高速列车齿轮箱箱体动应力影响规律
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摘要
通过线路测试研究了列车运行速度、线路条件与车轮镟修对齿轮箱箱体动应力的影响规律,结合轴箱振动加速度分析了箱体动应力的变化规律。研究结果表明:齿轮箱箱体动应力与轴箱垂向加速度的幅值谱基本一致,主频均为570 Hz,反映了箱体动应力水平与轮轨相互作用产生的高频激励密切相关;列车运行速度由200 km·h~(-1)增大到300 km·h~(-1)时,齿轮箱箱体的应力幅值呈现增大趋势,尤其在箱体开裂的齿面检查孔位置,其等效应力由5.56 MPa增大至16.67 MPa,增大约2倍;轨道磨耗造成的不平顺对列车轴箱和齿轮箱箱体的振动具有较大的影响,列车由磨耗线路运营至打磨线路时,轴箱高频阶段振动幅值水平明显降低,箱体关键点的等效应力由16.26 MPa减小到10.16 MPa,减小38%;车轮高阶多边形在列车高速运行时(300 km·h~(-1))产生的高频(550～650 Hz)激扰造成箱体高频振动和动应力、等效应力大幅提升,箱体关键点的等效应力在镟轮前后由17.45 MPa减小到8.56 MPa,减小51%。可见,轨道打磨与车轮镟修均改善了齿轮箱箱体的受力状态,因此,选择合理的轨道打磨和轮对镟修周期可有效延长齿轮箱箱体的疲劳寿命。
The influence rules of running speed, line condition and wheel profiling on the dynamic stress of gearbox housing were studied based on the line test, and the change rule of dynamic stress of gearbox housing was analyzed combined with the vibration acceleration of axle box. Analysis result shows that the amplitude spectrums of dynamic stress of gearbox housing and the vertical acceleration of axle box are the same, and the main frequency is 570 Hz, which reflects that the dynamic stress level of the housing is closely related to the high frequency excitation caused by wheel-rail interaction. When the train running speed increases from 200 km·h~(-1) to 300 km·h~(-1), the stress amplitude of gearbox housing shows an increasing trend, especially in the tooth surface inspection hole of cracking housing. The equivalent stress increases from 5.56 MPa to 16.67 MPa, which is about 2 times larger. The irregularity caused by the rail wear has a great influence on the vibration of axle box and gearbox housing. When the train is running from worn line to grinding line, the vibration amplitude level of axle box in high frequency stage obviously reduces, and the equivalent stress of key point of the housing reduces from 16.26 MPa to 10.16 MPa, which decreases by 38%. The high frequency(550-650 Hz) excitation caused by the high-order polygon of the wheel at high speed(300 km·h~(-1)) causes the high frequency vibration, the dynamic stress and equivalent stress of the housing increase substantially, and the equivalent stress of key point of the housing decreases from 17.45 MPa to 8.56 MPa before and after wheel profiling, which decreases by 51%. So rail grinding and wheel profiling can improve the stress state of gearbox housing. Therefore, reasonable rail grinding and wheel profiling cycle can effectively prolong the fatigue life of gearbox housing.
The influence rules of running speed, line condition and wheel profiling on the dynamic stress of gearbox housing were studied based on the line test, and the change rule of dynamic stress of gearbox housing was analyzed combined with the vibration acceleration of axle box. Analysis result shows that the amplitude spectrums of dynamic stress of gearbox housing and the vertical acceleration of axle box are the same, and the main frequency is 570 Hz, which reflects that the dynamic stress level of the housing is closely related to the high frequency excitation caused by wheel-rail interaction. When the train running speed increases from 200 km·h~(-1) to 300 km·h~(-1), the stress amplitude of gearbox housing shows an increasing trend, especially in the tooth surface inspection hole of cracking housing. The equivalent stress increases from 5.56 MPa to 16.67 MPa, which is about 2 times larger. The irregularity caused by the rail wear has a great influence on the vibration of axle box and gearbox housing. When the train is running from worn line to grinding line, the vibration amplitude level of axle box in high frequency stage obviously reduces, and the equivalent stress of key point of the housing reduces from 16.26 MPa to 10.16 MPa, which decreases by 38%. The high frequency(550-650 Hz) excitation caused by the high-order polygon of the wheel at high speed(300 km·h~(-1)) causes the high frequency vibration, the dynamic stress and equivalent stress of the housing increase substantially, and the equivalent stress of key point of the housing decreases from 17.45 MPa to 8.56 MPa before and after wheel profiling, which decreases by 51%. So rail grinding and wheel profiling can improve the stress state of gearbox housing. Therefore, reasonable rail grinding and wheel profiling cycle can effectively prolong the fatigue life of gearbox housing.
