重载列车持续制动工况下踏面累积损伤仿真研究

doi:10.3901/JME.260724

摘要/Abstract

摘要： 长大坡道货运列车的踏面制动涉及复杂的热力耦合及材料损伤问题，而现有研究多集中于轮轨磨耗或常规工况分析，针对长大坡道工况缺少有效的数值建模方法及研究。构建一个面向重载列车踏面制动损伤分析的参数化热-力-损伤耦合数值框架，基于ANSYS APDL与Matlab的联合建模与求解，实现踏面在制动过程中的多场耦合响应与累积损伤预测。在此框架下，提出一种二维缩减建模数值程序，建立匀速制动与紧急制动两种模式下的解析化修正高斯摩擦热源模型，可准确描述长坡道运行中摩擦热流密度的时空演变，并结合修正Archard磨损理论迭代预测踏面磨耗，实现温度、热应力与材料响应特征的综合分析。结果表明，不同制动模式下的踏面温度与磨耗特征差异显著：紧急制动的峰值温度较匀速制动高约45.6%，高温平台区范围明显扩大，周向温度衰减趋缓。紧急制动中心区的最大瞬时磨耗深度为20.66×10^-10 m，显著高于匀速制动的4.736×10^-10 m；在累计磨耗方面，匀速制动中心区约为1.096 μm，而紧急制动约为2.12 μm。两种工况下的峰值磨耗时间分别出现在制动末期(匀速)和制动中期(紧急)，体现出短时高强度磨耗的特征。该数值框架具有良好的可扩展性，除磨耗损伤外，还可拓展用于热裂纹、热点、塑性变形等多种累积损伤分析，为多损伤耦合机理研究提供基础。研究突破了传统三维有限元模型的计算瓶颈，为长大坡道货运列车踏面寿命预测、维护策略优化及制动系统设计提供理论与工程支持。

关键词: 长大坡道, 重载列车, 踏面制动, 热损伤, 建模优化

Abstract: Tread braking of heavy-haul freight trains on long downhill gradients involves complex thermos-mechanical coupling and progressive material damage. However, existing research has primarily focused on wheel-rail wear or conventional operating conditions, with few effective numerical approaches for long-slope braking scenarios. This study develops a parametric thermo-mechanical-damage coupled framework for tread brake analysis, integrating ANSYS APDL and Matlab for efficient simulation of multi-field responses and cumulative damage evolution. A two-dimensional reduced-order model and an analytical modified Gaussian frictional heat source model are proposed for constant-speed and emergency braking modes. Combined with a modified Archard’s wear law, the framework enables iterative prediction of tread wear and comprehensive evaluation of temperature, thermal stress, and material response. Results indicate significant differences between braking modes. The peak temperature under emergency braking is about 45.6% higher than under constant-speed braking, with an expanded high-temperature plateau and slower circumferential decay. The maximum instantaneous wear depth reaches 20.66×10-¹⁰ m and 4.736×10-¹⁰ m, while the cumulative wear is 2.12 μm and 1.096 μm for emergency and constant-speed braking, respectively. Peak wear occurs at the mid-stage of emergency braking and the end-stage of constant-speed braking, reflecting a short-duration, high-intensity wear pattern. The proposed framework is highly extensible, applicable not only to wear prediction but also to thermal cracking, hotspots, and plastic deformation analysis, providing a solid basis for multi-damage coupling research. This work overcomes computational limitations of traditional 3D finite-element models and supports tread life prediction, maintenance optimization, and brake system design for heavy-haul trains on long gradients.

Key words: long downhill gradient, heavy-haul train, tread braking, thermal damage, modeling optimization

中图分类号:

U272
TH117

张金玉, 左建勇. 重载列车持续制动工况下踏面累积损伤仿真研究[J]. 机械工程学报, 2026, 62(16): 430-444.

ZHANG Jinyu, ZUO Jianyong. Numerical Simulation of Cumulative Wheel Tread Damage under Continuous Braking of Heavy-haul Trains[J]. Journal of Mechanical Engineering, 2026, 62(16): 430-444.

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链接本文: http://www.cjmenet.com.cn/CN/10.3901/JME.260724

http://www.cjmenet.com.cn/CN/Y2026/V62/I16/430

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