目的 研究重载铁路道岔区侧向通过时的极端动力学特性,精准定位易发生滚动接触疲劳（RCF）的区域,并量化心轨垂直磨耗对疲劳损伤演化的影响。方法 结合线性变截面拟合技术与Kik-Piotrowski多点接触算法,建立了高精度的重载车辆-道岔多体动力学模型。通过基准工况与极限工况（30 t轴重、50 km/h）下的多参数对比,严格验证了模型的通用性与可靠性。选取60 kg/m钢轨12号单开道岔,系统分析了不同速度、轴重对轮轨作用力的响应规律,基于材料安定图与表面疲劳指数定性评估了道岔滚动接触疲劳易发生区域,并引入3~6 mm的渐进式心轨垂直磨耗以探究其损伤加速效应。结果 重载货车侧逆向过岔时,垂向力随速度和轴重的增加而显著增大;横向力在尖轨上随参数增加而增大,但在心轨上受复杂接触游移影响而在20 kN左右低幅波动。RCF高危区域精确定位于距尖轨尖端1.24 m处及理论心轨尖端后方262 mm处。受非对称轮载转移与接触斑形态非线性重构的影响,心轨疲劳指数峰值并未随速度和轴重呈现单调变化趋势。此外,心轨垂磨深度的增加迫使疲劳指数最大值所在位置后移,且损伤程度显著高于无磨耗状态。结论 重载侧向过岔时,RCF极易在心轨变截面区萌生。心轨塑性压溃导致的垂直磨耗是加速疲劳失效的关键驱动因素,深度磨耗会显著提升严重疲劳损伤的风险。在实际重载运营中,除了控制轴重与限速等机械边界外,还需警惕热-机及环境介质等多因素耦合对疲劳演化的成倍放大效应,及时对心轨进行视情打磨与维护。
Abstract
Heavy-haul railways play a pivotal role in the modern freight transportation, yet the turnout zones remain the most vulnerable bottlenecks within the track network. The inherent structural discontinuities, particularly the variable cross-sections of the switch and nose rails, lead to severe dynamic wheel-rail interactions. This problem is drastically amplified during diverging route negotiations, where vehicles experience abrupt centrifugal forces, intense asymmetric load transfers, and high-frequency multi-point contacts. While extensive research has focused on rolling contact fatigue (RCF) during straight-line passages, a comprehensive system-level investigation into the dynamic behavior and RCF damage mechanisms of heavy-haul trains negotiating turnouts in the diverging reverse direction remains noticeably absent.
To bridge this critical research gap, this study establishes a high-fidelity, multi-body dynamic simulation model coupling a heavy-haul freight wagon with a complete turnout structure. The vehicle model integrates detailed structural parameters, including a K6 bogie and LM wheel tread profiles, while the track model represents a standard 60 kg/m rail, No. 12 single turnout. To accurately capture the complex spatial geometry of the turnout, a linear variable cross-section fitting technique is employed. The dynamic wheel-rail interaction is resolved using the Kik-Piotrowski multi-point contact algorithm, which balances computational efficiency with the precise capturing of non-Hertzian contact characteristics. The robustness and predictive accuracy of the model are systematically verified against established field trial data and standard engineering thresholds, including derailment coefficients and wheel load reduction rates, under both baseline (25 t axle load, 45 km/h) and extreme limit operational conditions (30 t axle load, 50 km/h).
Utilizing this validated framework, extensive parametric analyses are conducted to evaluate the influence of varying operating speeds (40, 45, and 50 km/h) and axle loads (23, 25, and 30 t) on the wheel-rail interaction forces. The computational results demonstrate that vertical wheel-rail forces exhibit a consistent and significant upward trend in response to increases in both speed and axle load. Conversely, the lateral forces present a distinct spatial sensitivity: while lateral forces on the switch rail increase monotonically with operational parameters, reaching a peak of 90 kN, the lateral forces on the nose rail fluctuate at a lower, relatively stable amplitude of approximately 20 kN, governed primarily by the complex contact wandering rather than load increments.
Furthermore, the dynamic loads are mapped onto a material shakedown diagram to calculate the surface fatigue index, enabling the precise spatial localization of RCF hotspots. The analysis reveals that the regions are most susceptible to severe RCF, where the material enters the ratcheting effect zone with irreversible plastic accumulation, are located at 1.24 meters from the tip of the switch rail and 262 mm from the theoretical tip of the nose rail. Interestingly, due to the non-linear reconfiguration of contact patch morphology and multi-point creepages during asymmetric load transfer, the peak surface fatigue index on the nose rail does not exhibit a simple monotonic relationship with increasing speed or axle load.
