Metal carbon fiber composite structure railway axle and manufacturing method

Abstract

The invention discloses a railway axle of a metal carbon fiber composite structure and a manufacturing method, the railway axle of the metal carbon fiber composite structure comprises a main shaft, a threaded inner pipe, axle head sleeves and tightening covers, the threaded inner pipe is arranged in the main shaft, the axle head sleeves are symmetrically arranged on the two sides of the main shaft, and the tightening covers are arranged at the two ends of the axle head sleeves and engaged with the threaded inner pipe in a threaded mode; wherein the main shaft comprises a main shaft body and extension shaft bodies, the extension shaft bodies are symmetrically arranged at the two ends of the main shaft body, the diameter of the extension shaft bodies is smaller than that of the main shaft body, a transition waistcoat is arranged between the main shaft body and the extension shaft bodies, and a bearing seat is arranged on one side of the outer wall of the shaft head sleeve in a conical transition mode and used for bearing limiting. A wheel seat is arranged on the other side of the outer wall of the shaft head sleeve and used for wheel positioning, and one end of the shaft head sleeve extends to form a combination waistcoat. While the self weight is reduced, the tensile strength and the corrosion resistance are improved, the contact area is effectively increased, axial movement of the main shaft is avoided, and the structural safety performance is effectively improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of railway axle manufacturing, and particularly relates to a metal-carbon fiber composite structure railway axle and a manufacturing method. BACKGROUND

[0002] The railway axle is an important structure connecting the train and the wheel, and the existing railway vehicle axle adopts a steel solid axle, which has the following defects: the self weight is too large (the single axle mass of a typical φ200mm axle is about 400kg), leading to an increase in the unsprung mass and affecting the train energy efficiency; the fatigue life is short: under alternating load, fretting wear is prone to occur, and fatigue cracks caused by fretting wear often appear within the maintenance period, which has a risk of failure; the energy loss is high: the rotational inertia is large, increasing the traction energy consumption by 15%-20%. The single carbon fiber axle and the steel wheel assembly have a mismatch in material mechanical properties, and the shear strength decay rate is as high as 40%, which has a large application risk. SUMMARY

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

[0004] The metal-carbon fiber composite structure railway axle of the present application comprises a main shaft, a threaded inner tube, a shaft head sleeve, and a shrinkage cover, the threaded inner tube is arranged in the main shaft, the shaft head sleeve is symmetrically arranged on both sides of the main shaft, and the shrinkage cover is arranged at both ends of the shaft head sleeve and is threadedly engaged with the threaded inner tube, wherein:

[0005] The main shaft comprises a main shaft body and an extension shaft body, the extension shaft body is symmetrically arranged at both ends of the main shaft body, the diameter of the extension shaft body is smaller than that of the main shaft body, and a transition shoulder is arranged between the main shaft body and the extension shaft body;

[0006] A bearing seat is arranged on one side of the outer wall of the shaft head sleeve, the bearing seat is arranged in a taper transition mode for bearing limiting, a wheel seat is arranged on the other side of the outer wall of the shaft head sleeve for wheel positioning, and a combination shoulder is extended from one end of the shaft head sleeve.

[0007] Further, in the above metal-carbon fiber composite structure railway axle, the main shaft is formed by winding polyacrylonitrile carbon-based fibers.

[0008] Further, in the above metal-carbon fiber composite structure railway axle, the extension shaft body matches the inner diameter of the shaft head sleeve, the shaft head sleeve and the extension shaft body are adhesively connected by epoxy resin, the transition shoulder and the combination shoulder are complementary, and the transition shoulder and the combination shoulder are adhesively connected by epoxy resin.

[0009] Further, in the metal-carbon fiber composite structure railway axle, the outer wall of the threaded inner tube is provided in a toothed structure, and the threaded inner tube is provided with threads at both ends of the inner wall.

[0010] Further, in the metal-carbon fiber composite structure railway axle, the one end of the shrink cover is provided with a threaded stud, the outer diameter of the shrink cover matches the outer diameter of the axle head sleeve, the threaded stud matches the threads, and the threaded stud is engaged with the threads through the axle head sleeve.

