Modelling and numerical analysis for rotatory friction welding of U75V steel rails

IF 2.5 4区材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY

Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications Pub Date : 2024-03-29 DOI:10.1177/14644207241242019

Han Zhang, Jiaqi Xie, Chang’an Li, Zhiming Zhu

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引用次数: 0

Abstract

This article presents a rotatory friction welding (RFW) method for U75V steel rail, aiming to mitigate challenges related to property discrepancies between the as-welded joints and the rail base metal (BM) and to narrow the heat-affected zone (HAZ) in conventional flash-butt welding (FBW) joints. A rotational intermediate plate is designed for rails with non-axisymmetric cross-sections, necessitating stationary during RFW. Advantages include achieving a relatively uniform welding heat input and maintaining the peak temperature of the contact interface near A1. To implement these concepts, a 2D finite element (FE) model for the RFW process of U75V rail steel rods was established and validated through experiments with identical process parameters. Microstructure predictions derived from continuous cooling transformation diagram confirm that ferrite microstructure is formed near A1 through rail steel RFW. Subsequently, a 3D FE model for intermediate plate RFW steel rails is developed to explore appropriate process parameter combinations. A suitable process parameters combination was identified, ensuring the peak temperature of the majority model contact interface does not exceed A1, resulting in a 76.7% reduction in HAZ (from ∼50 to 11.66 mm), and axial shortening of 8.10 mm, a significant decrease compared to the usual burn-off (30–40 mm) during FBW. These findings underscore the efficacy of this innovative welding solution and emphasize the significance of simulation technology in process optimization.

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U75V 钢轨旋转摩擦焊的建模和数值分析

本文介绍了一种用于 U75V 钢轨的旋转摩擦焊（RFW）方法，旨在减轻焊接接头与钢轨母材（BM）之间的性能差异带来的挑战，并缩小传统闪光对接焊（FBW）接头的热影响区（HAZ）。旋转中间板专为横截面非轴对称的钢轨而设计，因此在射频焊接过程中必须保持静止。其优点包括实现相对均匀的焊接热输入，并将接触界面的峰值温度保持在 A1 附近。为了实现这些概念，我们建立了 U75V 轨道钢棒射频焊接工艺的二维有限元 (FE) 模型，并通过相同工艺参数的实验进行了验证。根据连续冷却转变图得出的微观结构预测结果证实，通过轨道钢 RFW，在 A1 附近形成了铁素体微观结构。随后，建立了中间板 RFW 钢轨的三维有限元模型，以探索合适的工艺参数组合。最终确定了一个合适的工艺参数组合，确保大多数模型接触界面的峰值温度不超过 A1，从而使 HAZ 减少 76.7%（从 50 毫米减少到 11.66 毫米），轴向缩短 8.10 毫米，与 FBW 过程中通常的烧损（30-40 毫米）相比显著减少。这些研究结果证明了这种创新焊接方案的有效性，并强调了模拟技术在工艺优化中的重要意义。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 工程技术-材料科学：综合

CiteScore

4.70

自引率

8.30%

发文量

166

审稿时长

3 months

期刊介绍： The Journal of Materials: Design and Applications covers the usage and design of materials for application in an engineering context. The materials covered include metals, ceramics, and composites, as well as engineering polymers. "The Journal of Materials Design and Applications is dedicated to publishing papers of the highest quality, in a timely fashion, covering a variety of important areas in materials technology. The Journal''s publishers have a wealth of publishing expertise and ensure that authors are given exemplary service. Every attention is given to publishing the papers as quickly as possible. The Journal has an excellent international reputation, with a corresponding international Editorial Board from a large number of different materials areas and disciplines advising the Editor." Professor Bill Banks - University of Strathclyde, UK This journal is a member of the Committee on Publication Ethics (COPE).