WO2017107832A1 - 一种提高机车车轮耐磨性的超声加工方法及应用 - Google Patents

一种提高机车车轮耐磨性的超声加工方法及应用 Download PDF

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WO2017107832A1
WO2017107832A1 PCT/CN2016/109987 CN2016109987W WO2017107832A1 WO 2017107832 A1 WO2017107832 A1 WO 2017107832A1 CN 2016109987 W CN2016109987 W CN 2016109987W WO 2017107832 A1 WO2017107832 A1 WO 2017107832A1
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Prior art keywords
ultrasonic machining
wheel
locomotive wheel
ultrasonic
locomotive
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PCT/CN2016/109987
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English (en)
French (fr)
Inventor
赵显华
谢祥科
刘秀娟
赵志明
马冉
王爱福
王阳
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山东华云机电科技有限公司
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Priority claimed from CN201510971350.7A external-priority patent/CN106881559A/zh
Priority claimed from CN201510975217.9A external-priority patent/CN106881560A/zh
Application filed by 山东华云机电科技有限公司 filed Critical 山东华云机电科技有限公司
Priority to US15/770,830 priority Critical patent/US20180318972A1/en
Priority to EP16877643.3A priority patent/EP3395495A4/en
Publication of WO2017107832A1 publication Critical patent/WO2017107832A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P9/00—Treating or finishing surfaces mechanically, with or without calibrating, primarily to resist wear or impact, e.g. smoothing or roughening turbine blades or bearings; Features of such surfaces not otherwise provided for, their treatment being unspecified
    • B23P9/04—Treating or finishing by hammering or applying repeated pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P9/00—Treating or finishing surfaces mechanically, with or without calibrating, primarily to resist wear or impact, e.g. smoothing or roughening turbine blades or bearings; Features of such surfaces not otherwise provided for, their treatment being unspecified
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
    • B24B1/04—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes subjecting the grinding or polishing tools, the abrading or polishing medium or work to vibration, e.g. grinding with ultrasonic frequency
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/06—Surface hardening
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/34—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tyres; for rims

Definitions

  • the invention relates to an ultrasonic processing method and an application for improving the wear resistance of a locomotive wheel, and belongs to the technical field of ultrasonic metal surface processing.
  • railway transportation is based on the adhesive traction force and the adhesive braking force generated by the wheel-rail interaction to realize the train operation.
  • the energy and energy consumed in the railway transportation due to friction and wear between the wheel and rail are many, and the cost is also large.
  • rail transport moves toward high speed and heavy loads, the risk of accidents due to friction and wear is also increasing.
  • the various damages formed by the wheel-rail contact surface not only shorten the service life of the wheel-rail, but also cause the wheelset and the rail to fail after severe wear and endanger the driving safety.
  • Wheels are an important part of the railway rolling stock. During train operation, wheel rolling causes wear on the wheel tread and rim, and sliding the wheel on the rail can also cause tread damage. According to the failure analysis statistics, the main types of wheel damage of railway rolling stock are rim wear, rim fatigue crack, thermal damage, wheel tread stripping and cracking.
  • the rim is an important part of the wheel, so that the wheel can reliably pass the curve and the ballast, which plays an important role in the safety and stability of the train.
  • the abnormal wear of the rim often changes the normal wheel-rail relationship and reduces Vehicle dynamic performance and ride comfort.
  • the force of the rail on the wheelset is partly at the tread of the wheel, and the other part acts on the rim of the wheelset. At this time, the wear of the rim is the fastest.
  • the basis of the repair of the wheel pair of the machine is judged by detecting the thickness of the rim. When the thickness of the rim is reduced to a certain value, the wheel pair needs to be repaired, otherwise the operation safety of the train will be affected.
  • the machining method adopted by the machine wheel for the repairing process is CNC turning, that is, when the thickness of the wheel rim is reduced to a certain value, the diameter of the wheel is reduced by CNC turning, so that the thickness of the rim after turning is restored to the required value. Value. After turning, no further surface treatments are carried out.