[0011] The metal-carbon fiber composite structure railway axle manufacturing method comprises:

[0012] Main shaft manufacturing: selecting a threaded inner tube according to the designed length, winding polyacrylonitrile-based carbon fibers on the threaded inner tube according to the designed diameters of the main shaft body, the extended shaft body and the transition shoulder therebetween, and coating epoxy resin between each layer;

[0013] Axle head sleeve manufacturing: selecting axle steel and turning the axle head sleeve with a joint shoulder, finishing, processing the inner wall and the outer wall of the axle head sleeve to the matching size, sandblasting the surface to Sa2.5 level, and performing quenching and tempering treatment on the formed axle head sleeve;

[0014] Layered bonding: gradually pressing the transition shoulder and the joint shoulder of the main shaft and the axle head sleeve, and filling epoxy resin slurry in the gap;

[0015] Gradient curing: placing the layered bonded main shaft and the axle head sleeve into a curing device for three-stage temperature rising curing;

[0016] Shrink cover manufacturing: selecting 40Cr alloy steel, performing machining after quenching and tempering heat treatment, matching the threaded stud with the threads inside the threaded inner tube, and assembling to form a complete railway axle.

[0017] Further, in the metal-carbon fiber composite structure railway axle manufacturing method, in the main shaft manufacturing step, the tension of the polyacrylonitrile-based carbon fibers during winding is controlled at 20-50 N, the impregnation amount of the epoxy resin between each layer is controlled at 0.3-0.5 g / m 2 , and the winding speed is controlled at 5-15 m / min.

[0018] Further, in the metal-carbon fiber composite structure railway axle manufacturing method, in the axle head sleeve manufacturing step, the quenching temperature during quenching is controlled at 850℃, the quenching time is 30 min, the tempering temperature is controlled at 550℃, the tempering time is 2 h, the tensile property is controlled at ReH≥500, Rm: 680-580 Mpa, and A≥18%.

[0019] Further, in the above-mentioned metal-carbon fiber composite structure railway axle manufacturing method, in the gradient curing step, the first stage curing temperature is 80 DEG C, the curing time is 2h, the second stage curing temperature is 150 DEG C, the curing time is 1h, the third stage curing temperature is 200 DEG C, the curing time is 0.5h, and after curing, the main shaft tensile strength is greater than or equal to 2500Mpa, the modulus is greater than or equal to 200Gpa, and the density is less than or equal to 1.9g / cm 3 .

[0020] Further, in the above-mentioned metal-carbon fiber composite structure railway axle manufacturing method, in the shrinkage cover manufacturing step, the shrinkage cover is quenched and tempered, and the hardness HRC is controlled to be 28-32.

[0021] The metal-carbon fiber composite structure railway axle and the manufacturing method have the following advantages and beneficial effects:

[0022] The main shaft and the threaded inner tube are matched, the self weight is reduced, the tensile strength and the corrosion resistance are improved, the transition shoulder and the combination shoulder are matched, the contact area is effectively improved, the main shaft axial movement is avoided, and the structural safety performance is effectively improved. BRIEF DESCRIPTION OF DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or the prior art description. Obviously, the drawings in the following description are only used to further understand the present application and form a part of the present application. For those skilled in the art, other drawings can also be obtained without creative labor based on these drawings. In the drawings:

[0024] Figure 1 It is a cross-sectional structure schematic diagram of the metal-carbon fiber composite structure railway axle of the present application;

[0025] Figure 2 It is a structure schematic diagram of the transition shoulder and the combination shoulder of the metal-carbon fiber composite structure railway axle of the present application;

[0026] Figure 3 It is a finite element analysis equivalent stress diagram of the axle in the embodiment;

[0027] Figure 4 It is a finite element analysis equivalent stress diagram of the main shaft in the embodiment.

[0028] Explanation of the drawings:

[0029] 1: main shaft, 11: main shaft body, 12: extended shaft body, 13: transition shoulder;

[0030] 2: threaded inner tube, 21: thread;

[0031] 3: shaft head sleeve, 31: bearing seat, 32: wheel seat, 33: combination shoulder;

[0032] 4: shrink cover, 41: stud. DETAILED DESCRIPTION

[0033] To make the objectives, technical solutions, and advantages of the present application clearer, the technical solutions of the present application will be described below in connection with specific embodiments of the present application and corresponding drawings. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments. Based on the embodiments of the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of protection of the present application.

