目的 明确轨顶水基摩擦调节剂（FM）制备过程中剪切速率与制备温度对产品黏度特性、微观形貌及轮轨黏着性能的影响规律,确定关键工艺参数的优化区间,为国产化FM稳定制备提供依据。方法 在团队自研轨顶水基FM的配方基础上,通过对比不同制备剪切速率和不同制备温度FM的黏度特性、微观形貌和黏着性能,分析制备剪切速率和制备温度对FM黏着性能的影响机理。首先制备不同剪切速率和温度的FM,研究FM的表观黏度并分析其黏度特性规律;然后利用轮轨滚动接触疲劳试验机开展滚动接触模拟试验,分析不同制备参数下FM黏着性能变化规律。结果 FM黏着性能与制备剪切速率密切相关,随着制备剪切速率增加,FM黏着性能保持转数呈先上升后下降趋势;制备剪切速率为4.0 m/s时,黏着性能保持转数最高且最低黏着系数稳定,黏着性能最佳。FM的黏着性能与制备温度成反比,随温度升高,黏着性能保持转数和最低黏着系数先稳定后下降;制备温度为30 ℃时,FM的黏着性能最优,温度超过45 ℃时FM会因结构破坏而失效。综上,FM制备的最佳工艺参数为4.0 m/s的制备剪切速率、30 ℃的制备温度,该工艺参数下FM的黏着性能提升约57.14%。结论 FM黏着性能受制备剪切速率与制备温度共同影响,并与黏度变化趋势一致,合理的剪切速率和温度组合能够保持FM的稳定性,提升FM的轮轨黏着性能。
Abstract
Applying water-based top-of-rail friction modifiers (hereinafter referred to as friction modifiers) to the rail surface can significantly reduce wear and damage in curved track sections. However, the preparation process of friction modifiers developed in China remains imperfect, and the adhesion performance of the final product is highly sensitive to preparation parameters such as preparation shear rate and preparation temperature. In this work, a self-developed water-based top-of-rail friction modifier was selected as the research object. By comparing the viscosity characteristics, micro-morphology, and adhesion performance of friction modifiers prepared under different shear rates and temperatures, the mechanisms by which these preparation parameters affected adhesion performance were analyzed, and the optimal shear rate and temperature parameters for preparing friction modifiers were determined. Friction modifiers were firstly prepared with a vertical single-axis variable-speed mixer at shear rates ranging from 2.4 to 5.6 m/s and temperatures from 15 to 60 ℃. A high-precision rotational viscometer was subsequently used to measure the viscosity of both the CMC-Na base solution and the finished friction modifiers and to analyze variations in viscosity, pseudoplasticity, and thixotropy. Rolling contact simulation tests were then conducted with the MJP-30A wheel-rail rolling contact wear and fatigue testing machine to evaluate adhesion indicators, namely, the minimum adhesion coefficient and the lasting cycles, under different preparation conditions. Finally, scanning electron microscopy was employed to examine the surface morphology of friction modifiers prepared with different parameter combinations. The results showed that the viscosity and rheological properties of the friction modifiers were jointly affected by the preparation shear rate and temperature. As the shear rate increased, the viscosity firstly rose and then decreased, reaching its maximum at 4.0 m/s, where CMC-Na exhibited the weakest pseudoplasticity and the system became less susceptible to shear thinning. Increasing preparation temperature led to a continuous increase in viscosity, while the thixotropy of CMC-Na weakened above 30 ℃ and disappeared completely at 45 ℃, indicating the destruction of its internal network structure. Meanwhile, adhesion performance was also affected by both shear rate and temperature. With the increasing shear rate, the minimum adhesion coefficient remained stable before decreasing, while the lasting cycles firstly increased and then decreased, reaching 1 100.33 r at 4.0 m/s. As preparation temperature increased, the minimum adhesion coefficient rose slightly before 30 ℃ and then dropped sharply, reaching as low as 0.036 4 at 60 ℃. The lasting cycles similarly peaked near 30 ℃ and decreased markedly in the high-temperature range. In addition, shear rate had little effect on the uniformity of friction modifiers, whereas elevated preparation temperatures significantly reduced uniformity, resulting in surface roughness and graphite agglomeration. Considering the combined effect of preparation shear rate and temperature, the optimal preparation shear rate and temperature of the friction modifier were determined to be 4.0 m/s and 30 ℃, respectively. By revealing the effects of preparation parameters on adhesion performance, this work provides theoretical support for the development of friction modifiers in China and holds significant engineering application value.
关键词
轨顶FM /
制备剪切速率 /
制备温度 /
黏度特性 /
轮轨黏着 /
轮轨摩擦
Key words
top-of-rail friction modifiers /
preparation shear rate /
preparation temperature /
rheological behavior /
wheel-rail adhesion /
wheel-rail friction
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基金
国家自然科学基金（52320105007,52275176）; 中央高校基本科研业务费专项资金（2682024CG007）
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