  • the surface roughness of the rim portion after turning is generally about 6.3.
  • the surface of the rim after turning is in a tensile stress state, and the presence of tensile stress causes the initial wear of the wheel pair to be very fast, so that the service life of the wheel pair is greatly reduced.
  • the present invention provides an ultrasonic machining method for improving the wear resistance of a locomotive wheel.
  • the invention also provides for the use of the above processing methods.
  • An ultrasonic machining method for improving wear resistance of a locomotive wheel includes: ultrasonically machining a rim of a locomotive wheel, that is, ultrasonically machining a surface of a rim that rotates along the main shaft by using an ultrasonic machining tool head.
  • the ultrasonic machining method for improving the wear resistance of a locomotive wheel includes ultrasonically machining the rim of the locomotive wheel while ultrasonically machining the rim of the locomotive wheel, that is, using an ultrasonic machining tool head.
  • the surface of the tread that rotates along the main axis is ultrasonically machined.
  • the locomotive wheel is a new factory locomotive wheel or a worn locomotive wheel.
  • the rim and/or the tread of the semi-finished locomotive wheel are ultrasonically machined when the locomotive wheel is a worn locomotive wheel.
  • the rim and/or the tread of the locomotive wheel are subjected to turning semi-finishing, even if the surface roughness of the rim and/or the tread is between 3.2 and 10 ⁇ m.
  • the parameters of the ultrasonic machining are: the rotational speed of the main shaft is 5-45 r/min; the feed amount is 0.03-0.2 mm/r; and the pressure of the ultrasonic machining tool head to the machined surface is 300-3000 N.
  • the parameters of the ultrasonic machining are: the rotational speed of the main shaft is 19 r/min; the feed amount is 0.1 mm/r; and the pressure of the ultrasonic machining tool head to the machined surface is 1200 N.
  • the surface of the rim that rotates along the main axis and/or the surface of the tread is ultrasonically machined using an ultrasonic machining tool head, the number of round trips of the ultrasonic machining being 1-3 times.
  • the surface of the rim that rotates along the main axis and/or the surface of the tread is ultrasonically machined using an ultrasonic machining tool head having an amplitude of 5-25 ⁇ m.
  • Ultrasonic machining is performed on the area where the locomotive wheel corresponds to wear.
  • the parameters of the ultrasonic machining are: the spindle speed is 5-45r/min; the feed amount is 0.03-0.2mm/r; the ultrasonic processing tool head is to be pressed against the machined surface. It is 300-3000N.
  • the abraded area is subjected to turning semi-finishing before ultrasonic machining, even if its surface roughness is between 3.2 and 10 ⁇ m.
  • the parameters of the ultrasonic machining are: the rotational speed of the main shaft is 19 r/min; the feed amount is 0.1 mm/r; and the pressure of the ultrasonic machining tool head to the machined surface is 1200 N.
  • the ultrasonic processing method of the invention can solve the phenomenon that the friction and wear of the wheel and rail of the locomotive vehicle is serious and the repair cost is high.
  • the ultrasonic processing method of the invention not only can process the locomotive wheels of the factory, but also repair and repair the worn locomotive wheels, wherein the surface of the locomotive wheel rim and/or the tread is subjected to ultrasonic processing. After processing, the tensile stress of the metal surface of the rim and/or the tread becomes compressive stress, the surface roughness value is greatly reduced, and the ideal compressive stress is preset on the surface thereof, and the surface hardness is improved.
  • the grain is refined, the wear resistance is greatly improved, the wheel-rail contact relationship is improved, and the rolling contact fatigue damage of the wheel pair is reduced. Reduce the wear rate of the wheel, extend the repair cycle and service life of the wheel.
  • FIG. 1 is a schematic view showing the processing of a locomotive wheel by using an ultrasonic processing method according to the present invention
  • FIG. 2 is a schematic view of a region to be ultrasonically processed on a locomotive wheel, wherein a broken line portion is a region to be processed;
  • An ultrasonic machining method for improving the wear resistance of a locomotive wheel comprises: ultrasonically machining a rim 2 of a locomotive wheel, that is, ultrasonically machining the surface of the rim 2 rotating along the main shaft by means of the ultrasonic machining tool head 1.
