高速列车制动盘残余应力数值仿真及试验验证

通过建立极坐标下热应力平衡方程,求解得到制动盘热应力表达式;采用有限元分析法对初速度为270 km/h的高速列车合金锻钢制动盘紧急制动工况后的残余应力进行数值模拟分析。结果表明,较大的残余拉应力分布在摩擦面上,随厚度方向逐渐减小,最大残余应力值542 MPa,且在摩擦环内应力分布并不均匀。用X射线应力测定仪对制动盘摩擦环的残余应力进行测定,试验测得最大残余应力值为348.4 MPa。仿真结果和试验结果相差35.7%,结果虽相差较大,但变化趋势基本一致,且合乎实际。理论仿真结果能直接用于制动盘疲劳裂纹扩展评定和寿命预测。

Numerical Simulation and Test of Brake Disc Residual Stress on High-speed Train

A thermal stress balance equation on brake disc is established and solved in a polar system.Using finite element,the numerical simulation on the residual stress of alloy forged steel brake disc is done after the emergency braking condition at 270 km /h.The simulation results showed that the larger residual stress value is in the surface friction,and friction ring in stress distribution is not uniform.The largest value is in the friction face vicinity with the thickness direction gradually decreased.The largest residual stress value is 542 MPa.Residual stress of brake disc was measured by x-ray analyzer,and the largest measuring residual stress value is 348.4 MPa.The difference is 35.7 percent between simulation results and test result.It is large,but realistic.The research results provided a direct basis for evaluating crack growth and forecasting lifespan of the brake disc for high-speed train.