Abstract:
At present, the domestic solid friction modifier products are not yet mature, and there is a lack of systematic optimization of the formulation and preparation process. In order to achieve the friction control ability of the solid friction modifier, thermosetting phenolic resin was used as a binder, while molybdenum disulfide, polytetrafluoroethylene, and graphite were used as fillers in this study. The orthogonal test group of the formula was designed to obtain a solid friction modifier with excellent friction control ability and stability. The preparation steps of the solid friction modifier were mixing evenly, loading raw materials, cold isostatic pressing and heat treatment. The crushing strength test of solid friction modifier was carried out on a uniaxial compression device with a loading rate of 0.02 mm/s. The wheel-rail rolling contact simulation test was used to study the wheel-rail wear rate and rolling contact fatigue damage behavior under dry conditions and under the condition of applying the preferred solid friction modifier. The wheel-rail rolling contact simulation test were carried out under dry conditions and at the room temperature, The contact stress was 900 MPa, the wheel speed was 400 r/min, the rail speed was 395 r/min, and the creep rate was 2%. Firstly, the adhesion performance of solid friction modifier was tested, the specific methods were as follows, adding solid friction modifier for 2 minutes, then removing the solid friction modifier, recording the average adhesion coefficient of wheel and rail and the effective holding speed. Next, wheel-rail wear and rolling contact fatigue tests were carried out, the wheel/rail specimens experienced 5 000 dry cycles at room temperature, and then 20 000 dry cycles and 20 000 solid friction modifier cycles were carried out respectively. The total number of cycles under drying and solid friction modifier conditions was 25 000. The results showed that MoS
2 and PTFE as fillers had the most significant effect on the adhesion performance of solid friction modifiers, which could effectively improve the adhesion coefficient control ability of solid friction modifiers and effectively maintain the number of revolutions; PF as a binder had the most significant effect on the crushing strength of solid friction modifier. Based on the comprehensive adhesion performance, crushing strength and wheel-rail wear damage behavior, sample 1-3 # ( FM-A ) was the optimal ratio. At this time, the mass fractions of PF, MoS
2, PTFE and Graphite were 20.4%, 24.5%, 36.7% and 18.4%, respectively. After applying the solid friction modifier, a friction control film was formed at the wheel-rail contact interface, so that the friction between the wheel-rail was transformed into the friction between the wheel-rail-friction control film, the force between the wheel-rail was reduced, and the adhesion coefficient was reduced to a suitable range, and the wear rate of the wheel-rail sample was reduced. At the same time, when the fatigue crack passed through the wheel-rail contact zone, the fatigue crack opening was closed under the action of contact stress and solid friction modifier. Under these two effects, the solid friction modifier effectively reduced the surface damage, plastic deformation and fatigue damage behavior of the wheel and rail.