Metallic carbon fiber composite railway wheel and method of manufacture

Abstract

The application discloses a metal-carbon fiber composite structure railway wheel and a manufacturing method thereof. The metal-carbon fiber composite structure railway wheel comprises a metal wheel core, a web plate, a metal wheel hoop and a positioning assembly. The web plate is sleeved on the metal wheel core, the metal wheel hoop is sleeved on the web plate, and the positioning assembly is arranged between the web plate and the metal wheel hoop and used for limiting the web plate and the metal wheel hoop. The positioning assembly comprises a positioning block and a positioning pin. The positioning block is arranged between the web plate and the metal wheel hoop, and the positioning pin is connected and fixed with the web plate through the positioning block. The whole structure is simple, the web plate is made of carbon fiber, the overall strength of the wheel is effectively ensured, the overall weight of the railway wheel is effectively reduced, and the noise reduction effect is achieved. The metal wheel core, the web plate and the metal wheel hoop are assembled and connected, the replacement cost is effectively reduced, and waste is avoided.

Description

Technical Field

[0001] This invention belongs to the field of railway wheel manufacturing technology, and particularly relates to a metal carbon fiber composite railway wheel and its manufacturing method. Background Technology

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

[0003] To at least partially solve the technical problems existing in the prior art, the present invention provides a metal carbon fiber composite structure railway wheel and a manufacturing method thereof.

[0004] The metal-carbon fiber composite railway wheel of the present invention includes a metal wheel core, spokes, a metal wheel rim, and a positioning component. The spokes are fitted onto the metal wheel core for limiting their position, and the metal wheel rim is fitted onto the spokes. The positioning component is disposed between the spokes and the metal wheel rim for limiting the position of the spokes and the metal wheel rim, wherein:

[0005] The positioning component includes a positioning block and a positioning pin. The positioning block is disposed between the spoke and the metal wheel rim, and the positioning pin passes through the positioning block and is connected and fixed to the spoke.

[0006] Furthermore, in the aforementioned metal-carbon fiber composite railway wheel, the metal wheel rim is arranged in a circular shape, with eight first grooves evenly formed along the circumferential direction on the inner side of the upper end of the metal wheel rim, and a limiting groove is provided on the inner side of the lower end of the metal wheel rim.

[0007] Furthermore, in the aforementioned metal-carbon fiber composite railway wheel, the spokes are arranged in a circular shape, and eight second grooves are evenly formed along the circumferential direction at the upper end of the outer ring of the spokes. The second grooves correspond to the first grooves to form a positioning groove, which is matched with the positioning block. The positioning block is fitted with the positioning groove, and the positioning pin passes through the positioning block and engages with the spoke thread. A limiting step is provided at the lower end of the outer ring of the spokes. The limiting step is complementary to the limiting groove, and the limiting step is fitted with the limiting groove.

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

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

[0010] The spokes are made of T800 carbon fiber or epoxy resin prepreg.

[0011] The metal wheel rims are made of CL65K steel;

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

[0013] Methods for manufacturing railway wheels with metal-carbon fiber composite structures include:

[0014] Metal wheel rim manufacturing: Select CL65K steel billets of appropriate size, forge and roll them into wheel rims of the required size, and heat treat them with quenching and tempering before use;

[0015] Spoke fabrication: The carbon fiber woven preform is then cured by hot pressing, with the porosity controlled to <0.5%, and the surface is subjected to plasma treatment with a power of 200W and a treatment time of 5min.

[0016] Hot pressing: At this time, the formed metal wheel rim is induction heated to 150-180℃, and the metal wheel rim is interference-fitted with the formed spokes. The interference amount 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 manufacturing: Select ER8 steel billets of appropriate size and forge them into wheel cores of the required size. Then, perform normalizing heat treatment on the formed metal wheel cores and process the outer ring of the metal wheel cores.

[0018] Cold pressing: At this time, the cooled metal wheel core is pressed into the spokes with an interference fit of 0.04-0.08mm and the pressing pressure is controlled at 50-100KN.

[0019] Positioning component fabrication: Positioning components are fabricated from 30CrMnTi steel plates.

[0020] Positioning component installation: The positioning component is installed into the positioning slot to form a complete railway wheel.

[0021] Furthermore, in the above-mentioned method for manufacturing railway wheels with metal-carbon fiber composite structure, in the spoke manufacturing step, when T800 carbon fiber is selected, the layup adopts alternating layers of 0° / ±45°, and nano-silica toughening agent is implanted between the layers.

[0022] When using epoxy resin prepreg, cut it first before laying it up.

[0023] Furthermore, in the above-mentioned method for manufacturing railway wheels with metal-carbon fiber composite structures, in the spoke fabrication step, the curing temperature is controlled at 180-200℃, the pressure is controlled at 6-8 MPa, and the temperature is maintained for 2 hours.

