黄启芮,张沭玥,王文健,师陆冰,林强,丁昊昊.钢轨轨面静电喷涂SiO2增黏颗粒行为与利用率研究[J].表面技术,2023,52(6):196-207.
HUANG Qi-rui,ZHANG Shu-yue,WANG Wen-jian,SHI Lu-bing,LIN Qiang,DING Hao-hao.Behaviour and Utilization Rate of SiO2 Particles by Electrostatic Spraying on Rail Surface[J].Surface Technology,2023,52(6):196-207 |
| 钢轨轨面静电喷涂SiO2增黏颗粒行为与利用率研究 |
| Behaviour and Utilization Rate of SiO2 Particles by Electrostatic Spraying on Rail Surface |
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| DOI：10.16490/j.cnki.issn.1001-3660.2023.06.017 |
| 中文关键词: 静电喷涂 轮轨增黏 撒砂增黏 增黏颗粒 颗粒参数 |
| 英文关键词:electrostatic spraying wheel/rail adhesion sanding adhesion viscosity increase particles particle parameters |
| 基金项目:国家重点研发计划政府间国际科技创新合作重点专项(2018YFE0109400);四川省苗子工程项目(2021JDRC0086);中国国家铁路集团有限公司科技研究开发计划系统性重大项目(P2021J038) |
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| Author | Institution |
| HUANG Qi-rui | Tangshan Institute, Southwest Jiaotong University, Hebei Tangshan 063000, China |
| ZHANG Shu-yue | School of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, China |
| WANG Wen-jian | Tangshan Institute, Southwest Jiaotong University, Hebei Tangshan 063000, China;School of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, China |
| SHI Lu-bing | Zhengzhou Research Institute of Mechanical Engineering Co., Ltd., Zhengzhou 450052, China |
| LIN Qiang | School of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, China |
| DING Hao-hao | Tangshan Institute, Southwest Jiaotong University, Hebei Tangshan 063000, China;School of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, China |
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| 中文摘要: |
| 目的 为了改善传统撒砂过程中SiO2增黏微粒利用率低的问题，将静电喷涂技术引入轮轨增黏领域，研究不同喷涂参数与颗粒粒径对SiO2微粒行为与利用率的影响，并进一步对比分析静电喷涂微粒与传统撒砂的增黏效果。方法 利用Gema静电喷枪与静电喷涂动态试验平台进行喷涂试验;利用MJP–30A轮轨滚动磨损与接触疲劳试验机进行轮轨黏着与磨损试验;利用光学显微镜(OM)对SiO2微粒吸附情况进行观察与分析，并通过电子天平测量与计算轨面颗粒量与颗粒利用率。结果 相较于未施加静电电压，静电电压为90 kV时轨面颗粒量提升了3.8倍。静电电压由30 kV增加至70 kV时，颗粒利用率提升约60%;当静电电压进一步增加至90 kV时，由于颗粒带电量趋于饱和，颗粒利用率仅提升10%。SiO2微粒利用率随着喷嘴高度与颗粒粒径的增大先增大后减小，喷嘴高度为25 cm且颗粒粒径为300目时颗粒利用率最高，可达60%;300目SiO2微粒在静电电压为90 kV时，随着喷枪移速的增大，喷枪在单位距离上喷涂时间相对减少，使得喷涂在钢轨轨面的颗粒量降低。90 kV静电喷涂SiO2微粒增黏时，最大黏着系数接近传统撒砂增黏，有效作用时间是传统撒砂的2.2倍，轮轨磨损率仅为传统撒砂增黏的75%与65%，轮轨损伤显著减轻。结论 利用静电喷涂技术可以有效提升SiO2微粒在钢轨轨面的利用率，并提升颗粒在轨面的吸附性;静电喷涂SiO2微粒增黏与传统撒砂增黏的黏着系数相近，且轮轨磨损率更低。 |
| 英文摘要: |
| In railway systems, sands are often applied to the wheel-rail interface to improve the adhesion coefficient. However, hard particles such as quartz sand will inevitably cause wear to the wheel and rail after entering the contact area of wheel and rail. The viscosity increase effect of sand sprinkling mainly comes from the broken sand particles and has nothing to do with particle size. Therefore, using SiO2 particles instead of sand particles to increase viscosity can not only meet the viscosity increase effect but also significantly reduce wheel-rail damage. However, due to the small particle size and lightweight of SiO2 particles, it is difficult to effectively apply SiO2 particles to the wheel-rail interface by using the sand spout device in the current railway system. If electrostatic spraying is used to improve the utilization rate of SiO2 particles, it will have a high application prospect. Therefore, the work aims to introduce electrostatic spraying technology into the wheel-rail viscosity increase field and study the effects of different spraying parameters and particle sizes on the behavior and utilization of SiO2 particles, so as to solve the problem of low utilization of SiO2 viscosity increase particles in the traditional sanding process, and further compare and analyze the viscosity increase effects of electrostatic spraying particles and traditional sanding. The rail material selected