[0034] As shown in Figures 1 to 2 The metal carbon fiber composite structure railway axle of the present application comprises a main shaft 1, a threaded inner tube 2, a shaft head sleeve 3, and a shrink cover 4. The threaded inner tube 2 is arranged in the main shaft 1, the shaft head sleeve 3 is symmetrically arranged on both sides of the main shaft 1, and the shrink cover 4 is arranged at both ends of the shaft head sleeve 3 and is threadedly engaged with the threaded inner tube 2. Among them:

[0035] The main shaft 1 comprises a main shaft body 11 and an extended shaft body 12. The extended shaft body 12 is symmetrically arranged at both ends of the main shaft body 11. The diameter of the extended shaft body 12 is smaller than that of the main shaft body 11. A transition shoulder 13 is arranged between the main shaft body 11 and the extended shaft body 12.

[0036] A bearing seat 31 is arranged on one side of the outer wall of the shaft head sleeve 3. The bearing seat 31 is arranged in a taper transition manner and is used for bearing limiting. The bearing seat 31 effectively reduces the stress concentration coefficient. A wheel seat 32 is arranged on the other side of the outer wall of the shaft head sleeve 3 and is used for wheel positioning. The shaft head sleeve 3 extends at one end to form a combination shoulder 33.

[0037] Further, in the metal carbon fiber composite structure railway axle of the present application, the main shaft 1 is formed by winding polyacrylonitrile carbon-based fibers, which effectively reduces the self-weight and improves the tensile strength and corrosion resistance.

[0038] Further, in the metal carbon fiber composite structure railway axle of the present application, the extended shaft body 12 matches the inner diameter of the shaft head sleeve 3. The shaft head sleeve 3 and the extended shaft body 12 are adhesively connected by epoxy resin. The transition shoulder 13 and the combination shoulder 33 are complementary. The transition shoulder 13 and the combination shoulder 33 are adhesively connected by epoxy resin, which effectively increases the contact area and suppresses the axial movement.

[0039] Further, in the metal carbon fiber composite structure railway axle of the present application, the outer wall of the threaded inner tube 2 is arranged in a tooth-shaped structure. Thread 21 is arranged at both ends of the inner wall of the threaded inner tube 2. Thus, the threaded inner tube 2 and the main shaft 1 are mechanically interlocked, thereby enhancing the torsional strength.

[0040] Further, in the metal carbon fiber composite structure railway axle of the present application, the end of the shrink cover 4 is provided with a stud 41, the outer diameter of the shrink cover 4 matches the outer diameter of the axle head sleeve 3, the stud 41 matches the thread 21, the stud 41 penetrates through the axle head sleeve 3 and engages with the thread 21, thereby effectively enhancing the integrity of the axle head sleeve 3 and the main shaft 1, and avoiding the axial displacement of the axle head sleeve 3.

[0041] The metal carbon fiber composite structure railway axle manufacturing method comprises:

[0042] Main shaft manufacturing: selecting a threaded inner tube according to the designed length, designing the diameter of the main shaft body, the extended shaft body and the transition shoulder therebetween, winding polyacrylonitrile-based carbon fiber on the threaded inner tube, and coating epoxy resin between each layer;

[0043] Axle head sleeve manufacturing: selecting axle steel material and turning the axle head sleeve with a combination shoulder, finishing, processing the inner wall and outer wall of the axle head sleeve to the matching size, sandblasting the surface to Sa2.5 level, and performing quenching and tempering treatment on the formed axle head sleeve;

[0044] Layered bonding: gradually pressing the transition shoulder and the combination shoulder of the main shaft and the axle head sleeve, and filling epoxy resin paste in the gap;

[0045] Gradient curing: placing the layered bonded main shaft and axle head sleeve into a curing device for three-stage temperature rising curing;

[0046] Shrink cover manufacturing: selecting 40Cr alloy steel, performing machining after quenching and tempering heat treatment, matching the stud with the thread inside the threaded inner tube, and assembling to form a complete railway axle.

[0047] Further, in the metal carbon fiber composite structure railway axle manufacturing method of the present application, in the main shaft manufacturing step, the tension control of the polyacrylonitrile-based carbon fiber winding is 20-50 N, the epoxy resin impregnation amount between each layer is controlled to be 0.3-0.5 g / m 2 , and the winding speed is controlled to be 5-15 m / min.

[0048] Further, in the metal carbon fiber composite structure railway axle manufacturing method of the present application, in the axle head sleeve manufacturing step, the quenching temperature during quenching is controlled to be 850℃, the quenching time is 30 min, the tempering temperature is controlled to be 550℃, the tempering time is 2 h, the tensile property is controlled to be ReH≥500, Rm: 680-580 Mpa, and A≥18%.