  • the locomotive wheel is a new factory locomotive wheel.
  • An ultrasonic processing method for improving the wear resistance of a locomotive wheel according to Embodiment 1 the difference being that the parameters of the ultrasonic machining are: the rotation speed of the main shaft is 5-45 r/min; the feed amount is 0.03-0.2 mm. /r; The pressure of the ultrasonic machining tool head on the machined surface is 300-3000N.
  • An ultrasonic machining method for improving the wear resistance of a locomotive wheel as described in Embodiment 1 is that the locomotive wheel is a worn locomotive wheel.
  • the rim of the semi-finished locomotive wheel is ultrasonically machined.
  • the rim of the locomotive wheel is turned semi-finished even if the rim has a surface roughness of 3.2-10 ⁇ m.
  • An ultrasonic machining method for improving the wear resistance of a locomotive wheel as described in Embodiments 1-3 the difference being that the surface of the rim 2 rotating along the main shaft is ultrasonically processed by the ultrasonic machining tool head 1, the ultrasonic machining The number of round trips is 1-3 times.
  • An ultrasonic machining method for improving the wear resistance of a locomotive wheel as described in Embodiments 1-3 the difference being that the surface of the rim 2 rotating along the main shaft is ultrasonically processed by the ultrasonic machining tool head 1, the ultrasonic machining The amplitude is 5-25 ⁇ m.
  • An ultrasonic processing method for improving the wear resistance of a locomotive wheel comprising: ultrasonically machining the rim 2 and the tread 3 of the locomotive wheel, that is, using the ultrasonic machining tool head 1 to perform the surface of the rim 2 and the tread 3 that rotate along the main shaft.
  • the locomotive wheel is a new factory locomotive wheel.
  • An ultrasonic machining method for improving the wear resistance of a locomotive wheel according to Embodiment 6 is characterized in that the ultrasonic machining parameters are: a spindle speed of 5-45 r/min; and a feed amount of 0.03-0.2 mm /r; The pressure of the ultrasonic machining tool head on the machined surface is 300-3000N.
  • An ultrasonic machining method for improving the wear resistance of a locomotive wheel as described in Embodiment 6 is that the locomotive wheel is a worn locomotive wheel.
  • the rim 2 and the tread 3 of the semi-finished locomotive wheel are ultrasonically machined.
  • the rim 2 and the tread 3 of the locomotive wheel are subjected to turning semi-finishing even if the surface roughness of the rim 2 and the tread 3 is 3.2-10 ⁇ m.
  • the ultrasonic machining tool head 1 has a pressure of 1200 N on the surface to be machined.
  • the pressure of the ultrasonic processing tool head to be processed is changed to be 100N, 300N, respectively. 1200N, 3000N, 3500N, after machining, the residual stress of the wheel rim is as follows:
  • FIG. 3a is a metallographic diagram of the surface of the rim processed when the pressure of the ultrasonic processing tool head to the surface to be processed is 100N;
  • FIG. 3b is a metallographic diagram of the surface of the rim processed when the pressure of the ultrasonic processing tool head to the surface to be processed is 300N;
  • Figure 3c is a metallographic diagram of the surface of the rim processed when the pressure of the ultrasonic machining tool head to the surface to be machined is 1200N;
  • Figure 3d is a metallographic diagram of the surface of the rim processed when the pressure of the ultrasonic machining tool head to the machined surface is 3000N;
  • Figure 3e is a metallographic diagram of the surface of the rim processed when the pressure of the ultrasonic machining tool head to the machined surface is 3500N.
  • Ultrasonic machining is performed on the area where the locomotive wheel corresponds to wear.
  • the parameters of the ultrasonic machining are: the spindle speed is 5-45r/min; the feed amount is 0.03-0.2mm/r; the ultrasonic processing tool head is to be pressed against the machined surface. It is 300-3000N.