引文
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[10] 刘文光,陈国平.轴向共振控制的结构疲劳裂纹扩展分析[J].南京航空航天大学学报,2010,42(3):298-302.LIU Wen-guang, CHEN Guo-ping. Fatigue crack propagation resonance controll structures on longitudinal vibration[J]. Journal of Nanjing University of Aeronautics and Astronautics, 2010, 42(3): 298-302. (in Chinese)
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[21] HUANG Wei, WANG Tie-jun, GARBATOV Y, et al. Fatigue reliability assessment of riveted lap joint of aircraft structures[J]. International Journal of Fatigue, 2012, 43(1): 54-61.
[22] ALDERLIESTEN R C. Critical review on the assessment of fatigue and fracture in composite materials and structures[J]. Engineering Failure Analysis, 2013, 35: 370-379.
[23] FOONG C H, PAVLOVSKAIA E, WIERCIGROCH M, et al. Chaos caused by fatigue crack growth[J]. Chaos Solitons and Fractals, 2003, 5(16): 651-659.
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[26] 陈智芳,姚建伟.高速万向轴式动力转向架体悬齿轮箱的研究[J].机车车辆工艺,2002(4):8-12.CHEN Zhi-fang, YAO Jian-wei. Development of suspended gearboxes for high speed cardan-shaft power bogies[J]. Locomotive and Rolling Stock Technology, 2002(4): 8-12. (in Chinese)
[27] 常程城.高速列车齿轮箱线路试验及振动传递关系研究[D].北京:北京交通大学,2015.CHANG Cheng-cheng. Research on transmission of vibration of high speed train gear box and gear box line test[D]. Beijing: Beijing Jiaotong University, 2015. (in Chinese)
[28] 任尊松,刘志明.高速动车组振动传递及频率分布规律[J].机械工程学报,2013,49(16):1-7.REN Zun-song, LIU Zhi-ming. Vibration and frequency domain characteristics of high speed EMU[J]. Journal of Mechanical Engineering, 2013, 49(16): 1-7. (in Chinese)
[29] 王文静,王燕,孙守光,等.高速列车转向架载荷谱长期跟踪试验研究[J].西南交通大学学报,2015,50(1):84-89.WANG Wen-jing, WANG Yan, SUN Shou-guang, et al. Long-term load spectrum test of high-speed train bogie[J]. Journal of Southwest Jiaotong University, 2015, 50(1): 84-89. (in Chinese)
[30] 刘志明.随机载荷下焊接构架疲劳寿命及可靠性研究[D].北京:北京交通大学,2001.LIU Zhi-ming. A research on fatigue life and reliability of welding frame under random loads[D]. Beijing: Beijing Jiaotong University, 2001. (in Chinese)
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[2] 沈志云.关于高速铁路及高速列车的研究[J].振动、测试与诊断,1998,18(1):1-7.SHEN Zhi-yun. On the study of high speed railways and trains[J]. Journal of Vibration, Measurement and Diagnosis, 1998, 18(1): 1-7. (in Chinese)
[3] 李广全,王文静,杨广雪.高速列车齿轮箱载荷特性分析[J].机械工程学报,2018,54(4):270-277.LI Guang-quan, WANG Wen-jing, YANG Guang-xue. Analysis on load characteristics of high-speed train gearbox[J]. Journal of Mechanical Engineering, 2018, 54(4): 270-277. (in Chinese)
[4] 王文静,张莹,曲俊生,等.高速列车齿轮箱箱体动应力响应及疲劳可靠性研究[J].中国铁道科学,2018,39(6):90-97.WANG Wen-jing, ZHANG Ying, QU Jun-sheng, et al. Dynamic stress response and fatigue reliability of gearbox housing for G-series high-speed train[J]. China Railway Science, 2018, 39(6): 90-97. (in Chinese)
[5] 李广全,刘志明,呙如兵,等.高速列车齿轮箱应力响应与疲劳损伤评估[J].交通运输工程学报,2018,18(1):79-88.LI Guang-quan, LIU Zhi-ming, GUO Ru-bing, et al. Stress response and fatigue damage assessment of high-speed train gearbox[J]. Journal of Traffic and Transportation Engineering, 2018, 18(1): 79-88. (in Chinese)
[6] QI Jun-tong, HAN Jian-da. Application of wavelets transform to fault detection in rotorcraft UAV sensor failure[J]. Journal of Bionic Engineering, 2007, 4(4): 265-270.