in the test was U75V rail cut at each section of 50 cm from the site, and the size of SiO2 micro-powder was 100, 200, 300 and 500 mesh, and the content of silica in SiO2 micro-powder was more than 95%. Before each coating test, the rail surface was sanded, polished and cleaned with anhydrous ethanol and the spray gun was flushed with compressed air to prevent powder from blocking the muzzle, and the grounding wire was fixed to the rail. During the test, the Gema electrostatic spray gun was fixed on the rodless slider of the dynamic test bench. At the end of the coating test, it stood for 5 min, and after the suspended particles in the air were completely deposited, the particles adsorbed on the rail surface were collected and weighed by an electronic balance, and then the effective utilization rate was calculated, and the particle adsorption was observed by an optical microscope. Compared with the traditional spraying method, the amount of SiO2 particles on the rail surface by electrostatic spraying increased about 3.8 times. When the electrostatic voltage was increased from 30 kV to 70 kV, the particle utilization rate increased by 60%, but when the electrostatic voltage was further increased to 90 kV, since the particle charge tended to saturate, the particle utilization rate only increased by 10%. The utilization rate of SiO2 particles firstly increased and then decreased with the increase of nozzle height and particle size. When the nozzle height was 25 cm and the particle size was 300 mesh, the particle utilization rate was the highest, reaching 60%. When the electrostatic voltage of the 300 mesh SiO2 particles was 90 kV, the spraying time of the spray gun on the unit distance was relatively shortened with the increase of the moving speed of the spray gun. Therefore, the number of spraying particles on the rail surface of the spray gun decreased with the increase of the speed. When the nozzle height was 10 and 25 cm, the particle utilization rate increased with the increase of flow rate. When the nozzle height was 35 cm, the particle utilization rate increased firstly and then decreased with the increase of the gun moving speed. Compared with the nozzle of 1 m/s, the particle utilization rate of 9 m/s nozzle height at 10 and 25 cm increased by 8% and 7% respectively, while the particle utilization rate at 35 cm decreased by 8%. When 2 g viscous particles were sprayed on a single time, the adhesion enhancement effect of direct spraying SiO2 particles was lower than traditional sand spraying and electrostatic spraying. At electrostatic voltage of 90 kV, the maximum adhesion coefficient of SiO2 particles by electrostatic spraying was close to traditional sand spraying, and the action revolution was 400 revolutions, which was 8 times of that under direct spraying SiO2 particles and 2.2 times of that under traditional sand spraying. When the amount of sand was 5 g/min, the adhesion coefficient of SiO2 particles by 90 kV electrostatic spraying was 0.28, which was close to 0.3 of traditional sand spraying, and the wheel-rail damage was only 75% and 65% of that under traditional sand spraying. The damage to wheel-rail increased by direct spraying SiO2 particles was 66% and 57% of that under traditional sand spraying, but its adhesion coefficient was lower than 0.2. Electrostatic spraying technology can effectively improve the utilization rate of SiO2 particles on the rail surface and enhance the adsorption of particles on the rail surface. The adhesion coefficient of electrostatic spraying SiO2 particles is similar to that under traditional sanding, and the wheel-rail damage rate is lower. |
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