  • Embodiment 10 An application for improving the wear resistance of a locomotive wheel as described in Embodiment 10, which differs in that it is subjected to turning semi-finishing before ultrasonic machining in the worn region, even if its surface roughness is 3.2- 10 ⁇ m.
  • the test comparison of the processed locomotive wheels in the embodiment 9 is as follows:
  • the factors affecting the machining effect are the spindle speed, feed rate and pressure.
  • the above three factors are taken as test factors, which are respectively recorded as A (corresponding to the spindle speed) and B ( Corresponding to the feed amount) and C (corresponding pressure).
  • each factor is determined to take three levels, namely:
  • L 9 (3 4 ) or L 27 (3 13 ) can be selected; because this experiment only examines the influence of three factors on the surface machining effect of the locomotive wheel, and does not examine the interaction between the factors, so it is selected.
  • L 9 (3 4 ) orthogonal table L 9 (3 4 ) orthogonal table.
  • the spindle speed is 19r/min
  • the feed rate is 0.1mm/r
  • the total wear rate of the rail and the wheel is the smallest when the pressure is 1200N.
  • the horizontal combination is A 2 B 2 C 2 .
  • the superior levels of factor B and factor C are B 2 and C 2 , respectively . Therefore, the combination is preferably A 2 B 2 C 2 .
  • the factor B feed has the greatest influence on the sliding wear rate.
  • the superior levels of factor B and factor C are B 2 and C 2 , respectively . Therefore, the combination is preferably A 2 B 2 C 2 .
  • the factor B feed has the greatest influence on the rolling wear rate.
  • the results from the rate of wear and the sliding wear rate of the rolling results are preferably a combination of A 2 B 2 C 2, the workpiece thus selected parameter A 2 B 2 C 2 corresponding friction wear test.