Recognizing the detrimental impact of structural degradation caused by plastic crushing, the study further quantifies the accelerating effect of progressive vertical wear (ranging from 3 mm to 6 mm) on the nose rail. The findings indicate that deeper vertical wear profiles significantly elevate the maximum fatigue index and force the damage hotspot to shift further away from the theoretical tip, drastically exacerbating the risk of severe shelling and fatigue fracture compared with an unworn state.
In conclusion, this research confirms that the variable cross-sections within the turnout, particularly the nose rail under progressive vertical wear, serve as the primary drivers of RCF failure in heavy-haul diverging passages. The findings underscore the critical necessity for timely, condition-based grinding and maintenance of the nose rail. Moreover, the study highlights that future RCF management must transcend pure mechanical boundaries, maintaining vigilance against the exponential damage amplification triggered by multi-factor coupling, such as thermal-mechanical softening and environmental fluid pressurization in actual heavy-haul operations.
关键词
普速道岔 /
动力学模型 /
钢轨滚动接触疲劳 /
疲劳指数
Key words
conventional speed turnout /
dynamic model /
rail rolling contact fatigue /
fatigue index
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] 翟婉明, 严隽耄, 孙翔. 大型货车对线路动力影响的研究[J]. 西南交通大学学报, 1993, 28(5): 37-41.
ZHAI W M, YAN J M, SUN X.Dynamic Effect of Heavy Haul Freight Cars on Railway Track[J]. Journal of Southwest Jiaotong University, 1993, 28(5): 37-41.
[2] 林云蕾, 周清跃. 辙叉用贝氏体钢的研究进展[J]. 铁道建筑, 2018, 58(10): 1-4.
LIN Y L, ZHOU Q Y.Research Development of Bainitic Steel for Frog[J]. Railway Engineering, 2018, 58(10): 1-4.
[3] 王延朋, 丁昊昊, 邹强, 等. 列车车轮踏面滚动接触疲劳研究进展[J]. 表面技术, 2020, 49(5): 120-128.
WANG Y P, DING H H, ZOU Q, et al.Research Progress on Rolling Contact Fatigue of Railway Wheel Treads[J]. Surface Technology, 2020, 49(5): 120-128.
[4] TORSTENSSON P T, SQUICCIARINI G, KRÜGER M, et al. Wheel-Rail Impact Loads and Noise Generated at Railway Crossings-Influence of Vehicle Speed and Crossing Dip Angle[J]. Journal of Sound and Vibration, 2019, 456: 119-136.
[5] 梁喜仁, 陶功权, 陆文教, 等. 地铁钢轨滚动接触疲劳损伤研究[J]. 机械工程学报, 2019, 55(2): 147-155.
LIANG X R, TAO G Q, LU W J, et al.Study on the Rail Rolling Contact Fatigue of Subway[J]. Journal of Mechanical Engineering, 2019, 55(2): 147-155.
[6] 司道林, 杨东升, 王树国, 等. 高速道岔辙叉结构不平顺动力学特性分析[J]. 铁道建筑, 2018, 58(1): 67-69.
SI D L, YANG D S, WANG S G, et al.Analysis on Dynamic Characteristics of High Speed Turnout Frog Structure in Irregularity State[J]. Railway Engineering, 2018, 58(1): 67-69.
[7] 李文博. 60 kg/m钢轨12号合金钢辙叉结构设计优化与制造工艺[D]. 成都: 西南交通大学, 2016: 25-27.
LI W B.Optimization Design and Manufacturing Technology of 60 kg/m Rails 12 Alloy Steel Frog[D]. Chengdu: Southwest Jiaotong University, 2016: 25-27.
[8] 曹洋, 王平. 固定辙叉心轨轨顶降低值优化[J]. 西南交通大学学报, 2015, 50(6): 1067-1073.
CAO Y, WANG P.Optimization of Nose Depth for Rigid Frog[J]. Journal of Southwest Jiaotong University, 2015, 50(6): 1067-1073.
[9] 刘永乾, 任尊松, 吴潇, 等. 钢轨打磨对小半径曲线钢轨滚动接触疲劳的影响研究[J]. 铁道学报, 2023, 45(8): 110-117.
LIU Y Q, REN Z S, WU X, et al.Influence of Rail Grinding on Rolling Contact Fatigue of Rail on Small-Radius Curve[J]. Journal of the China Railway Society, 2023, 45(8): 110-117.
