残余应力对高速列车制动盘裂纹扩展特性及疲劳损伤分析

doi:10.3901/JME.260717

摘要/Abstract

摘要： 残余应力是制动盘表面裂纹扩展的重要影响因素，基于线弹性断裂力学理论，使用ABAQUS-FRANC3D联合仿真方法研究残余应力影响下的制动盘裂纹扩展规律及服役寿命。首先使用SIMPACK软件建立高速列车动力学模型，获得了列车在轮轨激励作用下的振动特性，发现轮轨激励作用会使制动盘振动加剧。将轮轨激励作用下制动盘振动载荷加载至高速列车制动盘有限元模型开展热机耦合仿真计算，获得制动盘在有、无轮轨激励作用下的残余应力分布特性，发现制动过程结束后，会在制动盘周向形成18个较为显著的残余应力集中区域，其中最大残余应力可达247.32 MPa。随后，将含残余应力的模型导入FRANC3D分析裂纹扩展特性。结果表明：随着裂纹形状比增大，应力强度因子曲线由“凸”变“凹”；形状比偏小时裂纹主要沿深度扩展，偏大时沿径向扩展；当裂纹沿径向存在偏转角度时，Ⅰ型应力强度因子随角度增大而减小；两条径向无错位平行裂纹表现为抑制作用，间距越小抑制越强。最后考虑了残余应力对制动盘疲劳裂纹萌生与扩展分析，发现轮轨激励作用会加剧制动盘疲劳裂纹扩展，降低制动盘的服役寿命。研究结果可为高速列车制动盘运维策略制定提供参考。

关键词: 高速列车, 制动盘, 轮轨激励, 裂纹扩展, 应力强度因子, 疲劳损伤

Abstract: Residual stress is an important factor affecting the crack propagation on the surface of brake disc. Based on the theory of linear elastic fracture mechanics, the crack propagation law and service life of brake disc under the influence of residual stress was studied by using ABAQUS-FRANC3D co-simulation method. Firstly, the dynamic model of high-speed train is established by SIMPACK software, and the vibration characteristics of train under wheel-rail excitation are obtained. It is found that wheel-rail excitation will aggravate the vibration of brake disc. The vibration load of the brake disc under the wheel-rail excitation is loaded into the finite element model of the brake disc of the high-speed train to carry out the thermal-mechanical coupling simulation calculation, and the residual stress distribution characteristics of the brake disc under the action of wheel-rail excitation and no wheel-rail excitation are obtained. It is found that after the braking process is completed, 18 significant residual stress concentration areas are formed in the circumferential direction of the brake disc, and the maximum residual stress can reach 247.32 MPa. Subsequently, the simulation model containing residual stress is imported into FRANC3D to study crack propagation characteristics. It is found that, with increasing crack shape ratio, the stress intensity factor curve of a single crack changes from convex to concave. A small shape ratio leads to crack growth mainly in the depth direction, whereas a large shape ratio leads to growth mainly in the radial direction. When a surface crack has a certain deflection angle along the radial direction, the mode I stress intensity factor at the crack tip decreases as the deflection angle increases. The interaction between two parallel radial cracks without axial misalignment is found to be inhibitory, with stronger inhibition observed at smaller crack spacing. Finally, the analysis of the influence of residual stress on the initiation and propagation of fatigue cracks in brake discs shows that wheel-rail excitation will accelerate the propagation of fatigue cracks in brake discs and reduce their service life. The research results can provide a reference for formulating the operation and maintenance strategies of high-speed train brake discs.

Key words: high-speed train, brake disc, wheel-rail excitation, crack propagation, stress intensity factor, fatigue damage

中图分类号:

TH132

朱海燕, 王文涛, 李祥坤, 肖乾, 陈道云, 张卫华, 朱文良. 残余应力对高速列车制动盘裂纹扩展特性及疲劳损伤分析[J]. 机械工程学报, 2026, 62(16): 392-405.

ZHU Haiyan, WANG Wentao, LI Xiangkun, XIAO Qian, CHEN Daoyun, ZHANG Weihua, ZHU Wenliang. Analysis of Residual Stress on Crack Propagation Characteristics and Fatigue Damage of High-speed Train Brake Disc[J]. Journal of Mechanical Engineering, 2026, 62(16): 392-405.

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http://www.cjmenet.com.cn/CN/Y2026/V62/I16/392

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