  • the test results show that the wear resistance of the wheel specimens is improved by more than 50% in the rolling wear and sliding wear tests after surface treatment. At the same time, the wear rate of the rail samples after surface treatment is also significantly reduced.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Heat Treatment Of Articles (AREA)
  • Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)

Abstract

一种提高机车车轮耐磨性的超声加工方法，包括：利用超声加工工具头(1)对沿主轴旋转的轮缘(2)和/或踏面(3)的表面进行超声加工。这种超声加工方法能够解决目前机车车辆轮轨摩擦磨损严重、修理费用高的现象。此外，不但可以对刚出厂的机车车轮进行加工，还能对磨损后的机车车轮进行修复加工，其中，采用超声加工方法对机车车轮轮缘部和/或踏面部进行表面加工后，会使其金属表面的拉应力变成压应力，表面粗糙度值会大大降低的同时，在其表面预置理想的压应力，其表面的硬度得到提高，晶粒得到细化，耐磨性大幅提高，改善轮轨接触关系，减小轮对的滚动接触疲劳损伤，减小车轮的磨耗速率，延长车轮的镟修周期以及使用寿命。

Description

一种提高机车车轮耐磨性的超声加工方法及应用 技术领域
本发明涉及一种提高机车车轮耐磨性的超声加工方法及应用，属于超声金属表面加工的技术领域。
背景技术
众所周知，铁路运输是基于轮轨相互作用产生的黏着牵引力和黏着制动力以实现列车运行的，轮轨间因摩擦磨损在铁路运输中消耗的能量和能源很多，耗资也很大。随着铁路运输向高速、重载发展，因摩擦磨损所致的事故风险也在增加。轮轨接触面形成的各种损伤，不但缩短了轮轨的使用寿命，在严重磨损后还会导致轮对和钢轨失效，危及行车安全。
车轮是铁路机车车辆的重要走行部件。在列车运行中，车轮滚动会使车轮踏面和轮缘发生磨耗，而车轮在钢轨上滑动也会造成踏面损伤。据失效分析统计，铁道机车车辆车轮损伤的主要类型有轮缘磨耗、轮辋疲劳裂纹、热损伤、车轮踏面剥离和崩裂等。
轮缘是车轮上的重要组成部分，使车轮能可靠地通过曲线和道岔，对列车行驶的安全性及稳定性具有重要作用，轮缘的异常磨耗往往会使正常的轮轨关系发生改变，降低车辆动力性能和乘车舒适度。
火车在经过曲线和道岔时，钢轨对轮对的作用力一部分在车轮的踏面处，另一部分作用于轮对的轮缘部，此时，轮缘部的磨损最快。机车轮对的镟修依据，是通过检测轮缘的厚度来判断，当轮缘的厚度减小到一个确定值时，就需要对轮对进行镟修，否则会影响列车的运行安全。
机车轮对镟修加工现采用的加工方式为数控车削，即当轮对轮缘厚度减小到一定值时，通过数控车削，将车轮直径减小，使车削后的轮缘厚度恢复到要求的数值。经过车削后，不再进行其它的表面处理。经车削后的轮缘部表面粗糙度值一般在Ra值6.3左右。经车削后的轮缘表面处于拉应力状态，拉应力的存在使得轮对初期磨损非常快，从而使轮对的使用寿命大大降低。
发明内容
针对现有技术的不足，本发明提供一种提高机车车轮耐磨性的超声加工方法。
本发明还提供上述加工方法的应用。
本发明的技术方案如下：
一种提高机车车轮耐磨性的超声加工方法，包括：对机车车轮的轮缘进行超声加工，即利用超声加工工具头对沿主轴旋转的轮缘的表面进行超声加工。
根据本发明优选的，所述提高机车车轮耐磨性的超声加工方法，包括，在对机车车轮的轮缘进行超声加工的同时，还对机车车轮的踏面进行超声加工，即利用超声加工工具头对沿主轴旋转的踏面的表面进行超声加工。
根据本发明优选的，所述机车车轮是新出厂的机车车轮或是磨损后的机车车轮。
根据本发明优选的，当所述机车车轮是磨损后的机车车轮时，对经半精加工后的机车车轮的轮缘和/或踏面进行超声加工。
