Wear and crack initiation prediction of rail irregularity welding zone

LIN Fengtao; WANG Zixu; TAN Rongkai; ZHANG Zihao; DU Ruiting; SHI Zhiqin

doi:DOI:10.16579/j.issn.1001.9669.2025.01.016

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Wear and crack initiation prediction of rail irregularity welding zone

·Fatigue·Damage·Fracture·Failure Analysis· | 更新时间：2025-01-23

- Wear and crack initiation prediction of rail irregularity welding zone
- Journal of Mechanical Strength Vol. 47, Issue 1, Pages: 146-154(2025)
- 作者机构：
  
  1.华东交通大学轨道交通基础设施性能监测与保障国家重点实验室，南昌 330013
  2.华东交通大学载运工具与装备教育部重点实验室，南昌 330013
  3.机车车辆智能运维铁路行业重点实验室，南昌 330013
  4.中国铁路西安局集团有限公司西安机务段，西安 710000
  5.中国铁路太原局集团有限公司，太原 030013
- 作者简介：
  
  LIN Fengtao, E-mail: ecjtu411@163.com
- 基金信息：
  
  National Natural Science Foundation of China(52065021);Jiangxi “Double Thousand Plan” Science and Technology Innovation Leading Talent Project(S2021GDKX1442);Jiangxi Province Major Disciplines and Technology Leading Personnel Training Program(20213BCJL22040);Jiangxi Provincial Department of Education Science and Technology Research Project(GJJ210641);Independent Project of Key Laboratory of Conveyance and Equipment of Ministry of Education(KLCEZ2022⁃10);Jiangxi Graduate Student Innovation Special Fund Project(YC2022⁃s479)
- DOI：DOI:10.16579/j.issn.1001.9669.2025.01.016
  CLC：
- Published：15 January 2025，
  
  Received：13 November 2023，
  
  Revised：22 February 2024，
- 稿件说明：
移动端阅览
LIN FENGTAO, WANG ZIXU, TAN RONGKAI, et al. Wear and crack initiation prediction of rail irregularity welding zone. [J]. Journal of mechanical strength, 2025, 47(1): 146-154.
DOI：

LIN FENGTAO, WANG ZIXU, TAN RONGKAI, et al. Wear and crack initiation prediction of rail irregularity welding zone. [J]. Journal of mechanical strength, 2025, 47(1): 146-154. DOI：

摘要

为探究钢轨焊接区的磨耗及裂纹萌生与轴重及摩擦因数的关系，通过对大量不平顺焊接区的实地测量，拟合了两种典型焊接区的不平顺数据，建立了上凸和下凹两类典型焊接区不平顺轮轨接触的有限元模型。结合摩擦功模型和Archard磨耗理论，对焊接区最大磨耗截面进行预测，基于Jiang-Sehitoglu模型对焊接区裂纹萌生寿命进行预测。发现随着轴重的增加，上凸及下凹焊接区的磨耗速率均增大；且轴重达到16 t时上凸型焊接区磨耗速率显著增大，而下凹型焊接区在轴重达到18 t时磨耗速率显著增大；摩擦因数从0.2增加到0.35，上凸和下凹两类焊接区最大磨耗量分别为1.93 mm、1.08 mm；且上凸型焊接区磨耗速率在摩擦因数为0.3时显著增大，而下凹型焊接区磨耗速率在摩擦因数为0.35时显著增大。轴重从12 t增加到18 t，上凸型焊接区服役寿命的衰减幅度较小，而下凹型焊接区服役寿命衰减幅度较大。此外，当摩擦因数从0.2增加至0.35时，其对上凸型焊接区服役寿命的影响明显小于轴重（12~18 t）的影响。然而，当摩擦因数从0.2增加至0.35时，其对下凹型焊接区服役寿命的影响与轴重（12~18 t）的影响相当。结果表明，随着轴重和摩擦因数的增加，对钢轨焊接区下凹型不平顺的寿命影响更加显著；在工务维护过程中，应着重关注下凹型焊接区的出现并及时标记和修复。

Abstract

In order to investigate the relation between abrasion and crack initiation in the welded zone of rails and axle weight and friction coefficient

through the field measurement of a large number of uneven weld zones

two kinds of typical weld zone uneven data were fitted

and two kinds of typical uneven wheel-rail contact finite element models of upper convex and lower concave weld zones were established. Combined with the friction work model and Archard wear theory

the maximum wear cross section of the welded zone was predicted

and the crack initiation life of the welded zone was predicted based on the Jiang-Sehitoglu model. It is found that with the increase of axle load

the abrasion rate of both the upper convex and lower concave weld zone increases

and the abrasion rate of the upper convex weld zone increases significantly when the axle load reaches 16 t

while the abrasion rate of the lower concave weld zone increases significantly when the axle load reaches 18 t. When the friction coefficient increases from 0.2 to 0.35

the maximal abrasion amount of the two types of weld zones of the upper convex and the lower concave is 1.93 mm and 1.08 mm

respectively. The abrasion rate of the upper convex type increases significantly at a friction coefficient of 0.3

while the abrasion rate of the lower concave type increases significantly at a coefficient of 0.35. When the axle load increases from 12 t to 18 t

the service life of the upper convex weld zone decreases less

while the service life of the lower concave weld zone decreases more. In addition

when the friction coefficient is increased from 0.2 to 0.35

its effect on the service life of the upper convex weld zone is significantly smaller than that of the axle load （12-18 t）. However

when the friction coefficient is increased from 0.2 to 0.35

the effect on the service life of the lower concave weld zone is comparable to that of the axle load （12-18 t）. The results show that with the increase of axle load and friction coefficient

the influence of concave irregularity on the life of rail welding zone is more significant. In the process of engineering maintenance

we should pay attention to the appearance of concave welding zone and mark and repair it in time.

关键词

铁道工程轮轨关系磨耗预测裂纹萌生预测

Keywords

Railway engineeringWheel-rail relationWear predictionCrack initiation prediction

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