University, Shijiazhuang 050043;
2. Hebei Key Laboratory of traffic engineering materials, Shijiazhuang 050043

Received:2016-09-22 Revised:2017-06-20 Online:2017-11-20 Published:2017-11-20

摘要/Abstract

摘要： 由于列车的高速化和重载化，钢轨磨损问题越来越严重，采用修复质量高、修复速度快的激光熔覆技术可以对其进行在线快速修复。为此，采用三维扫描仪首先对磨损钢轨进行扫描，然后将扫描点云数据进行三维重构、路径规划及数据格式转换，最后利用优化的数据驱动机器手臂和激光熔覆装置对磨损钢轨进行自动修复。修复工艺结果表明，对5 mm的磨耗层进行7层修复，利用修复道与道之间和层与层之间的回火作用，修复层的组织马氏体含量少，硬度为330~360 HV；经过600℃回火处理10 min后，加入钒元素的铁基合金粉末激光熔覆修复后钢轨母材、热影响区、修复层硬度均在300~340 HV，组织为回火索氏体；修复钢轨的耐磨性约为钢轨母材的87%，达到修复目的。

关键词: 钢轨磨损, 合金粉末, 激光熔覆, 路径规划, 三维扫描

Abstract: The rail abrasion is getting more and more serious due to the high speed and heavy load of the train. Laser cladding technology can repair worn rails online with high quality and high speed. For this reason, a 3D scanner is used to scan the worn rail firstly, and the scanning point cloud data is used for 3D reconstruction to form a solid model. Then the repair path planning and data format are transferred to adapt the robot arm. Finally the optimized data which could drive the machine arm and laser cladding device to repair the worn rail is obtained. The results show that:the 5mm high wear of the rail is repaired by 7 layers, and the microstructure of the repaired layers has little martensite due to the tempering between scanning path by path, layer by layer. The hardness of the alloy is 330-360 HV. After a tempering treatment at 600℃ for 10 min, the microstructure of the Fe based alloy powder for the addition of vanadium after cladding is tempered sorbite, and the hardness of rail parent metal, heat affected zone and repaired layers of the alloy are both between 280 HV to 340 HV. The wear resistance of the repair zone is superior to the rail material, and the abrasion loss of the repair rail is 87% of the rail body, which indicated the rail repair purpose is achieved.

Key words: 3D scanning, alloy powder, laser cladding, path planning, rail abrasion

中图分类号:

U214

齐海波, 徐全盖, 赵衍庆, 郭腾达, 任德亮. 无缝线路磨损钢轨激光熔覆自动修复方式的研究[J]. 机械工程学报, 2017, 53(22): 160-165.

QI Haibo, XU Quangai, ZHAO Yanqing, GUO Tengda, REN Deliang. Study on Realization Method of Automatic Repair Wear Rail by Laser Cladding[J]. Journal of Mechanical Engineering, 2017, 53(22): 160-165.

参考文献

[1] 刘启跃, 王文健, 周仲荣. 高速与重载铁路钢轨损伤及预防技术差异研究[J]. 润滑与密封, 2007, 32(11):11-14. LIU Qiyue, WANG Wenjian, ZHOU Zhongrong. An investigation on difference of rail damage and preventive technique of high-speed and heavy-haul railway[J]. Lubrication Engineering, 2007, 32(11):11-14.
[2] 陈辉, 曾伟德, 车小莉, 等. 铁路在线钢轨焊补修复技术[J]. 铁道建筑, 2005, (8):106-108. CHEN Hui, ZENG Weide, CHE Xiaoli, et al. On line rail welding repair technology of railway[J]. Railway Engineering, 2005, (8):106-108.
[3] 高琦. 钢轨表面堆焊修复新技术[J]. 电焊机,2012, 42(5):71-76. GAO Qi. Study on a new technology of rail surfacing repairing[J]. Electric Welding Machine, 2012, 42(5):71-76.
[4] DIMELFIR J, SANDERS P G, HUNTER B, et al. Mitigation of subsurface crack propagation in railroad rails by laser surface modification[J]. Surface and Coatings Technology, 1998, 106(1):30-43.
[5] 周卫家, 张伟, 姚建华. 应用激光堆焊技术对磨损轴件的修复工艺[J]. 机电工程,2004, 21(11):45-47. ZHOU Weijia, ZHANG Wei, YAO Jianhua. Research of repairing the abraded shafts using laser overlaying welding technology[J]. Mechanical & Electrical Engineering Magazine, 2004, 21(11):45-47.
[6] 毕东勋,杨文辉. 高锰耐磨钢衬板的堆焊修复[J].热加工工艺, 2009, 38(19):154-155 BI Dongxun, YANG Wenhui. Surfacing restoring of lining plate of high Mn wear-resistant steel[J]. Hot Working Technology, 2009, 38(19):154-155.
[7] 杨胶溪,刘华东. U71Mn钢轨表面激光熔覆Fe基合金组织与性能研究[J]. 铁道工程学报,2010, 27(7):34-37. YANG Jiaoxi, LIU Huadong. Research on the microstructure and properties of laser cladding Fe-base alloy on U71 Mn rail surface[J]. Journal of Railway Engineering Society, 2010, 27(7):34-37.
[8] 曾晓雁,胡乾午,李重洋,等. 一种用于钢轨表面在线处理的移动式激光加工装置:中国,201010114198.8[P]. 2010-02-10. ZENG Xiaoyan, HU Qianwu, LI Chongyang, et al. A mobile laser processing device for on-line processing of rail surface:China, 201010114198.8[P]. 2010-02-10.
[9] 胡杰,郭火明,王文健,等. 激光熔覆对轮轨材料摩擦磨损性能的影响[J]. 润滑与密封,2012,37(9):51-55. HU Jie, GUO Huoming, WANG Wenjian, et al. Effect of laser cladding on friction and wear properties of wheel/rail materials[J]. Lubrication Engineering, 2012, 37(9):51-55.
[10] 徐朝明. 曲线钢轨轨头侧面磨损的电弧焊补修复[J]. 铁道建筑,1998(5):32-33. XU Chaoming. Arc welding repairing of the curve rail side wear of rail head[J]. Railway Engineering, 1998(5):32-33.
[11] 齐海波,任德亮,张豪,等. 用于钢轨表面在线测量及激光选择性修复的装置及方法:中国, 201210415868.9[P]. 2012-10-26. QI Haibo, REN Deliang, ZHANG Hao, et al. Device and method of on-line measurement for rail surface and laser selective repair:China, 201210415868.9[P]. 2012-10-26.
[12] 郑哲文. 光纤激光填丝修复U71Mn钢轨工艺及装置研究[D]. 石家庄:石家庄铁道大学,2014. ZHENG Zhewen. Process and device of wire filling fiber laser overlaying welding for U71Mn rail[D]. Shijiazhuang:Shijiazhuang Tiedao University, 2014.
[13] 付志凯, 王文健, 丁昊昊,等. 激光熔覆铁基合金对轮轨材料磨损与损伤性能的影响[J]. 材料热处理学报, 2015, 36(8):217-222. FU Zhikai,WANG Wenjian, DING Haohao, et al. Effect of laser cladding Fe-based alloy on wear performance of wheel and rail steels[J]. Transactions of materials and heat treatment, 2015, 36(8):217-222.
[14] 铁道部标准计量研究所. TB/T1631-2002钢轨电弧焊补技术条件[S]. 北京:中国铁道出版社,2002. Institute of Standard Measurement of the Ministry of Railways. TB/T1631-2002 Technical conditions of rail arc welding[S]. Beijing:China Railway Publishing House, 2002.