根据本发明优选的，对机车车轮的轮缘和/或踏面进行车削半精加工，即使所述轮缘和/或踏面的表面粗糙度为3.2-10μm。
根据本发明优选的，所述超声加工的参数为：主轴的转速为5-45r/min；进给量为0.03-0.2mm/r；超声加工工具头对待加工表面的压力为300-3000N。
根据本发明优选的，所述超声加工的参数为：主轴的转速为19r/min；进给量为0.1mm/r；超声加工工具头对待加工表面的压力为1200N。
根据本发明优选的，利用超声加工工具头对沿主轴旋转的轮缘的表面和/或踏面的表面进行超声加工，所述超声加工的往返次数为1-3次。
根据本发明优选的，利用超声加工工具头对沿主轴旋转的轮缘的表面和/或踏面的表面进行超声加工，所述超声加工的振幅为5-25μm。
一种利用如上述超声加工方法以提高机车车轮耐磨性的应用：
针对机车车轮对应存在磨损的区域进行超声加工，所述超声加工的参数为：主轴的转速为5-45r/min；进给量为0.03-0.2mm/r；超声加工工具头对待加工表面的压力为300-3000N。
根据本发明优选的，在所述磨损的区域进行超声加工之前，对其进行车削半精加工，即使其的表面粗糙度为3.2-10μm。
根据本发明优选的，所述超声加工的参数为：主轴的转速为19r/min；进给量为0.1mm/r；超声加工工具头对待加工表面的压力为1200N。
本发明的优势在于：
本发明所述的超声加工方法能够解决目前机车车辆轮轨摩擦磨损严重、修理费用高的现象。本发明所述的超声加工方法不但可以对刚出厂的机车车轮进行加工，还能对磨损后的机车车轮进行修复加工，其中，采用超声加工方法对机车车轮轮缘部和/或踏面部进行表面加工后，会使轮缘和/或踏面的金属表面的拉应力变成压应力，表面粗糙度值会大大降低的同时，在其表面预置理想的压应力，其表面的硬度得到了提高，晶粒得到了细化，耐磨性大幅提高，改善了轮轨接触关系，减小轮对的滚动接触疲劳损伤。减小车轮的磨耗速率，延长车轮的镟修周期以及使用寿命。
附图说明
图1是本发明所述利用超声加工方法对机车车轮的加工示意图；
图2是机车车轮上待超声加工的区域示意图，其中虚线部分为待加工区域；
图3a、图3b、图3c、图3d、图3e、为本发明中，通过改变超声加工压力对待加工表面超声加工后的金相图；
在图1和图2中，1、超声加工工具头；2、轮缘；3、踏面；4、虚线是指利用超声加工的区域。
具体实施方式
下面结合实施例和说明书附图对本发明做详细的说明，但不限于此。
如图1-2所示。
实施例1、
一种提高机车车轮耐磨性的超声加工方法，包括：对机车车轮的轮缘2进行超声加工，即利用超声加工工具头1对沿主轴旋转的轮缘2的表面进行超声加工。所述机车车轮是新出厂的机车车轮。
实施例2、
如实施例1所述的一种提高机车车轮耐磨性的超声加工方法，其区别在于，所述超声加工的参数为：主轴的转速为5-45r/min；进给量为0.03-0.2mm/r；超声加工工具头对待加工表面的压力为300-3000N。
实施例3、
如实施例1所述的一种提高机车车轮耐磨性的超声加工方法，其区别在于，所述机车车轮是磨损后的机车车轮。
当所述机车车轮是磨损后的机车车轮时，对经半精加工后的机车车轮的轮缘进行超声加工。
对机车车轮的轮缘进行车削半精加工，即使所述轮缘的表面粗糙度为3.2-10μm。
实施例4、
如实施例1-3所述的一种提高机车车轮耐磨性的超声加工方法，其区别在于，利用超声加工工具头1对沿主轴旋转的轮缘2的表面进行超声加工，所述超声加工的往返次数为1-3次。
实施例5、
如实施例1-3所述的一种提高机车车轮耐磨性的超声加工方法，其区别在于，利用超声加工工具头1对沿主轴旋转的轮缘2的表面进行超声加工，所述超声加工的振幅为5-25μm。
实施例6、
一种提高机车车轮耐磨性的超声加工方法，包括：对机车车轮的轮缘2和踏面3进行超声加工，即利用超声加工工具头1对沿主轴旋转的轮缘2和踏面3的表面进行超声加工。所述机车车轮是新出厂的机车车轮。
实施例7、
如实施例6所述的一种提高机车车轮耐磨性的超声加工方法，其区别在于，所述超声加工的参数为：主轴的转速为5-45r/min；进给量为0.03-0.2mm/r；超声加工工具头对待加工表面的压力为300-3000N。
实施例8、
