Research on Thermal Fatigue Crack Opening and Closing Behavior of Railway Brake Disc Based on the Virtual Crack Closure Technique

doi:10.3901/JME.2025.20.103

Abstract

Abstract: The propagation of thermal fatigue crack is the main reason of railway brake disc damage and even failure. In order to study the crack opening and closing state, contact state of crack surface and crack propagation behavior, the virtual crack closure technique and finite element secondary development are combined to analyze the finite element model of the brake disc with prefabricated cracks. The results show that the presence of surface crack of the brake disc has no significant effect on the compressive stress field during braking, but it affects the distribution of residual tensile stress field, and the stress concentration phenomenon appears at the crack front. During the braking process, the normal contact pressure between the crack surfaces of the brake disc changes layer by layer along the crack depth direction from the friction surface, and the relative magnitude of the normal contact pressure between the surface and the deep changes. The normal relative displacement between the crack surfaces of the brake disc diffuses from the crack center to the crack front in a shell shape, and gradually increases to the maximum with the cooling process. With the crack propagation, the crack opening time of the brake disc gradually delays and the crack appearance tends to flatten.

Key words: brake disc, thermal fatigue crack, virtual crack closure, crack propagation, finite element analysis

CLC Number:

U270

HE Jiahuan, SHEN Jiacheng, LU Chun, ZHAO Jie, YUAN Bo. Research on Thermal Fatigue Crack Opening and Closing Behavior of Railway Brake Disc Based on the Virtual Crack Closure Technique[J]. Journal of Mechanical Engineering, 2025, 61(20): 103-112.