[10] 郝凯, 刘鹏飞, 王晨, 等. 重载货车车轮磨耗及滚动接触疲劳仿真研究[J]. 北京交通大学学报, 2024, 48(6): 102-112.
HAO K, LIU P F, WANG C, et al.Simulation Study on Wheel Wear and Rolling Contact Fatigue of Heavy-Haul Freight Wagons[J]. Journal of Beijing Jiaotong University, 2024, 48(6): 102-112.
[11] 李金城. 基于高速列车过岔动力学的道岔磨耗和疲劳研究[D]. 成都: 西南交通大学, 2022: 95-123.
LI J C.Research on Turnout Wear and Fatigue Based on High-Speed Train Crossing Dynamics[D]. Chengdu: Southwest Jiaotong University, 2022: 95-123.
[12] 严强. 基于轮轨接触概率分布的地铁道岔钢轨滚动接触疲劳损伤分析[D]. 成都: 西南交通大学, 2021: 19-20.
YAN Q.Analysis of Rolling Contact Fatigue Damage of Metro Turnout Rail Based on Wheel Rail Contact Probability Distribution[D]. Chengdu: Southwest Jiaotong University, 2021: 19-20.
[13] 栗杨, 赵鑫, 温泽峰, 等. 重载铁路小半径曲线内轨滚动接触疲劳机理研究[J]. 铁道学报, 2024, 46(7): 91-100.
LI Y, ZHAO X, WEN Z F, et al.Investigation on Mechanisms of Rolling Contact Fatigue Occurring on Low Rails of Sharp Curves on Heavy Haul Railway Line[J]. Journal of the China Railway Society, 2024, 46(7): 91-100.
[14] 栗杨, 白彬亨, 莫日格吉勒, 等. 重载曲线缓和段钢轨滚动接触疲劳机理[J]. 浙江大学学报(工学版), 2023, 57(9): 1775-1784.
LI Y, BAI B H, MO R, et al.Mechanism of Rolling Contact Fatigue Occurring on Rails of Heavy Haul Railway Transition Line[J]. Journal of Zhejiang University (Engineering Science), 2023, 57(9): 1775-1784.
[15] 高原, 王平, 陈嵘, 等. 重载铁路固定辙叉区轮轨瞬态滚动接触行为分析[J]. 铁道学报, 2020, 42(6): 35-43.
GAO Y, WANG P, CHEN R, et al.Analysis of 3D Transient Wheel-Rail Rolling Contact Behavior for Fixed Frog in Heavy Haul Railways[J]. Journal of the China Railway Society, 2020, 42(6): 35-43.
[16] WANG X T, LIU C, CHEN R, et al.Analysis of Load Characteristics and Fatigue Life Prediction of Fixed Frog Nose Rail under Complex Conditions Based on Load Spectrum Compilation[J]. Engineering Failure Analysis, 2024, 160: 108128.
[17] 曾志平, 徐榕, 阮莹, 等. 地铁大坡度道岔制动工况下钢轨表面接触应力变化规律研究[J]. 表面技术, 2021, 50(6): 243-249.
ZENG Z P, XU R, RUAN Y, et al.Research on the Change Law of Rail Surface Contact Stress under the Braking Condition of Metro Turnout[J]. Surface Technology, 2021, 50(6): 243-249.
[18] 窦随权, 张晓峰, 张沭玥, 等. 重载铁路磨耗与接触疲劳失效车轮损伤机制研究[J]. 表面技术, 2024, 53(23): 131-142.
DOU S Q, ZHANG X F, ZHANG S Y, et al.Damage Mechanism of Worn and Fatigue Heavy Haul Railway Wheels[J]. Surface Technology, 2024, 53(23): 131-142.
[19] 李鹏, 姚鑫宇, 王梁, 等. 激光固态相变贝氏体道岔钢滚动磨损与接触疲劳行为研究[J]. 表面技术, 2025, 54(17): 150-161.
LI P, YAO X Y, WANG L, et al.Rolling Wear and Contact Fatigue Behavior of Bainite Turnout Steel with Laser Solid-State Phase Transformation[J]. Surface Technology, 2025, 54(17): 150-161.
[20] 王彦杰, 王梁, 张沭玥, 等. 激光固态相变U75V材料滚动接触疲劳损伤行为研究[J]. 表面技术, 2025, 54(19): 127-142.
WANG Y J, WANG L, ZHANG S Y, et al.Rolling Contact Fatigue Damage Behavior of U75V Material after Laser Solid-State Phase Transition[J]. Surface Technology, 2025, 54(19): 127-142.