如实施例6所述的一种提高机车车轮耐磨性的超声加工方法，其区别在于，所述机车车轮是磨损后的机车车轮。
当所述机车车轮是磨损后的机车车轮时，对经半精加工后的机车车轮的轮缘2和踏面3进行超声加工。
对机车车轮的轮缘2和踏面3进行车削半精加工，即使所述轮缘2和踏面3的表面粗糙度为3.2-10μm。
实施例9、
如实施例1-8所述的一种提高机车车轮耐磨性的超声加工方法，其区别在于，所述超声加工的参数为：主轴的转速为19r/min；进给量为0.1mm/r；超声加工工具头1对待加工表面的压力为1200N。
如本实施例，改变超声加工工具头对待加工表面的压力分别为：100N、300N、 1200N、3000N、3500N，经加工后所述车轮轮缘的残余应力均值如下：
Figure PCTCN2016109987-appb-000001
其中图3a为超声加工工具头对待加工表面的压力为100N时，所加工出的轮缘表面的金相图；
其中图3b为超声加工工具头对待加工表面的压力为300N时，所加工出的轮缘表面的金相图；
其中图3c为超声加工工具头对待加工表面的压力为1200N时，所加工出的轮缘表面的金相图；
其中图3d为超声加工工具头对待加工表面的压力为3000N时，所加工出的轮缘表面的金相图；
其中图3e为超声加工工具头对待加工表面的压力为3500N时，所加工出的轮缘表面的金相图。
实施例10、
一种利用如实施例1-9所述超声加工方法以提高机车车轮耐磨性的应用：
针对机车车轮对应存在磨损的区域进行超声加工，所述超声加工的参数为：主轴的转速为5-45r/min；进给量为0.03-0.2mm/r；超声加工工具头对待加工表面的压力为300-3000N。
实施例11、
一种利用如实施例10所述提高机车车轮耐磨性的应用，其区别在于，在所述磨损的区域进行超声加工之前，对其进行车削半精加工，即使其的表面粗糙度为3.2-10μm。
实施例12、
一种利用如实施例10所述提高机车车轮耐磨性的应用，其区别在于，所述超声加工的参数为：主轴的转速为19r/min；进给量为0.1mm/r；超声加工工具头1对待加工表面的压力为1200N。
试验对比例：
对实施例9中加工后的机车车轮进行试验对比如下：
在机车车轮的表面进行超声加工的过程中，影响加工效果的因素有主轴转速、进给量和压力，本试验将上述三个因素作为试验因素，分别记作A(对应主轴转速)、B(对应进给量)和C(对应压力)。本试验对比例中确定各因素分别取三个水平，即：
A(对应主轴转速)对应的三个标准包括：A1＝5r/min；A2＝19r/min；A3＝45r/min；
B(对应进给量)对应的三个标准包括：B1＝0.03mm/r；B2＝0.1mm/r；B3＝0.2mm/r；
C(对应压力)对应的三个标准包括：C1＝300N；C2＝1200N；C3＝3000N。
表1：超声加工应用于机车车轮表面耐磨性能试验参数
Figure PCTCN2016109987-appb-000002
由表1的试验数据可知，当A(对应主轴转速)对应A2＝19r/min、B(对应进给量)对应B2＝0.1mm/r、C(对应压力)对应C2＝1200N时，得到最佳的表面粗糙度、硬度、硬度提高均是最高。
下面再结合正交试验对上述数据进行分析，以验证是否也是当A(对应主轴转速)对应A2＝19r/min、B(对应进给量)对应B2＝0.1mm/r、C(对应压力)对应C2＝1200N时，得到最佳的表面粗糙度、硬度、硬度提高均是最高。
正交试验数据分析：
A1＝5r/min；A2＝19r/min；A3＝45r/min；
B(对应进给量)对应的三个标准包括：B1＝0.03mm/r；B2＝0.1mm/r；B3＝0.2mm/r；
C(对应压力)对应的三个标准包括：C1＝300N；C2＝1200N；C3＝3000N。
表2：三个试验因素水平表
Figure PCTCN2016109987-appb-000003
按照正交试验数据方法，可以选用L9(34)或L27(313)；因本试验仅考察三个因素对机车车轮表面加工效果的影响，不考察因素间的交互作用，故选用L9(34)正交表。
在L9(34)正交表中填入各因素的水平值，便形成了正交试验方案(表3)：
表3：正交试验方案
Figure PCTCN2016109987-appb-000004