[0049] Further, in the manufacturing method of the metal-carbon fiber composite structure railway axle of the present application, in the gradient curing step, the first stage curing temperature is 80°C, the curing time is 2h, the second stage curing temperature is 150°C, the curing time is 1h, and the third stage curing temperature is 200°C, and the curing time is 0.5h.

[0050] Further, in the manufacturing method of the metal-carbon fiber composite structure railway axle of the present application, in the shrinkage cover manufacturing step, the hardness HRC of the shrinkage cover after quenching and tempering heat treatment is controlled to be 28-32.

[0051] Embodiment:

[0052] Main shaft manufacturing: select a threaded inner tube with an outer diameter of 100mm, an inner wall of M65 thread, and a tooth depth of 1.2mm and a tooth pitch of 4mm according to the designed length, wrap polyacrylonitrile-based carbon fiber on the threaded inner tube, and coat epoxy resin between each layer, control the tension of the polyacrylonitrile-based carbon fiber during winding to be 20-50N, control the epoxy resin impregnation amount between each layer to be 0.3-0.5g / m 2 , control the winding speed to be 5-15m / min, make the diameter of the extended shaft body 130mm, the diameter of the main shaft body 154mm, and the transition shoulder between the extended shaft body and the main shaft body divided into 3 steps, each step being 8mm high;

[0053] Shaft head sleeve manufacturing: select axle steel material and turn it into a shaft head sleeve with a joint shoulder, finish machining to make the inner diameter of the shaft head sleeve 130mm, the outer diameter of the joint shoulder 154mm, and the joint shoulder divided into 3 steps, each step being 8mm high, sandblast the surface to Sa2.5 level, and quench and temper the formed shaft head sleeve, control the quenching temperature to be 850°C, the quenching time to be 30min, the tempering temperature to be 550°C, the tempering time to be 2h, and the tensile property to be ReH≥500, Rm: 680-580Mpa, and A≥18%;

[0054] Layered bonding: press the transition shoulder and the joint shoulder of the main shaft and the shaft head sleeve step by step, and fill epoxy resin paste in the gap;

[0055] Gradient curing: place the layered bonded main shaft and shaft head sleeve into a curing device for three-stage temperature rising curing, the first stage curing temperature is 80°C, the curing time is 2h, the second stage curing temperature is 150°C, the curing time is 1h, and the third stage curing temperature is 200°C, and the curing time is 0.5h;

[0056] Shrinkage cover manufacturing: select 40Cr alloy steel, control the hardness HRC of the shrinkage cover after quenching and tempering heat treatment to be 28-32, machine process to make the studs M65 external threads, and assemble to form a complete railway axle.

[0057] Compared with the prior art, the metal carbon fiber composite structure railway axle and the manufacturing method have the following advantages and beneficial effects: the cooperation of the main shaft and the threaded inner tube improves the tensile strength and the corrosion resistance while reducing the self weight, the cooperation of the transition shoulder and the combination shoulder effectively improves the contact area, avoids the axial movement of the main shaft, and effectively improves the structural safety performance.

[0058] It should be noted that, in this document, unless otherwise explicitly specified and limited, the term "connection" or its synonyms should be understood broadly, for example, the "connection" can be a fixed connection or a detachable connection; can be a mechanical connection or an electrical connection; can be a direct connection or an indirect connection through an intermediate medium; can be an internal connection of two elements or an interaction relationship between two elements, and those skilled in the art can understand the specific meaning of the above-mentioned term in the present application according to the specific circumstances. Moreover, expressions such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between the entities or operations. At the same time, the term "includes", "contains" or any other variant thereof is intended to cover non-exclusive inclusion, so that the process, method, article or equipment including a series of elements not only includes those elements, but also includes other elements not explicitly listed or inherent to such process, method, article or equipment. In addition, "front", "back", "left", "right", "up", "down" in this document are referred to the placement state shown in the drawings.

