Metal carbon fiber composite structure railway wheel and manufacturing method thereof

Abstract

The invention discloses a railway wheel of a metal carbon fiber composite structure and a manufacturing method, the railway wheel of the metal carbon fiber composite structure comprises a metal wheel core, a wheel disk, a metal wheel rim and a positioning assembly, the metal wheel core is sleeved with the wheel disk in a limiting mode, the wheel disk is sleeved with the metal wheel rim, and the positioning assembly is arranged between the wheel disk and the metal wheel rim. The positioning assembly is used for limiting the spoke plate and the metal wheel rim and comprises a positioning block and a positioning pin, the positioning block is arranged between the spoke plate and the metal wheel rim, and the positioning pin penetrates through the positioning block to be fixedly connected with the spoke plate. The overall structure is simple, the wheel disks are made of carbon fibers, the overall strength of the wheel is effectively guaranteed, meanwhile, the overall weight and the noise reduction effect of the railway wheel are effectively reduced, the metal wheel core, the wheel disks and the metal wheel rims are connected in an assembled mode, the replacement cost is effectively reduced, and waste is avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of railway wheel manufacturing, and in particular relates to a railway wheel with a metal-carbon fiber composite structure and a manufacturing method thereof. Background Art

[0002] Railway wheels are a vital component of trains, rolling on rails and bearing the entire vehicle load. Therefore, wheel materials must possess high strength, high hardness, and excellent wear and heat resistance. Existing railway wheels are often made of solid steel, which has the following drawbacks: excessive weight (conventional railway wheels exceed 300kg), resulting in increased unsprung mass and severely impacting train efficiency; noise levels exceeding 85dB during operation, severely impacting the environment along the line; and, over long-term use, when railway wheels wear to a certain limit, they must be replaced, which results in the entire wheel being scrapped, resulting in significant cost waste. Summary of the Invention

[0003] In order to at least partially solve the technical problems existing in the above-mentioned prior art, the present invention provides a railway wheel with a metal-carbon fiber composite structure and a manufacturing method.

[0004] The metal-carbon-fiber composite railway wheel of the present invention comprises a metal wheel core, a spoke plate, a metal wheel hoop, and a positioning assembly. The spoke plate is sleeved on the metal wheel core, the metal wheel hoop is sleeved on the spoke plate, and the positioning assembly is arranged between the spoke plate and the metal wheel hoop to limit the position of the spoke plate and the metal wheel hoop, wherein:

[0005] The positioning assembly includes a positioning block and a positioning pin. The positioning block is arranged between the spoke plate and the metal hoop. The positioning pin passes through the positioning block and is connected and fixed to the spoke plate.

[0006] Furthermore, in the above-mentioned metal-carbon-fiber composite railway wheel, the metal wheel hoop is arranged in a circular ring shape, 8 first grooves are evenly opened on the inner side of the upper end of the metal wheel hoop along the circumferential direction, and a limiting groove is arranged on the inner side of the lower end of the metal wheel hoop.

[0007] Furthermore, in the above-mentioned metal-carbon-fiber composite railway wheel, the spoke plate is arranged in a circular ring shape, and 8 second grooves are evenly opened in the circumferential direction at the upper end of the outer ring of the spoke plate. The second grooves correspond to the first grooves to form a positioning groove, and the positioning groove matches the positioning block. The positioning block is engaged with the positioning groove. The positioning pin passes through the positioning block and is threadedly engaged with the spoke plate. A limiting step is provided at the lower end of the outer ring of the spoke plate. The limiting step is complementary to the limiting groove and is engaged with the limiting groove.

[0008] Furthermore, in the above-mentioned metal-carbon-fiber composite railway wheel, the metal wheel core is arranged in a circular ring shape, the outer ring of the metal wheel core and the inner ring of the spoke plate are both arranged in a polygonal structure, the metal wheel core is matched with the fixed spoke plate, and the metal wheel core and the fixed spoke plate are interference fit.

