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钢轨闪光焊接头单双频感应加热模拟

Simulation of single- and dual-frequency induction heating of rail flash-butt welded joints

  • 摘要: 钢轨闪光焊焊后感应正火处理对提高接头寿命、提升列车安全性具有重要意义.为了优化感应正火的工艺方式,文中建立了钢轨闪光焊接头感应正火电—磁—热双向耦合模型,利用数值模拟的方式研究了单频、双频感应正火的差异性.从关键节点的动态升温过程、接头横纵截面温度分布均匀性差异等角度进行了对比分析. 结果表明,在相同的平均线圈加热功率下,双频的加热效率提升了14%;轨底脚易达到热平衡,轨底区域的温度均匀性最差;双频加热可以显著提升温度均匀性,端面温度极差相比单频减小21 ℃;在完全覆盖焊后热影响区的条件下,双频减小热影响区宽度6 mm,有效减小了热处理后接头软化区宽度,提升接头性能.最后,对比了节点升温曲线试验实测值与模拟值的差异,证明了文中所建立模型的准确性与可靠性,为后续感应加热参数的优化提供指导.

     

    Abstract: Induction normalizing treatment after rail flash-butt welding is of critical importance to improve the service life of joints and enhance train safety. To optimize the induction normalizing process, an electro-magneto-thermal bidirectional coupling model for induction normalizing of rail flash-butt welded joints was established, and the differences between single- and dual-frequency induction normalizing were investigated by means of numerical simulation. A comparative analysis was conducted from the perspectives of the dynamic heating process of key nodes and the difference in temperature distribution uniformity in the transverse and longitudinal sections of the joint. The results show that under the same average coil heating power, the heating efficiency of dual-frequency heating increases by 14%; the rail foot easily reaches thermal equilibrium, and the temperature uniformity in the rail base region is the worst; dual-frequency heating can significantly improve temperature uniformity, and the maximum temperature difference on the end face is reduced by 21 ℃ compared with single-frequency heating; under the condition of fully covering the post-weld heat-affected zone, dual-frequency heating reduces the width of the heat-affected zone by 6 mm, which effectively reduces the width of the softened zone of the joint after heat treatment and improves the joint performance. Finally, the difference between the experimentally measured and simulated values of the node heating curves was compared, which proves the accuracy and reliability of the established model and provides guidance for the subsequent optimization of induction heating parameters.

     

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