Figure PCTCN2016109987-appb-000005
从表3中直观可以看出，主轴转速为19r/min，进给量为0.1mm/r，压力为1200N时钢轨与车轮的总磨损率最小，其水平组合为A2B2C2。
对试验的结果进行分析
1.从滑动磨损的总磨损率进行分析，表4
Figure PCTCN2016109987-appb-000006
对于因素A主轴转速来说，可以看出k1＞k3＞k2。由于结果指标为磨损率，期望得到磨损率的最小值，所以可以判断A2为A因素的优水平。
同理可以得到因素B和因素C的优水平分别为B2和C2。因此优组合为A2B2C2。另外从极差R的大小可以看出，在三个实验因素中，因素B进给量对滑动磨损率的影响最大。
2.从滚动磨损的总磨损率进行分析，表5
Figure PCTCN2016109987-appb-000007
对于因素A主轴转速来说，可以看出k1＞k3＞k2。由于结果指标为磨损率，期望得到磨损率的最小值，所以可以判断A2为A因素的优水平。
同理可以得到因素B和因素C的优水平分别为B2和C2。因此优组合为A2B2C2。另外从极差R的大小可以看出，在三个实验因素中，因素B进给量对滚动磨损率的影响最大。
由滑动磨损率的分析结果及滚动磨损率的结果可知，优组合均为A2B2C2，因此选取A2B2C2对应的参数加工的工件进行摩擦磨损试验。试验结果表明，经表面处理后，在滚动磨损和滑动磨损试验中车轮试样的耐磨性均提高了50％以上，同时，经表面处理后的车轮对钢轨试样的磨损率也明显降低。

Claims (10)

  1. 一种提高机车车轮耐磨性的超声加工方法，其特征在于，该方法包括：对机车车轮的轮缘进行超声加工，即利用超声加工工具头对沿主轴旋转的轮缘的表面进行超声加工。
  2. 根据权利要求1所述的一种提高机车车轮耐磨性的超声加工方法，其特征在于，所述加工方法在对机车车轮的轮缘进行超声加工的同时，还对机车车轮的踏面进行超声加工，即利用超声加工工具头对沿主轴旋转的踏面的表面进行超声加工。
  3. 根据权利要求1或2所述的一种提高机车车轮耐磨性的超声加工方法，其特征在于，所述机车车轮是新出厂的机车车轮或是磨损后的机车车轮。
  4. 根据权利要求1或2所述的一种提高机车车轮耐磨性的超声加工方法，其特征在于，当所述机车车轮是磨损后的机车车轮时，对经半精加工后的机车车轮的轮缘和/或踏面进行超声加工。
  5. 根据权利要求1或2所述的一种提高机车车轮耐磨性的超声加工方法，其特征在于，对机车车轮的轮缘和/或踏面进行车削半精加工，即使所述轮缘和/或踏面的表面粗糙度为3.2-10μm。
  6. 根据权利要求1或2所述的一种提高机车车轮耐磨性的超声加工方法，其特征在于，所述超声加工的参数为：主轴的转速为5-45r/min；进给量为0.03-0.2mm/r；超声加工工具头对待加工表面的压力为300-3000N。
  7. 根据权利要求1或2所述的一种提高机车车轮耐磨性的超声加工方法，其特征在于，所述超声加工的参数为：主轴的转速为19r/min；进给量为0.1mm/r；超声加工工具头对待加工表面的压力为1200N。
  8. 根据权利要求1或2所述的一种提高机车车轮耐磨性的超声加工方法，其特征在于，利用超声加工工具头对沿主轴旋转的轮缘的表面和/或踏面的表面进行超声加工，所述超声加工的往返次数为1-3次。
  9. 根据权利要求1或2所述的一种提高机车车轮耐磨性的超声加工方法，其特征在于，利用超声加工工具头对沿主轴旋转的轮缘的表面和/或踏面的表面进行超声加工，所述超声加工的振幅为5-25μm。
  10. 一种利用如权利要求1或2所述超声加工方法以提高机车车轮耐磨性的 应用：
    针对机车车轮对应存在磨损的区域进行超声加工，所述超声加工的参数为：主轴的转速为5-45r/min；进给量为0.03-0.2mm/r；超声加工工具头对待加工表面的压力为300-3000N；
    优选的，在所述磨损的区域进行超声加工之前，对其进行车削半精加工，即使其的表面粗糙度为3.2-10μm；所述超声加工的参数为：主轴的转速为19r/min；进给量为0.1mm/r；超声加工工具头对待加工表面的压力为1200N。
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