[0009] Furthermore, in the above-mentioned metal-carbon-fiber composite railway wheel, the metal wheel core is made of ER8 steel;

[0010] The spoke plate is made of T800 carbon fiber or epoxy resin prepreg;

[0011] The metal wheel rim is made of CL65K steel;

[0012] The positioning component is made of 30CrMnTi.

[0013] The manufacturing method of the metal carbon fiber composite structure railway wheel includes:

[0014] Metal wheel rim production: Select CL65K steel billets of appropriate size, forge and roll them into wheels of required size, and then temper and heat treat them for later use;

[0015] Web production: At this time, the carbon fiber preform is woven and then hot-pressed to form a solid body. The porosity is controlled to be less than 0.5%, and the surface is plasma treated with a power of 200W and a treatment time of 5 minutes.

[0016] Hot pressing: At this time, the formed metal wheel hoop is induction heated to 150-180℃, and the metal wheel hoop and the formed spoke are interference fit. The interference is controlled to be 0.1-0.15% of the wheel diameter. During assembly, ensure that the first groove and the second groove correspond to form a positioning groove;

[0017] Metal wheel core production: Select ER8 steel billets of appropriate size and forge them into wheel cores of required size. The formed metal wheel cores are subjected to normalizing heat treatment and the outer ring of the metal wheel cores is processed at the same time.

[0018] Cold press fitting: At this time, the cooled metal wheel core and the spoke plate are interference fitted, with the interference amount being 0.04-0.08mm, and the press fitting pressure is controlled at 50-100KN;

[0019] Positioning component production: 30CrMnTi steel plate is used to process and produce the positioning component;

[0020] Positioning assembly installation: Install the positioning assembly into the positioning groove to form a complete railway wheel.

[0021] Furthermore, in the above-mentioned method for manufacturing a metal-carbon fiber composite railway wheel, in the web plate manufacturing step, when T800 carbon fiber is selected, the layers are laid in an alternating 0° / ±45° pattern, and a nano-silica toughening agent is implanted between the layers;

[0022] When epoxy resin prepreg is selected, it should be cut first and then laid out.

[0023] Furthermore, in the above-mentioned method for manufacturing a metal-carbon-fiber composite railway wheel, in the web plate manufacturing step, the curing temperature is controlled at 180-200° C., the pressure is controlled at 6-8 MPa, and the temperature is kept at this temperature for 2 hours.

[0024] Furthermore, in the above-mentioned method for manufacturing a metal-carbon fiber composite railway wheel, in the metal wheel core manufacturing step, the heat treatment tensile strength is ≥700 MPa, the impact toughness KU2 is ≥80 J, and the normalizing grain size is ≥7 levels.

[0025] Furthermore, in the above-mentioned method for manufacturing a railway wheel with a metal-carbon fiber composite structure, in the step of manufacturing the metal wheel core, the outer ring of the metal wheel core is machined to have a roughness Ra of ≤1.6 μm.

[0026] The metal-carbon fiber composite railway wheel and the manufacturing method of the present invention have the following advantages and beneficial effects:

[0027] The overall structure of the present invention is simple, and the spoke plate is made of carbon fiber. While effectively ensuring the overall strength of the wheel, it effectively reduces the overall weight and noise reduction effect of the railway wheel. By assembling and connecting the metal wheel core, the spoke plate and the metal wheel hoop, the replacement cost is effectively reduced and waste is avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the embodiments or the description of the prior art. Obviously, the drawings described below are only used to further understand the embodiments of the present invention and constitute part of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative work. In the drawings:

[0029] Figure 1 The figure is a schematic cross-sectional view of the metal-carbon fiber composite railway wheel of the present invention.