References

[1] 左建勇，王雪萍，周苏芬，等. 动车组制动盘热仿真方法适用性研究[J]. 中国铁道科学，2022，43(5)：78-86. ZUO Jianyong，WANG Xueping，ZHOU Sufen，et al. Applicability research on thermal simulation methods for EMU brake discs[J]. China Railway Science，2022，43(5)：78-86.
[2] 周继承，黄伯云. 列车制动摩擦材料研究进展[J]. 材料科学与工程学报，1999，17(2)：91-93. ZHOU Jicheng，HUANG Boyun. Progress in the resaerch of train-brake friction materials[J]. Journal of Materials Science and Engineering，1999，17(2)：91-93.
[3] CHOI J H，LEE I. Finite element analysis of transient thermoelastic behaviors in disk brakes[J]. Wear，2004，257(1-2)：47-58.
[4] 汤忖江，陈蕴博，左玲立，等. 高速列车制动盘材质应用现状和研究进展[J]. 材料导报，2018，32(A01)：443-448. TANG Cunjiang，CHEN Yunbo，ZUO Lingli，et al. Application status and research progress of brake disc materials for high-speed train[J]. Materials Reports，2018，32(A01)：443-448.
[5] GRIFFITH A A. The phenomena of rupture and flow in solids[J]. Philosophical Transactions of the Royal Society A：Mathematical，Physical and Engineering Sciences，1921，221(723)：163-198.
[6] IRWIN G R. Analysis of stresses and strains near the end of a crack traversing a plate[J]. Journal of Applied Mechanics，1957，24(3)：361-364.
[7] PARIS P C，ERDOGAN F. A critical analysis of crack propagation laws[J]. Journal of Basic Engineering，1963，85(4)：528-533.
[8] RYBICKI E F，KANNINEN M F. A finite element calculation of stress intensity factors by a modified crack closure integral[J]. Engineering Fracture Mechanics，1977，9(4)：931-938.
[9] FAWAZ S A. Application of the virtual crack closure technique to calculate stress intensity factors for through cracks with an elliptical crack front[J]. Engineering Fracture Mechanics，1998，59(3)：327-342.
[10] XIE D，BIGGERS Jr S B. Strain energy release rate calculation for a moving delamination front of arbitrary shape based on the virtual crack closure technique. Part I：Formulation and validation[J]. Engineering Fracture Mechanics，2006，73(6)：771-785.
[11] XIE D，BIGGERS Jr S B. Progressive crack growth analysis using interface element based on the virtual crack closure technique[J]. Finite Elements in Analysis and Design，2006，42(11)：977-984.
[12] SOBOTKA J C，MCCLUNG R C. Sensitivity of crack-growth lives to sustained thermal gradients[J]. International Journal of Fatigue，2024，178：108000.
[13] HE J C，ZHU S P，GAO J W，et al. Microstructural size effect on the notch fatigue behavior of a Ni-based superalloy using crystal plasticity modelling approach[J]. International Journal of Plasticity，2024，172：103857.
[14] MARKHAM M J，FATEMI A，PHAN N. Mixed-mode small fatigue crack growth rates and modeling in additively manufactured metals[J]. International Journal of Fatigue，2024，183：108258.
[15] LU C，SHEN J C，FU Q，et al. Research on radial crack propagation of railway brake disc under emergency braking conditions[J]. Engineering Failure Analysis，2023，143：106877.
[16] 石晓玲. 高速列车锻钢制动盘热疲劳寿命评估研究[D]. 北京：北京交通大学，2016. SHI Xiaoling. Research on thermal fatigue life evaluation of forging brake disc used for high speed trains[D]. Beijing：Beijing Jiaotong University，2016.
[17] WU S C，ZHANG S Q，XU Z W. Thermal crack growth-based fatigue life prediction due to braking for a high-speed railway brake disc[J]. International Journal of Fatigue，2016，87：359-369.
[18] 李志强. 高速列车制动盘热斑特征及裂纹萌生扩展机制研究[D]. 北京：北京交通大学，2016. LI Zhiqiang. Research on characteristics of hot spots and initiation and propagation mechanisms of cracks of brake discs used for high speed trains[D]. Beijing：Beijing Jiaotong University，2016.
[19] 谢晓东，李志强，刘志成，等. 服役高铁制动盘微观组织演变和力学性能表征[J]. 中南大学学报(自然科学版)，2022，53(10)：3869-3878. XIE Xiaodong，LI Zhiqiang，LIU Zhicheng，et al. Characterization and evolution of microstructure and mechanical properties of serviced high-speed rail brake discs[J]. Journal of Central South University(Science and Technology)，2022，53(10)：3869-3878.
[20] 刘禹，单颖春，刘献栋，等. 高温对汽车灰铸铁制动盘热疲劳裂纹萌生寿命的影响[J]. 机械工程学报，2019，55(8)：97-105. LIU Yu，SHAN Yingchun，LIU Xiandong，et al. Effect of high temperature on thermal fatigue crack initiation life of automotive gray cast iron brake disc[J]. Journal of Mechanical Engineering，2019，55(8)：97-105.
[21] 国家铁路局. TB/T 2980-2023，机车车辆基础制动装置盘形制动制动盘[S]. 北京：中国铁道出版社有限公司，2023. National Railway Administration of the People’s Republic of China. TB/T 2980-2023，Foundation brake rigging for rolling stock-Disc brakes-Brake disc[S]. Beijing：China Railway Publishing House Co.，Ltd.，2023.
[22] 李继山. 高速列车合金锻钢制动盘寿命评估研究[D]. 北京：中国铁道科学研究院，2006. LI Jishan. Study on life estimation for alloy forging steel brake disc of high-speed train[D]. Beijing：China Academy of Railway Sciences，2006.
[23] 李继山，韩晓辉，范荣巍. 高速列车制动盘残余应力数值仿真及试验验证[J]. 铁道机车车辆，2010，30(6)：8-10，85. LI Jishan，HAN Xiaohui，FAN Rongwei. Numerical simulation and test of brake disc residual stress on high-speed train[J]. Railway Locomotive & Car，2010，30(6)：8-10，85.
[24] 周素霞，谢基龙. 高速客车空心车轴裂纹扩展特性研究[J]. 工程力学，2009，26(7)：232-237. ZHOU Suxia，XIE Jilong. Research of the fatigue crack propagation characteristic on railway hollow axles[J]. Engineering Mechanics，2009，26(7)：232-237.
[25] 中国国家铁路集团有限公司. TG/CL 127-2013，铁路动车组运用维修规程[S]. 北京：中国标准出版社，2013. China State Railway Group Co.，Ltd. TG/CL 127-2013，Maintenance procedures for railway EMUs[S]. Beijing：Standards Press of China，2013.
[26] ZHAO X，ZHAO X G，LIU C，et al. A study on dynamic stress intensity factors of rail cracks at high speeds by a 3D explicit finite element model of rolling contact[J]. Wear，2016，366：60-70.
[27] KRUEGER R. Virtual crack closure technique：history，approach，and applications[J]. Applied Mechanics Reviews，2004，57(2)：109-143.
[28] 程靳，赵树山. 断裂力学[M]. 北京：科学出版社，2006. CHENG Jin，ZHAO Shushan. Fracture mechanics[M]. Beijing：China Science Publishing & Media Ltd.，2006.
[29] 刘艳萍. 焊接桥梁钢疲劳裂纹扩展行为研究[D]. 武汉：华中科技大学，2010. LIU Yanping. Study on fatigue crack growth behavior in welded steel plates used for bridges[D]. Wuhan：Huazhong University of Science and Technology，2010.
[30] LEWIS J C, SINES G. Fracture mechanics：Fourteenth symposium-Volume I：Theory and analysis[M]. Pennsylvania：ASTM International，1983.
[31] ANTUNES F V，SOUSA T，BRANCO R，et al. Effect of crack closure on non-linear crack tip parameters[J]. International Journal of Fatigue，2015，71：53-63.
[32] WELLS A A. Crack opening displacements from elastic-plastic analyses of externally notched tension bars[J]. Engineering Fracture Mechanics，1969，1(3)：399-410.
[33] 岑升波. 高速列车铸钢制动盘热疲劳性能研究及寿命预测[D]. 成都：西南交通大学，2016. CEN Shengbo. Study on thermal fatigue performance and life prediction of cast steel brake disc of high speed train[D]. Chengdu：Southwest Jiaotong University，2016.