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摘要: 列车车轮踏面表层金属滚动接触疲劳是影响列车运行安全性和舒适性的核心科学问题. 借助金相显微镜、扫描电镜、透射电镜和显微硬度计，通过开展列车车轮材料的标准滚动接触疲劳试验，将标准接触疲劳样品的损伤行为与实际服役车轮的损伤行为对比分析，研究了列车车轮的滚动接触疲劳裂纹评价方法. 结果表明：车轮表层金属接触疲劳开裂是表层金属累积塑性变形损伤的结果；标准滚动接触疲劳样品剥离坑的深度恰好等于硬化层的深度，实际服役车轮剥离坑的深度小于硬化层的深度；将车轮表面的滚动接触疲劳裂纹命名为“三角形指向性裂纹”；初步建立了车轮表面滚动接触疲劳损伤程度的定量评价方法.Abstract: Rolling contact fatigue of the wheel tread, which affects the safety and comfort of train, is the key scientific issue. Standard rolling contact fatigue test was carried out for a common wheel material and the damage behaviors of the standard rolling contact fatigue sample and the service wheel were compared using metallographic microscope, scanning electron microscope, transmission electron microscope and microhardness tester. The rolling contact fatigue crack evaluation method of the train wheel were studied. The results show that the rolling contact fatigue cracking is the result of cumulative plastic deformation damage of the surface metal. The depth of the spalling pit of the standard rolling contact fatigue sample is exactly equal to the depth of the hardened layer. The depth of the spalling pit of the service wheel is less than the depth of the hardening layer. The rolling contact fatigue crack on the wheel surface is designated as “triangular directional crack. Quantitative evaluation method for rolling contact fatigue damage degree of wheel surface was proposed.
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图 1 滚动接触疲劳主试样(车轮)(a)和陪试样(钢轨) (b)的尺寸
Figure 1. Specimen size of (a) rolling contact fatigue main sample and (b) accompanying sample
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图 2 标准滚动接触疲劳试样表面损伤形貌
Figure 2. Surface morphology of the damaged standard rolling contact fatigue sample
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图 4 标准接触疲劳样品(a)和服役车轮(b)剥离坑截面形貌
Figure 4. Spalling pit cross-section topography of (a) the standard rolling contact fatigue sample and (b) service wheel
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图 5 标准接触疲劳样品表面未剥离(a) (b)及剥离坑(c) (d) (e)的微观形貌
Figure 5. Micro-morphology of the surface of the standard rolling contact fatigue sample (a) (b) without spalling and (c) (d) (e) spalling pit
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图 6 标准接触疲劳样品(a)和实际服役车轮(b)剥离坑左侧、中间和右侧近表层显微硬度梯度
Figure 6. Gradient microhardness of the left，middle and right sides of the spalling pit on (a) the standard rolling contact fatigue sample and (b) service wheel
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图 7 标准接触疲劳样品(a)和实际服役车轮(b)近表层微观组织形变规律
Figure 7. Near-surface microstructure deformation of (a) the standard rolling contact fatigue sample and (b) service wheel
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图 8 标准接触疲劳样品基体(a)(b)、形变层(c)(d)以及实际服役车轮形变层(e)(f)透射电镜观察
Figure 8. Transmission electron microscopic observation of (a) (b) the standard rolling contact fatigue sample matrix，(c) (d) deformed layer and (e) (f) service wheel deformed layer
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图 9 车轮试样表面金属滚动接触剥离剥落示意图
Figure 9. Schematic diagram of rolling contact fatigue spalling on wheel sample surface
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图 10 三角形指向性裂纹示意图(a)及统计图(b)
Figure 10. (a) Triangular directional crack diagram and (b) statistical diagram
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图 11 滚动接触疲劳样品裂纹扩展路径
Figure 11. Crack propagation path of the rolling contact fatigue sample
表 1 轮轨材料化学成分 (质量分数)
Table 1 Chemical composition of wheel and rail material (mass fraction)
Material w(C)/% w(Si)/% w(Mn)/% w(P)/% w(S)/% w(Cr)/% w(Cu)/% w(Mo)/% w(Ni)/% w(V)/% Wheel 0.56 0.35 0.78 0.007 0.007 0.15 0.14 0.03 0.12 <0.02 Rail 0.71 0.39 0.10 0.013 0.011 − − − − − 
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表 2 车轮材料机械性能
Table 2 Mechanical properties of wheel material
Yeild strength，σ0.2/MPa Tensile strength，σb/MPa Elongation/% Microhardness/HV 601 945 19 294
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表 3 滚动接触疲劳试验条件
Table 3 Rolling contact fatigue test condition
Contact stress/MPa Slip/% Speed/(r/min) Experimental environment Accompanying material 1 400 0.3 1 000 Water lubrication U71MnG
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表 4 滚动接触疲劳裂纹数据统计表
Table 4 Statistics data of the rolling contact fatigue crack
Crack number 1# 2# 3# 4# 5# 6# 7# 8# 9# 10# 11# 12# 13# Crack straight lengthd inward/μm 113 143 167 205 220 222 241 249 253 380 448 732 892 Crack propagation depth/μm 88 99 113 149 154 131 158 123 159 214 288 410 219 Crack propagation angle，β/(°) 42 29 42 46 52 33 39 33 40 33 42 37 27 Statistics (13) Mean value Maximum value Minimum value Range Mid-value Crack straight lengthd inward /μm 328 892 113 779 241 Crack propagation depth /μm 177 410 88 322 154 Crack propagation angle，β/(°) 38 52 27 25 39
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