[0030] Description of reference numerals:

[0031] 1: Metal wheel core;

[0032] 2: spoke plate, 21: second groove, 22: limiting step;

[0033] 3: metal wheel hoop, 31: first groove, 32: limiting groove;

[0034] 4: positioning assembly, 41: positioning block, 42: positioning pin;

[0035] 5: Positioning slot. DETAILED DESCRIPTION

[0036] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with specific embodiments of the present invention and corresponding drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0037] like Figure 1 As shown, the metal-carbon-fiber composite railway wheel of the present invention comprises a metal wheel core 1, a spoke plate 2, a metal wheel hoop 3 and a positioning assembly 4. The spoke plate 2 is sleeved on the metal wheel core 1, and the metal wheel hoop 3 is sleeved on the spoke plate 2. The positioning assembly 4 is arranged between the spoke plate 2 and the metal wheel hoop 3 to limit the position of the spoke plate 2 and the metal wheel hoop 3, wherein:

[0038] The positioning assembly 4 includes a positioning block 41 and a positioning pin 42 . The positioning block 41 is disposed between the spoke 2 and the metal wheel hoop 3 . The positioning pin 42 passes through the positioning block 41 and is connected and fixed to the spoke 2 .

[0039] Furthermore, in the metal-carbon-fiber composite railway wheel of the present invention, the metal wheel hoop 3 is arranged in a circular ring shape, and eight first grooves 31 are evenly opened on the inner side of the upper end of the metal wheel hoop 3 along the circumferential direction, and a limiting groove 32 is provided on the inner side of the lower end of the metal wheel hoop 3.

[0040] Furthermore, in the metal-carbon-fiber composite railway wheel of the present invention, the spoke plate 2 is arranged in a circular ring shape, and 8 second grooves 21 are evenly opened along the circumferential direction on the upper end of the outer ring of the spoke plate 2. The second grooves 21 correspond to the first grooves 31 to form a positioning groove 5. The positioning groove 5 matches the positioning block 41. The positioning block 41 is engaged with the positioning groove 5. The positioning pin 42 passes through the positioning block 41 and is threadedly engaged with the spoke plate 2, thereby effectively ensuring that the metal wheel hoop 3 and the spoke plate 2 are relatively fixed, avoiding sliding between the metal wheel hoop 3 and the spoke plate 2 during the operation of the railway wheel. A limiting step 22 is provided at the lower end of the outer ring of the spoke plate 2. The limiting step 22 is complementary to the limiting groove 32, and the limiting step 22 is engaged with the limiting groove 32, thereby effectively avoiding axial displacement of the spoke plate 2 and the metal wheel hoop 3.

[0041] Furthermore, in the metal-carbon-fiber composite railway wheel of the present invention, the metal wheel core 1 is arranged in a circular ring shape, the outer ring of the metal wheel core 1 and the inner ring of the spoke plate 2 are both arranged in a polygonal structure, the metal wheel core 1 is matched with the fixed spoke plate 2, and the metal wheel core 1 and the fixed spoke plate 2 are interference fit, thereby avoiding sliding between the metal wheel core 1 and the spoke plate 2 during the operation of the railway wheel.

[0042] Furthermore, in the metal-carbon-fiber composite railway wheel of the present invention, the metal wheel core 1 is made of ER8 steel;

[0043] The spoke plate 2 is made of T800 carbon fiber or epoxy resin prepreg, which effectively reduces the weight of the spoke plate 2 and the noise generated during operation while ensuring the strength support;

[0044] The metal wheel rim 3 is made of CL65K steel, which effectively ensures the wear resistance of the metal wheel rim 3;

[0045] The positioning component 4 is made of 30CrMnTi.

[0046] Specifically, when the metal wheel hoop 3 is severely worn during operation, the metal wheel hoop 3 is replaced by first removing the positioning assembly 4, axially moving the metal wheel hoop 3 toward the end where the positioning assembly 4 is installed, so that the metal wheel hoop 3 is separated from the spoke plate 2, and then replacing the metal wheel hoop 3;

[0047] When the metal wheel core 1 is severely worn, the metal wheel core 1 is axially moved and removed for replacement, so that the easily worn parts of the metal wheel core 1 and the metal wheel rim 3 can be quickly replaced, effectively reducing the use cost.

[0048] The manufacturing method of the metal carbon fiber composite structure railway wheel includes:

[0049] Metal wheel rim production: Select CL65K steel billets of appropriate size, forge and roll them into wheels of required size, and then temper and heat treat them for later use;

[0050] Web production: At this time, the carbon fiber preform is woven and then hot-pressed to form a solid body. The porosity is controlled to be less than 0.5%, and the surface is plasma treated with a power of 200W and a treatment time of 5 minutes.