[0024] Furthermore, in the above-mentioned method for manufacturing railway wheels with metal-carbon fiber composite structures, 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.

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

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

[0027] The invention has a simple overall structure. The spokes are made of carbon fiber, which effectively ensures the overall strength of the wheel while reducing the overall weight and noise of the railway wheel. The assembly connection between the metal wheel core, spokes and metal wheel rims effectively reduces replacement costs and avoids waste. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only for further understanding of the embodiments of the present invention and constitute a part of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings:

[0029] Figure 1 This is a cross-sectional structural diagram of the metal-carbon fiber composite railway wheel of the present invention.

[0030] Explanation of reference numerals in the attached figures:

[0031] 1: Metal wheel core;

[0032] 2: Spoke plate; 21: Second groove; 22: Limiting step;

[0033] 3: Metal wheel rim; 31: First groove; 32: Limiting groove;

[0034] 4: Positioning component; 41: Positioning block; 42: Positioning pin;

[0035] 5: Positioning groove. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0037] like Figure 1 As shown, the metal-carbon fiber composite railway wheel of the present invention includes a metal wheel core 1, spokes 2, a metal wheel rim 3, and a positioning component 4. The spokes 2 are fitted onto the metal wheel core 1 for limiting their position, and the metal wheel rim 3 is fitted onto the spokes 2. The positioning component 4 is disposed between the spokes 2 and the metal wheel rim 3 for limiting the position of the spokes 2 and the metal wheel rim 3.

[0038] The positioning component 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 rim 3, and 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 structure railway wheel of the present invention, the metal wheel rim 3 is arranged in a circular shape, and eight first grooves 31 are evenly opened on the inner side of the upper end of the metal wheel rim 3 along the circumferential direction, and a limiting groove 32 is provided on the inner side of the lower end of the metal wheel rim 3.

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

[0041] Furthermore, in the metal carbon fiber composite structure railway wheel of the present invention, the metal wheel core 1 is arranged in a circular shape, and 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, which avoids the slippage 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 structure railway wheel of the present invention, the metal wheel core 1 is made of ER8 steel;

[0043] The spokes 2 are made of T800 carbon fiber or epoxy resin prepreg, which effectively reduces the weight of the spokes 2 and the noise generated during operation while ensuring 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] Positioning component 4 is made of 30CrMnTi.

[0046] Specifically, when the metal wheel rim 3 is severely worn during operation, the metal wheel rim 3 is replaced. First, the positioning component 4 is removed, and the metal wheel rim 3 is moved axially to the end where the positioning component 4 is installed, so that the metal wheel rim 3 is separated from the spoke plate 2, and the metal wheel rim 3 is replaced.

[0047] When the metal wheel core 1 is severely worn, it can be moved axially to remove and replace it, thus enabling the quick replacement of easily worn parts such as the metal wheel core 1 and the metal wheel rim 3, effectively reducing the cost of use.

[0048] Methods for manufacturing railway wheels with metal-carbon fiber composite structures include:

[0049] Metal wheel rim manufacturing: Select CL65K steel billets of appropriate size, forge and roll them into wheel rims of the required size, and heat treat them with quenching and tempering before use;

[0050] Spoke fabrication: The carbon fiber woven preform is then cured by hot pressing, with the porosity controlled to <0.5%, and the surface is subjected to plasma treatment with a power of 200W and a treatment time of 5min.

[0051] Hot pressing: At this time, the formed metal wheel rim is induction heated to 150-180℃, and the metal wheel rim is interference-fitted with the formed spokes. The interference amount 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 manufacturing: Select ER8 steel billets of appropriate size and forge them into wheel cores of the required size. Then, perform normalizing heat treatment on the formed metal wheel cores and process the outer ring of the metal wheel cores.

[0053] Cold pressing: At this time, the cooled metal wheel core is pressed into the spokes with an interference fit of 0.04-0.08mm and the pressing pressure is controlled at 50-100KN.

[0054] Positioning component fabrication: Positioning components are fabricated from 30CrMnTi steel plates.

[0055] Positioning component installation: The positioning component is installed into the positioning slot to form a complete railway wheel.

[0056] Furthermore, in the metal carbon fiber composite structure railway wheel manufacturing method of the present invention, in the spoke manufacturing step, when T800 carbon fiber is selected, the layup adopts 0° / ±45° alternating stacking, and nano-silica toughening agent is implanted between the layers.

[0057] When using epoxy resin prepreg, cut it first before laying it up.

[0058] Furthermore, in the metal carbon fiber composite structure railway wheel manufacturing method of the present invention, in the spoke manufacturing step, the curing temperature is controlled at 180-200℃, the pressure is controlled at 6-8 MPa, and the temperature is maintained for 2 hours.

