大功率交流传动机车车轮多边形磨耗形成机理研究

High-power AC drive electric locomotive has the characteristics of high axle load and high traction power. The service conditions of the wheel are very complex. Severe polygonal wear of locomotive wheels causes strong vibration and large noise, which results in the fatigue failure of some components of the locomotive and threatens the running safety of it. The project will carry out field test and analysis of relevant high-power AC drive electric locomotives and lines. The characteristics and development rule of the polygonal wear of locomotive wheels are obtained. The relationship between the wheel polygonal wear and vibration characteristics of locomotive/track system is investigated to explain the formation mechanism of polygonal wear. The test results are also used to verify the prediction model. The prediction model is developed to simulate the wheel polygonal wear of locomotive. The sub-models of it consists of a rigid-flexible locomotive/track coupling dynamics model, traction/braking control model, improved wheel/rail rolling contact model considering large creep, and a friction wear model of wheel material considering the competitive relation between wear and hardening. Based on the test results, the prediction model is applied to investigate the effects of the wheel initial defect, traction/braking control system, suspension parameters of the bogie, the flexible vibration of key components of the bogie and track parameters on the locomotive wheel polygonal wear. The initiation and development mechanisms of the locomotive wheel polygonal wear are further revealed. Some measures to eliminate the locomotive wheel polygonal wear are proposed. The project results will provide theory basis for further optimal design of the locomotive.

大功率交流传动机车具有轴重大和牵引功率高等特点，车轮工作状态恶劣，严重车轮多边形磨耗引发了强烈的机车振动和噪声，导致机车部件出现疲劳断裂，威胁行车安全。本项目将对相关的大功率交流传动机车及线路进行现场跟踪试验分析，掌握车轮多边形磨耗特征和演化规律，探明多边形磨耗形成与机车/轨道系统振动特性的关系，为揭示车轮多边形形成机理提供数据支撑，并验证理论模型。建立机车车轮多边形磨耗预测模型，其子模型包括：机车-轨道刚柔耦合系统动力学模型、牵引/制动控制模型、考虑大蠕滑的轮轨滚动接触力学模型以及考虑磨耗和材料硬化竞争关系的车轮材料摩擦磨损模型。结合试验研究，基于预测模型，研究车轮初始缺陷、牵引/制动控制方式、转向架系统悬挂参数、转向架关键部件柔性振动和轨道参数等对车轮多边形磨耗的影响，从而揭示机车车轮多边形磨耗的形成和发展机理，提出抑制机车车轮多边形磨耗的措施。为机车系统进一步优化设计提供理论依据。

大功率交流传动机车具有轴重大和牵引功率高等特点，服役环境恶劣，发生的车轮多边形磨耗引发了强烈的机车振动和噪声，导致机车部件出现疲劳断裂，威胁行车安全。本项目围绕大功率机车车轮多边形磨耗形成机理问题，开展了以下主要研究工作：（1）开展了车轮多边形磨耗现场调查，掌握了车轮多边形磨耗特征和演变规律；（2）开展了机车关键部件振动特性研究，探明了多边形磨耗形成与机车/轨道系统振动特性的关系；（3）建立了考虑轮对、构架和轨道结构柔性的机车车轮多边形磨耗预测模型，再现了机车车轮多边形磨耗的产生和发展过程；（4）结合试验研究和仿真分析，揭示了车轮多边形磨耗的形成机理，探明了车轮多边形磨耗的关键影响因素，提出了相应的控制措施，并在多个机务段得到应用与验证。.项目执行期间，共发表论文13篇，其中SCI收录6篇，EI收录4篇；参加国际会议14人次，国内会议1人次；申请国家发明专利6项，已授权5项；获得软件著作权1项；培养已毕业博士1人，硕士6人。