[0051] Hot pressing: At this time, the formed metal wheel hoop is induction heated to 150-180℃, and the metal wheel hoop and the formed spoke are interference fit. The interference is controlled to be 0.1-0.15% of the wheel diameter. During assembly, ensure that the first groove and the second groove correspond to form a positioning groove;

[0052] Metal wheel core production: Select ER8 steel billets of appropriate size and forge them into wheel cores of required size. The formed metal wheel cores are subjected to normalizing heat treatment and the outer ring of the metal wheel cores is processed at the same time.

[0053] Cold press fitting: At this time, the cooled metal wheel core and the spoke plate are interference fitted, with the interference amount being 0.04-0.08mm, and the press fitting pressure is controlled at 50-100KN;

[0054] Positioning component production: 30CrMnTi steel plate is used to process and produce the positioning component;

[0055] Positioning assembly installation: Install the positioning assembly into the positioning groove to form a complete railway wheel.

[0056] Furthermore, in the method for manufacturing a metal-carbon fiber composite railway wheel of the present invention, in the web plate manufacturing step, when T800 carbon fiber is selected, the layers are laid in an alternating 0° / ±45° pattern, and a nano-silica toughening agent is implanted between the layers;

[0057] When epoxy resin prepreg is selected, it should be cut first and then laid out.

[0058] Furthermore, in the method for manufacturing a metal-carbon-fiber composite railway wheel of the present invention, in the web plate manufacturing step, the curing temperature is controlled at 180-200° C., the pressure is controlled at 6-8 MPa, and the temperature is kept at this temperature for 2 hours.

[0059] Furthermore, in the method for manufacturing a metal-carbon-fiber composite railway wheel of the present invention, in the metal wheel core manufacturing step, the heat treatment tensile strength is ≥700 MPa, the impact toughness KU2 is ≥80 J, and the normalizing grain size is ≥7 levels.

[0060] Furthermore, in the method for manufacturing a metal-carbon-fiber composite railway wheel of the present invention, in the metal wheel core manufacturing step, the outer ring of the metal wheel core is machined to have a roughness Ra of ≤1.6 μm.

[0061] In summary, compared with the prior art, the metal-carbon fiber composite railway wheel and manufacturing method of the present invention have the following advantages and beneficial effects: the overall structure of the present invention is simple, the spoke plate is made of carbon fiber, and while effectively ensuring the overall strength of the wheel, the overall weight of the railway wheel and the noise reduction effect are effectively reduced. The metal wheel core, spoke plate and metal wheel hoop are connected by assembly, which effectively reduces replacement costs and avoids waste.

[0062] It should be noted that, in this document, unless otherwise expressly specified or limited, the term "connected" or its synonyms should be interpreted broadly. For example, "connected" can mean a fixed or removable connection; a mechanical or electrical connection; a direct connection or an indirect connection through an intermediate medium; or the internal communication between two elements or the interaction between two elements. A person of ordinary skill in the art will understand the specific meanings of these terms in the present invention based on the specific circumstances. Furthermore, expressions such as "first" and "second" are used solely to distinguish one entity or operation from another and do not necessarily require or imply any actual relationship or order between these entities or operations. Furthermore, the terms "comprise," "include," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a process, method, article, or apparatus comprising a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus. Furthermore, the terms "front," "rear," "left," "right," "upper," and "lower" herein are used with reference to the positions shown in the accompanying drawings.

[0063] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A metal-carbon fiber composite railway wheel, characterized in that: The metal-carbon-fiber composite railway wheel comprises a metal wheel core, a spoke plate, a metal wheel hoop, and a positioning assembly. The spoke plate is sleeved on the metal wheel core, and the metal wheel hoop is sleeved on the spoke plate. The positioning assembly is arranged between the spoke plate and the metal wheel hoop to limit the position of the spoke plate and the metal wheel hoop, wherein: The positioning assembly includes a positioning block and a positioning pin. The positioning block is arranged between the spoke plate and the metal wheel hoop. The positioning pin passes through the positioning block and is connected and fixed to the spoke plate.

