高速列车盘形制动器热-结构耦合方法研究  

Study on the thermal-structural coupling method for disc brake of high-speed train

作　　者：刘楠 金星 史建航 王炳锟 施玉奇 丰明阳 LIU Nan;JIN Xing;SHI Jianhang;WANG Bingkun;SHI Yuqi;FENG Mingyang(CRRC Qingdao Sifang Rolling Stock Research Institute Co.,Ltd.,Qingdao 266031,China;CRRC Braking System Co.,Ltd.,Qingdao 266031,China)

机构地区：[1]中车青岛四方车辆研究所有限公司,山东青岛266031 [2]中车制动系统有限公司,山东青岛266031

出　　处：《铁道科学与工程学报》2024年第2期456-464,共9页Journal of Railway Science and Engineering

基　　金：中车青岛四方车辆研究所有限公司科研项目(2021SRI106)。

摘　　要：盘形制动器热负荷计算是高速列车制动盘研发设计的关键环节,其计算结果是列车运行参数配置的依据。开发合适的计算方法建立计算精度高、工况适用性广的热-结构耦合计算模型是盘形制动器热负荷计算的关键问题。针对动车组用轴装制动盘制动过程,充分考虑制动闸片和制动盘的几何特性、运动特性和载荷工况,提出位移梯度循环法,基于ABAQUS软件建立盘形制动器摩擦副三维瞬态传热有限元模型,运用位移梯度循环法推导出热流加载式,用以计算制动过程中产生的摩擦热流,解决摩擦作用沿制动盘周向差异造成的耦合结果偏差。运用位移梯度循环法对制动盘进行热-结构耦合分析,并将仿真结果与试验数据、现场调研成果进行对比,通过仿真与试验结果的峰值温度误差率、相关性系数等统计学指标及现场调研观测结果评定该模型的计算精度及工况适用性。研究结果表明:基于位移梯度循环法的热-结构耦合模型可有效模拟制动盘在制动过程中温度变化规律且具有良好的重复性与稳定性,结构场分析出的制动盘热裂纹失效易发位置与该型号制动盘装车运用情况相符。研究成果可有效模拟高速列车在制动时制动盘的热-结构耦合过程,尤其在大轴重下的持续制动或间隔制动工况下,制动时间越长,计算精度越高。The thermal load calculation of disc brake is a key link in the development and design of high-speed train brake disc,and its calculation results are used as the basis to determine the train operation parameters.Developing suitable calculation methods and establishing a thermal-structural coupling calculation model with high calculation accuracy and wide applicability of working conditions is the key issue of the thermal load calculation of disc brakes.In view of the braking process of axle mounted brake discs for multiple units,the displacement gradient cycle method was proposed by considering the geometric characteristics,motion characteristics and load conditions of brake pads and brake discs.Based on the ABAQUS®software program,a three-dimensional transient heat transfer finite element(FEM)model of disc brake friction pairs was established,and the heat flow loading formula was derived by using the displacement gradient cycle method,which was helpful in calculating the friction heat flow generated in the braking process and solving the coupling result deviation caused by the friction effect along the circumferential difference of the brake disc.The displacement gradient cycle method was used to analyze the thermal-structural coupling of the brake disc.The statistical indicators,such as the peak temperature error rate and correlation coefficient,of the comparison between the simulation results with the test data and the field survey results were used to evaluate the calculation accuracy and working condition applicability of the model.The analysis results show that the thermal-structural coupling model based on the displacement gradient cycle method can effectively simulate the temperature change law of the brake disc during the braking process,and have good repeatability and stability.The brake disc hot crack failure prone location discovered by the structural field is consistent with the loading and operation of the brake disc of the same type.The research results can effectively simulate the thermal-structu

关 键 词：高速列车 盘形制动器 热-结构耦合 热负荷计算 位移梯度循环法 

分 类 号：U270[机械工程—车辆工程]