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

[0060] Furthermore, in the metal carbon fiber composite structure railway wheel manufacturing method of the present invention, in the metal wheel core manufacturing step, the surface roughness Ra of the outer ring of the metal wheel core is ≤1.6μm.

[0061] In summary, compared with the prior art, the metal carbon fiber composite structure railway wheel and manufacturing method of the present invention have the following advantages and beneficial effects: The present invention has a simple overall structure, the spokes are made of carbon fiber, which effectively ensures the overall strength of the wheel while effectively reducing the overall weight and noise of the railway wheel. The assembly connection between the metal wheel core, spokes and metal wheel rims effectively reduces replacement costs and avoids waste.

[0062] It should be noted that, unless otherwise expressly specified and limited, the term "connection" or its synonyms should be interpreted broadly in this document. For example, "connection" can be a fixed connection or a detachable connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal communication of two elements or the interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances. Furthermore, expressions such as "first" and "second" are merely used to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Meanwhile, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. In addition, the terms "front," "rear," "left," "right," "upper," and "lower" in this document refer to the placement states 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, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A metal-carbon fiber composite railway wheel, characterized in that, The metal-carbon fiber composite railway wheel includes a metal wheel core, spokes, a metal wheel rim, and a positioning assembly. The spokes are fitted onto the metal wheel core for limiting their position, and the metal wheel rim is fitted onto the spokes. The positioning assembly is disposed between the spokes and the metal wheel rim for limiting their position. The positioning component includes a positioning block and a positioning pin. The positioning block is disposed between the spoke and the metal wheel rim, and the positioning pin passes through the positioning block and is connected and fixed to the spoke. The metal wheel rim is arranged in a circular shape. Eight first grooves are evenly opened along the circumferential direction on the inner side of the upper end of the metal wheel rim, and a limit groove is provided on the inner side of the lower end of the metal wheel rim. The spokes are arranged in a ring shape. Eight second grooves are evenly formed along the circumference at the upper end of the outer ring of the spokes. The second grooves correspond to the first grooves to form a positioning groove. The positioning groove matches the positioning block. The positioning block is fitted into the positioning groove. The positioning pin passes through the positioning block and engages with the spokes by a thread. A limiting step is provided at the lower end of the outer ring of the spokes. The limiting step is complementary to the limiting groove. The limiting step is fitted into the limiting groove. The metal wheel core is arranged in a circular shape, and the outer ring of the metal wheel core and the inner ring of the spoke are both arranged in a polygonal structure. The metal wheel core is matched with the spoke, and the metal wheel core and the spoke are interference fit. The metal wheel core is made of ER8 steel; the spokes are made of T800 carbon fiber or epoxy resin prepreg; the metal wheel rim is made of CL65K steel; and the positioning components are made of 30CrMnTi. The T800 carbon fiber spokes adopt an alternating 0° / ±45° layered structure with nano-silica toughening agents embedded between the layers; the epoxy resin prepreg spokes are formed by cutting first and then laying up.

2. A method for manufacturing a metal-carbon fiber composite railway wheel according to claim 1, characterized in that, The method for manufacturing the metal-carbon fiber composite railway wheel includes: Metal wheel rim manufacturing: Select CL65K steel billets of appropriate size, forge and roll them into wheel rims of the required size, and heat treat them with quenching and tempering before use; Spoke fabrication: The carbon fiber woven preform is then cured by hot pressing, with the porosity controlled to <0.5%. The surface is then subjected to plasma treatment with a power of 200W, a treatment time of 5 minutes, a curing temperature of 180-200℃, a pressure of 6-8 MPa, and heat preservation for 2 hours. In the spoke manufacturing process, when T800 carbon fiber is used, the layup adopts alternating layers of 0° / ±45°, and nano-silica toughening agent is implanted between the layers. When using epoxy resin prepreg, cut it first and then lay it up. Hot pressing: At this time, the formed metal wheel rim is induction heated to 150-180℃, and the metal wheel rim is interference-fitted with the formed spokes. 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 manufacturing: Select ER8 steel billets of appropriate size and forge them into wheel cores of the required size. After forming, the metal wheel core is normalized and heat-treated. The tensile strength of the heat treatment is ≥700Mpa, the impact toughness KU2 is ≥80J, and the normalized grain size is ≥7. At the same time, the outer ring of the metal wheel core is machined. The surface roughness Ra of the outer ring of the metal wheel core is ≤1.6μm. Cold pressing: At this time, the cooled metal wheel core is pressed into the spokes with an interference fit of 0.04-0.08mm and the pressing pressure is controlled at 50-100KN. Positioning component fabrication: Positioning components are fabricated from 30CrMnTi steel plates. Positioning component installation: The positioning component is installed into the positioning slot to form a complete railway wheel.

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