目的 针对微观尺度下重载列车踏面制动摩擦闪温行为的研究需求,构建能够表征真实粗糙界面的微观轮瓦模型,并分析工况参数与粗糙形貌对摩擦闪温演化行为及其机理。方法 基于W-M分形函数生成三维双粗糙表面模型,建立具有随机形貌的微观摩擦界面,采用有限元热力耦合方法开展摩擦瞬态计算。通过接触力学与摩擦温升对模型进行验证,分别模拟压力、速度与粗糙形貌随机性下的摩擦过程,分析闪温时空特性。结果 随着制动压力增大,微凸体接触斑点由离散向连通演化,局部应力极值点发生迁移,导致热影响深度加深,闪温波动幅度增大且演化周期延长;滑动速度提升主要通过增强摩擦热流输入抬升闪温水平,使闪温峰值升高、波动频率增加并提前出现,但热影响深度随速度增大而减小,高速工况下热载荷更集中于材料表层。在相同粗糙度等级和分形参数条件下,仅由微凸体空间分布随机性引起的闪温峰值波动可达4.0%~30.5%,其影响量级与制动压力或速度变化相当,显著改变温度场的时空分布特征。结论 构建的三维双粗糙界面热力耦合模型能够描述光滑、单粗糙与统计学模型难以反映的非均匀、随机闪温行为。研究表明,微观形貌随机性与制动工况参数共同决定闪温强度及其时空演化特征,是踏面制动中金属镶嵌易发的重要微观热触发机制。该方法为重载列车制动界面闪温安全边界评估及形貌敏感性分析提供了新的建模思路与理论依据。
Abstract
This work presents a micro-scale thermo-mechanical modelling framework that quantifies flash-temperature behaviour at a wheel-shoe interface with realistic dual-rough surfaces and identifies the micro-mechanisms that promote metal pick-up. Three-dimensional rough surfaces with randomized asperity morphology are generated using the Weierstrass- Mandelbrot fractal function, and a fully coupled transient thermo-mechanical finite-element model is established to simulate frictional heating with explicit heat partitioning, heat conduction and elastic-plastic contact mechanics. Model verification against the Hertzian theory and an analytical smooth-surface temperature solution demonstrate close agreement, with only minor deviations in both contact pressure and temperature rise, confirming that the model can reliably capture micro-scale flash-temperature phenomena.
Parametric simulations are conducted by varying normal pressure from one to six megapascals, sliding speed from forty to one hundred and twenty kilometres per hour, and surface morphology using four rough surfaces with similar average roughness but different asperity distributions. When normal pressure increases, the real contact area increases from about twelve percent of the nominal contact area to nearly one-third, and the contact pattern evolves from sparse, isolated micro-spots into continuous, interconnected regions. The peak flash temperature rises from slightly above fifty degrees Celsius to nearly one hundred degrees, followed with a distinctly nonlinear trend because interactions among deformed asperities cause shifting stress peaks and saddle-shaped deformation. Higher pressure also enlarges the size of hot spots, increases thermal penetration into the subsurface and creates three-dimensional high-temperature regions that promote softening and local plastic shearing. In terms of temporal response, higher pressure shortens the time needed for flash temperature to reach its peak, increases the amplitude of temperature oscillation and reduces the oscillation frequency as the micro-contact network becomes more stable.
Sliding speed influences flash temperature through a different mechanism. As speed increases from forty to one hundred and twenty kilometres per hour, the peak flash temperature increases by more than twenty degrees Celsius in a nearly linear fashion because the rate of frictional heat generation grows proportionally. However, higher speeds significantly reduce thermal penetration depth. This occurs because the contact time of individual asperities becomes shorter than the characteristic heat diffusion time, concentrating thermal effects within the near-surface layer. Higher speeds also accelerate the renewal of micro-contacts and increase the frequency of temperature fluctuations, while the reduction in peak-arrival time becomes less pronounced once the speed exceeds roughly eighty kilometres per hour.
Surface morphology randomness introduces temperature variations comparable to those caused by changes in pressure or speed. Although all four surfaces have similar roughness, their different asperity heights, curvatures and spatial distributions result in peak flash temperature ranging from just above one hundred degrees Celsius to more than one hundred and twenty-five degrees. The peak temperature fluctuation can reach 4.0% to 30.5%. This change indicates that locally sharp roughness can dominate stress concentration and heat generation, and that surface flash temperature has a relatively small relationship with the overall contact area.
In summary, flash temperature at the wheel-shoe interface is transient, spatially drifting and strongly dependent on micro-scale morphology. Pressure governs asperity participation and the scale of thermal influence, speed controls heat-input rate and thermal diffusion depth, and morphology randomness introduces substantial stochastic fluctuations. These findings clarify the thermal-mechanical conditions that promote metal pick-up formation and provide a modelling tool for safety-margin evaluation and morphology-sensitive design of braking interfaces.
关键词
踏面制动 /
双粗糙表面 /
微观闪温 /
分形理论 /
热耦合摩擦
Key words
tread brake /
double rough surface /
micro flash temperature /
fractal theory /
thermal coupling friction
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