[21] PIOTROWSKI J, KIK W.A Simplified Model of Wheel/Rail Contact Mechanics for Non-Hertzian Problems and Its Application in Rail Vehicle Dynamic Simulations[J]. Vehicle System Dynamics, 2008, 46(1/2): 27-48.
[22] 陈雷. 中国铁路重载货车关键技术和可靠性评价[J]. 铁道车辆, 2010, 48(1): 1-4.
CHEN L.Key Technologies and Reliability Appraisal for Heavy Haul Freight Cars in Chinese Railway[J]. Rolling Stock, 2010, 48(1): 1-4.
[23] 李跃鹏. 朔黄铁路30 t重载道岔应用及强化措施[J]. 铁道建筑技术, 2019(6): 152-157.
LI Y P.Application and Strengthening Measures of 30 t Heavy Haul Turnout in Shuo-Huang Railway[J]. Railway Construction Technology, 2019(6): 152-157.
[24] 中国铁路总公司. 铁路技术管理规程-普速铁路部分[M]. 北京: 中国铁道出版社, 2014.
China Railway.Railway Technical Management Regulations-General Speed Railway Part[M]. Beijing: China Railway Publishing House, 2014.
[25] TB 10098—2017, 铁路线路设计规范[S].
TB 10098—2017, Code for Design of Railway Line[S].
[26] 刘信立. 30 t及以上轴重货车动力性能仿真研究[J]. 铁道建筑技术, 2013(10): 90-93.
LIU X L.Research on Dynamic Performance Simulation of 30 t and above Axle-Load Freight Wagon[J]. Railway Construction Technology, 2013(10): 90-93.
[27] 赵滨. 重载列车道岔区运行动力学仿真及轮轨摩擦特性研究[D]. 秦皇岛: 燕山大学, 2022: 24-25.
ZHAO B.Study on Dynamic Simulation and Wheel Rail Friction Characteristics of Heavy Haul Train in Turnout Area[D]. Qinhuangdao: Yanshan University, 2022: 24-25.
[28] 王树国. 延长重载道岔使用寿命的关键技术研究[D]. 北京: 中国铁道科学研究院, 2014: 44-45.
WANG S G.Research on the Key Technologies of Prolonging the Service Life of Heavy-Haul Turnouts[D]. Beijing: China Academy of Railway Sciences, 2014: 44-45.
[29] 杨新文, 张昭, 孟玮, 等. 道岔区固定辙叉心轨垂磨对轮轨动态接触的影响[J]. 同济大学学报(自然科学版), 2020, 48(11): 1595-1604.
YANG X W, ZHANG Z, MENG W, et al.Effect of Vertical Wear of Unmovable Frog Nose Rail on Dynamical Wheel-Rail Contact in Turnout Zone[J]. Journal of Tongji University (Natural Science), 2020, 48(11): 1595-1604.
[30] BOWER A F, JOHNSON K L.Plastic Flow and Shakedown of the Rail Surface in Repeated Wheel-Rail Contact[J]. Wear, 1991, 144(1/2): 1-18.
[31] EKBERG A, KABO E, ANDERSSON H.An Engineering Model for Prediction of Rolling Contact Fatigue of Railway Wheels[J]. Fatigue & Fracture of Engineering Materials & Structures, 2002, 25(10): 899-909.
[32] 中国铁路总公司. 普速铁路线路修理规则[M]. 北京: 中国铁道出版社, 2019.
China Railway.Rules for Repairing General-Speed Railway Lines[M]. Beijing: China Railway Publishing House, 2019.
[33] HAN F, WEI H, LIU Y.Thermal-Mechanical Coupling Analysis of Wheel-Rail Sliding Friction under Two-Point Contact Conditions[J]. Lubricants, 2023, 11(5): 232.
[34] CAPRIOLI S.Thermal Impact on Rolling Contact Fatigue of Railway Wheels[D]. Chalmers: Chalmers University of Technology, 2014.
[35] AKAMA M.Rolling Contact Fatigue and Wear of Rails and Wheels: A Comprehensive Review[J]. Machines, 2025, 13(10): 970.
[36] EKBERG A, KABO E.Fatigue of Railway Wheels and Rails under Rolling Contact and Thermal Loading: An Overview[J]. Wear, 2005, 258(7/8): 1288-1300.
基金
国家重点研发计划课题（2023YFB4603400）; 国家自然科学基金（52575234）; 中央高校基本科研业务费专项资金（2682024CG007）
PDF(2258 KB)
渝公网安备 50010702501715号 渝ICP备15012534号-3