[1]	邓建新, 袁邦颐, 黄秋林, 丁度坤, 辛曼玉, 刘光明. 基于工业机器人的复杂曲面磨抛关键技术综述[J]. 机械工程学报, 2024, 60(7): 1-21.
[2]	张伟民, 徐森生, 张月. 基于改进A^*算法的室内巡检机器人路径规划研究[J]. 机械工程学报, 2024, 60(20): 315-326.
[3]	王晓飞, 许家忠, 丁亮, 黄成, 杨怀广, 刘美军. 趋向性锁链式路径规划算法[J]. 机械工程学报, 2024, 60(19): 53-61.
[4]	徐文琳, 彭羽, 何智成, 姜潮. 复杂路径规划的机构分区运动学拓扑构型设计[J]. 机械工程学报, 2024, 60(11): 62-73.
[5]	闫守鑫, 王伟, 苏鹏飞, 贠超. 大型复杂锻件打磨路径的智能化规划方法[J]. 机械工程学报, 2024, 60(11): 216-225.
[6]	胡林, 杨冬兆, 张新, 章杰, 廖家才. 基于DQP-LMPC的智能车超车换道动态路径规划[J]. 机械工程学报, 2024, 60(10): 171-181.
[7]	聂士达, 刘辉, 廖志昊, 谢雨佳, 项昌乐, 韩立金, 林思豪. 考虑复杂地形的越野环境无人车辆路径规划研究[J]. 机械工程学报, 2024, 60(10): 261-272.
[8]	林晨, 魏洪乾, 荆威, 张幽彤. 汽车功能安全：面向敏感指令攻击场景的自主驾驶车辆路径规划风险缓解控制[J]. 机械工程学报, 2024, 60(10): 302-316.
[9]	普雪洁, 张建辉, 李建勇, 张健楠. 复杂技术系统隐性冲突求解路径规划方法[J]. 机械工程学报, 2024, 60(1): 309-328.
[10]	王伟志, 马国政, 韩珩, 李洋, 周雳, 赵海朝, 许建峰, 郭伟玲, 王海斗. 激光熔覆陶瓷涂层研究现状与展望[J]. 机械工程学报, 2023, 59(7): 92-109.
[11]	王慧鹏, 朱鹏华, 舒凤远, 何鹏, 刘存宇. 65Mn钢表面激光熔覆温度场模拟及性能研究[J]. 机械工程学报, 2023, 59(7): 216-224.
[12]	向红标, 杨大虎, 杨璐, 王收军, 张冕, 黄显, 霍文星. 复杂环境下磁弹性微型游泳机器人的路径规划与识别跟踪[J]. 机械工程学报, 2023, 59(5): 89-99.
[13]	吴宏宇, 牛文栋, 张玉玲, 王树新, 阎绍泽. 水下滑翔机多点探测能耗最低路径的规划方法[J]. 机械工程学报, 2023, 59(5): 156-166.
[14]	刘鹏, 贾寒冰, 张雷, 王震坡. 结构化道路下智能汽车自主换道轨迹规划研究[J]. 机械工程学报, 2023, 59(24): 271-281.
[15]	崔钰萍, 郑国磊. 电缆布局设计技术研究进展综述[J]. 机械工程学报, 2023, 59(2): 268-280.

无缝线路磨损钢轨激光熔覆自动修复方式的研究

Study on Realization Method of Automatic Repair Wear Rail by Laser Cladding

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价