Evolution Characteristics of Aluminum Thermal Weld Irregularity and Damage in Heavy-Haul Railway under Different Service Conditions
Abstract
:1. Introduction
2. Irregularities Testing
3. Numerical Simulation Analysis
3.1. Theoretical Basis of Model
3.2. Material Parameters
3.3. Contact Relationships
3.4. Model Establishment
3.5. Result Analysis
3.5.1. Evolution Characteristics of Wheel–Rail Vertical Force in Different Weld States
- (1)
- Initial state weld
3.5.2. Plastic Deformation Analysis of Rail
4. Conclusions
- (1)
- More than 200 days of irregularity monitoring was conducted on the welds, and the weld irregularities’ evolution characteristics with freight volume were obtained. Overall, the weld irregularity showed a trend of convexity to concavity throughout its service life. According to the weld irregularity evolution characteristics, the weld can be divided into three different states: initial state, where the shape of the weld shows a convex nature; the intermediate state, where the weld appears partially concave in the HFZ; damaged status, where the weld HZF is concave and the concave value exceeds the limit by 0.5 mm.
- (2)
- The wheel–weld interaction force evolution characteristics show that under different service states, wheels can cause a significant wheel–rail impact when passing through the weld. With a continuous increase in freight volume, the wheel–rail force and concave value show an exponential increasing trend. The weight of 250 MT at the weld reached the repairment control limit.
- (3)
- The frequency domain analysis of wheel–rail force shows that when the weld is in the initial state, the peak force frequency only exists at 51 Hz throughout the spectrum distribution; when in the intermediate state, 163 Hz and 632 Hz high-frequency components appear; when in the damaged state, the main frequency components in the distribution are 51 Hz and 801 Hz. As the weld service time increases, some high-frequency impact loads will gradually appear.
- (4)
- At the initial stage of cyclic load application, the weld will quickly experience plastic deformation within a range of about 20 mm horizontally on the rail head, and then the plastic deformation tends to stabilize. The concentration effect of vertical equivalent plastic strain is most clear at 2~5 mm below the rail head. Under the wheel–rail cyclic load, plastic deformation can be seen on the rail head surface within a range of 12 mm, with the maximum plastic deformation occurring at a depth of about 2~5 mm below the rail head.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Parameter | Character | Unit | Value |
---|---|---|---|
Vehicle mass | mc | t | 91.4 |
Bolster mass | mb | kg | 745 |
Side frame mass | ms | kg | 497 |
Wheelset mass | mw | t | 1.257 |
Axle load | mal | t | 25 |
Longitudinal stiffness of primary suspension | K1x | MN/m | 13 |
Lateral stiffness of primary suspension | K1y | MN/m | 11 |
Vertical stiffness of primary suspension | K1z | MN/m | 160 |
Vertical damping of primary suspension | C1z | kN.s/m | 4 |
Longitudinal stiffness of secondary suspension | K2x | MN/m | 4.4 |
Lateral stiffness of secondary suspension | K2y | MN/m | 4.4 |
Vertical stiffness of secondary spring | K2z | MN/m | 4.89 |
Vertical damping of secondary spring | C2z | kN.s/m | 50 |
Wheel radius | Rw | m | 0.42 |
Vehicle length | Lc | m | 12 |
Wheelbase of bogie | Lb | m | 1.83 |
Name | Parament | Density (kg/m3) | Elastic Modulus | Poisson’s Ratio |
---|---|---|---|---|
rail | 75 kg/m, length 21 m | 7850 | 210 GPa | 0.3 |
sleeper | 2.6 m × (0.26, 0.32) × 0.22 | 2520 | 38.3 GPa | 0.2 |
track bed | 43.2 × 4.5 × 0.4 | 2400 | 200 MPa | 0.25 |
Elastic Modulus | Poisson’s Ratio | Reference Strain Rate | A | B | C1 | n1 | n2 | ||
---|---|---|---|---|---|---|---|---|---|
199 GPa | 0.3 | 0.001 | 370.26 mPa | 1627.5 mPa | 0.00014 | 0.95 | 0.69 | 0.3134 | 0.41 |
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Liu, G.; Zhang, N.; Huang, W.; Shi, G.; Xiao, H.; Huang, L.; Liu, X. Evolution Characteristics of Aluminum Thermal Weld Irregularity and Damage in Heavy-Haul Railway under Different Service Conditions. Metals 2024, 14, 951. https://doi.org/10.3390/met14080951
Liu G, Zhang N, Huang W, Shi G, Xiao H, Huang L, Liu X. Evolution Characteristics of Aluminum Thermal Weld Irregularity and Damage in Heavy-Haul Railway under Different Service Conditions. Metals. 2024; 14(8):951. https://doi.org/10.3390/met14080951
Chicago/Turabian StyleLiu, Guangpeng, Nan Zhang, Weiming Huang, Guoliang Shi, Hong Xiao, Linchong Huang, and Xin Liu. 2024. "Evolution Characteristics of Aluminum Thermal Weld Irregularity and Damage in Heavy-Haul Railway under Different Service Conditions" Metals 14, no. 8: 951. https://doi.org/10.3390/met14080951