2. The metal-carbon-fiber composite railway wheel according to claim 1, characterized in that: The metal hoop is arranged in a circular ring shape, and 8 first grooves are evenly opened on the inner side of the upper end of the metal hoop along the circumferential direction, and a limiting groove is arranged on the inner side of the lower end of the metal hoop.

3. The metal-carbon-fiber composite railway wheel according to claim 2, characterized in that: The spoke plate is arranged in a circular ring shape, and 8 second grooves are evenly opened along the circumferential direction at the upper end of the outer ring of the spoke plate. The second grooves correspond to the first grooves to form a positioning groove, and the positioning groove matches the positioning block. The positioning block is engaged with the positioning groove. The positioning pin passes through the positioning block and is threadedly engaged with the spoke plate. A limiting step is provided at the lower end of the outer ring of the spoke plate. The limiting step is complementary to the limiting groove, and the limiting step is engaged with the limiting groove.

4. The metal-carbon-fiber composite railway wheel according to claim 3, characterized in that: The metal wheel core is arranged in a circular ring shape, the outer ring of the metal wheel core and the inner ring of the spoke plate are arranged in a polygonal structure, the metal wheel core is matched with the fixed spoke plate, and the metal wheel core and the fixed spoke plate are interference fit.

5. The metal-carbon-fiber composite railway wheel according to claim 1, characterized in that: The metal wheel core is made of ER8 steel; The spoke plate is made of T800 carbon fiber or epoxy resin prepreg; The metal wheel rim is made of CL65K steel; The positioning component is made of 30CrMnTi.

6. A method for manufacturing a metal-carbon fiber composite railway wheel, characterized in that: The method for manufacturing a metal-carbon-fiber composite railway wheel comprises: Metal wheel rim production: Select CL65K steel billets of appropriate size, forge and roll them into wheels of required size, and then temper and heat treat them for later use; Web production: At this time, the carbon fiber preform is woven and then hot-pressed to form a solid body. The porosity is controlled to be less than 0.5%, and the surface is plasma treated with a power of 200W and a treatment time of 5 minutes. Hot pressing: At this time, the formed metal wheel hoop is induction heated to 150-180℃, and the metal wheel hoop and the formed spoke are interference fit. The interference is controlled to be 0.1-0.15% of the wheel diameter. During assembly, ensure that the first groove and the second groove correspond to form a positioning groove; Metal wheel core production: Select ER8 steel billets of appropriate size and forge them into wheel cores of required size. The formed metal wheel cores are subjected to normalizing heat treatment and the outer ring of the metal wheel cores is processed at the same time. Cold press fitting: At this time, the cooled metal wheel core and the spoke plate are interference fitted, with the interference amount being 0.04-0.08mm, and the press fitting pressure is controlled at 50-100KN; Positioning component production: 30CrMnTi steel plate is used to process and produce the positioning component; Positioning assembly installation: Install the positioning assembly into the positioning groove to form a complete railway wheel.

7. The method for manufacturing a metal-carbon fiber composite railway wheel according to claim 6, characterized in that: In the spoke plate production process, when T800 carbon fiber is selected, the layers are laid in 0° / ±45° alternating layers, and nano-silica toughening agent is implanted between the layers; When epoxy resin prepreg is selected, it should be cut first and then laid out.

8. The method for manufacturing a metal-carbon fiber composite railway wheel according to claim 6, characterized in that: In the web production step, the curing temperature is controlled at 180-200°C, the pressure is controlled at 6-8 MPa, and the temperature is kept at this temperature for 2 hours.

9. The method for manufacturing a metal-carbon fiber composite railway wheel according to claim 6, characterized in that: In the metal wheel core manufacturing process, the heat treatment tensile strength is ≥700Mpa, the impact toughness KU2 is ≥80J, and the normalizing grain size is ≥7 levels.

10. The method for manufacturing a metal-carbon fiber composite railway wheel according to claim 6, characterized in that: In the metal wheel core manufacturing step, the outer ring of the metal wheel core is processed to have a roughness Ra≤1.6μm.

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