[0059] Finally, it should be noted that: the above examples are only used to illustrate the technical solutions of the present application, and not to limit them; although the present application has been described in detail with reference to the foregoing examples, those skilled in the art should understand that they can still modify the technical solutions recorded in the foregoing examples, or make equivalent replacement for part of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A metal-carbon-fiber composite railway axle, characterized in that: The metal-carbon-fiber composite railway axle comprises a main shaft, a threaded inner tube, an axle head sleeve, and a shrink cover. The threaded inner tube is arranged in the main shaft, the axle head sleeve is symmetrically arranged on both sides of the main shaft, and the shrink cover is arranged at both ends of the axle head sleeve and is threadedly engaged with the threaded inner tube, wherein: The main shaft includes a main shaft body and an extended shaft body, wherein the extended shaft bodies are symmetrically arranged at both ends of the main shaft body, the diameter of the extended shaft body is smaller than the diameter of the main shaft body, and a transition shoulder is arranged between the main shaft body and the extended shaft body; A bearing seat is provided on one side of the outer wall of the shaft head sleeve. The bearing seat is set in a conical transition and is used for bearing limitation. A wheel seat is provided on the other side of the outer wall of the shaft head sleeve for wheel positioning. A coupling shoulder is extended at one end of the shaft head sleeve.

2. The metal-carbon-fiber composite railway axle according to claim 1, characterized in that: The main shaft is formed by winding polyacrylonitrile carbon-based fibers.

3. The metal-carbon-fiber composite railway axle according to claim 1, characterized in that: The extended shaft body matches the inner diameter of the shaft head sleeve, the shaft head sleeve and the extended shaft body are bonded by epoxy resin glue, the transition shoulder and the connecting shoulder are complementary, and the transition shoulder and the connecting shoulder are bonded by epoxy resin glue.

4. The metal-carbon-fiber composite railway axle according to claim 1, characterized in that: The outer wall of the threaded inner tube is arranged in a tooth-shaped structure, and threads are arranged at both ends of the inner wall of the threaded inner tube.

5. The metal-carbon-fiber composite railway axle according to claim 4, characterized in that: A stud is provided at one end of the shrinking cover, the outer diameter of the shrinking cover matches the outer diameter of the shaft head sleeve, the stud matches the thread, and the stud passes through the shaft head sleeve and engages with the thread.

6. A method for manufacturing a metal-carbon fiber composite railway axle, characterized in that: The method for manufacturing a metal-carbon-fiber composite railway axle comprises: Spindle production: Select a threaded inner tube according to the designed length, design the diameters of the main shaft, extension shaft, and the transition shoulder between them, wrap polyacrylonitrile-based carbon fiber around the threaded inner tube, and apply epoxy resin between each layer; Axle head sleeve production: axle steel is selected and turned into an axle head sleeve with a joint shoulder, and then fine-machined to make the inner and outer walls of the axle head sleeve to match the size. The surface is sandblasted to Sa2.5 level, and the formed axle head sleeve is quenched and tempered; Layered bonding: Press the transition shoulders and joint shoulders of the main shaft and the shaft head sleeve step by step, and fill the gap with epoxy resin slurry; Gradient curing: Place the layered bonded spindle and shaft head sleeve into the curing equipment for three-stage temperature-raising curing; Production of shrinking cover: 40Cr alloy steel is selected and machined after tempering heat treatment to match the stud with the thread inside the threaded inner tube, and then assembled to form a complete railway axle.

7. The method for manufacturing a metal-carbon fiber composite railway axle according to claim 6, characterized in that: In the spindle manufacturing step, the tension of polyacrylonitrile-based carbon fiber winding is controlled at 20-50N, and the epoxy resin impregnation amount between each layer is controlled at 0.3-0.5g / m 2 , the winding speed is controlled at 5-15m / min.

8. The method for manufacturing a metal-carbon fiber composite railway axle according to claim 6, characterized in that: In the manufacturing steps of the shaft head sleeve, the quenching temperature is controlled at 850°C during tempering, the quenching time is 30 minutes, the tempering temperature is controlled at 550°C, the tempering time is 2 hours, and the tensile properties are controlled at ReH≥500, Rm: 680-580Mpa, and A≥18%.

9. The method for manufacturing a metal-carbon fiber composite railway axle according to claim 6, characterized in that: In the gradient curing step, the curing temperature of the first stage is 80°C, the curing time is 2 hours, the curing temperature of the second stage is 150°C, the curing time is 1 hour, and the curing temperature of the third stage is 200°C, the curing time is 0.5 hours.

10. The method for manufacturing a metal-carbon fiber composite railway axle according to claim 6, characterized in that: In the manufacturing process of the shrink cover, the hardness HRC of the shrink cover after tempering heat treatment is controlled to be 28-32.

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