[7] 汤和,汪元辉,张策,等.定量诊断齿轮箱故障方法的探讨[J].机械传动,1987,11(5):29-32. TANG He, WANG Yuan-hui, ZHANG Ce, et al. Discussion on the method of fault diagnosis for gearbox[J]. Journal of Mechanical Transmission, 1987, 11(5): 29-32. (in Chinese)
[8] 杨广雪,李广全,刘志明,等.轮轨激励下高速列车齿轮箱箱体振动特性分析研究[J].铁道学报,2017,39(11):46-52.YANG Guang-xue, LI Guang-quan, LIU Zhi-ming, et al. Vibration characteristics analysis of gearbox housing system of high-speed train subjected to wheel-rail excitation[J]. Journal of the China Railway Society, 2017, 39(11): 46-52. (in Chinese)
[9] XING Xiu-san. Physical entropy, information entropy and their evolution equations[J]. Science in China: Series A, 2001, 44(10): 1331-1339.
[10] 刘文光,陈国平.轴向共振控制的结构疲劳裂纹扩展分析[J].南京航空航天大学学报,2010,42(3):298-302.LIU Wen-guang, CHEN Guo-ping. Fatigue crack propagation resonance controll structures on longitudinal vibration[J]. Journal of Nanjing University of Aeronautics and Astronautics, 2010, 42(3): 298-302. (in Chinese)
[11] 陆人定.齿轮箱故障时域和频域综合诊断技术[J].机电工程技术,2007,36(6):17-19,51.LU Ren-ding. Synthetical diagnosis method of time domain and spectrums to gearbox fault[J].Mechanical and Electrical Engineering Technology, 2007, 36(6): 17-19, 51. (in Chinese)
[12] 黄冠华,王兴宇,梅桂明,等.内外激励下高速列车齿轮箱箱体动态响应分析[J].机械工程学报,2015,51(12):95-100.HUANG Guan-hua, WANG Xing-yu, MEI Gui-ming, et al. Dynamic response analysis of gearbox housing system subjected to internal and external excitation in high-speed train[J]. Journal of Mechanical Engineering, 2015, 51(12): 95-100. (in Chinese)
[13] 吴越,韩健,刘佳,等.高速列车车轮多边形磨耗对轮轨力和转向架振动行为的影响[J].机械工程学报,2018,54(4):37-46.WU Yue, HAN Jian, LIU Jia, et al. Effect of high-speed train polygonal wheels on wheel/rail contact force and bogie vibration[J]. Journal of Mechanical Engineering, 2018, 54(4): 37-46. (in Chinese)
[14] SNYDER T, STONE D H, KRISTAN J. Wheel flat and out-of round formation and growth[C]//IEEE. Proceedings of the 2003 IEEE/ASME Joint Railroad Conference. New York: IEEE, 2003: 143-148.
[15] BARKE D W, CHIU W K. A review of the effects of out-of-round wheels on track and vehicle components[J]. Journal of Rail and Rapid Transit, 2005, 219(3): 151-175.
[16] 周清跃,刘丰收,张银花,等.高速铁路轮轨匹配存在问题及对策[J].中国铁道科学,2017,38(5):78-84.ZHOU Qing-yue, LIU Feng-shou, ZHANG Yin-hua, et al. Solutions for problems at wheel-rail interface in high speed railway[J]. China Railway Science, 2017, 38(5): 78-84. (in Chinese)
[17] 马思群,王猛,王晓杰,等.高速列车平稳性与乘坐舒适度测试及评价[J].大连交通大学学报,2015,36(增1):66-68.MA Si-qun, WANG Meng, WANG Xiao-jie, et al. Evaluation and measurement of high speed train by ride comfort and ride index[J]. Journal of Dalian Jiaotong University, 2015, 36(S1): 66-68. (in Chinese)
[18] 马建民,李敬勇.焊接缺陷对铝合金焊接接头疲劳性能的影响[J].材料开发与应用,2003,18(6):31-34.MA Jian-min, LI Jing-yong. Effect of weld defects on the fatigue of aluminum alloy joint[J]. Development and Application of Materials, 2003, 18(6): 31-34. (in Chinese)
[19] 王文静,李广君,唐薇,等.高速动车组轴箱弹簧疲劳失效机理研究[J].铁道学报,2015,37(6):41-47.WANG Wen-jing, LI Guang-jun, TANG Wei, et al. Research on mechanism of fatigue crack of high speed train axle box spring[J]. Journal of the China Railway Society, 2015, 37(6): 41-47. (in Chinese)
[20] SALVINI P, VIVIO F, VULLO V. Fatigue life evaluation for multi-spot welded structures[J]. International Journal of Fatigue, 2012, 31(1): 122-129.
[21] HUANG Wei, WANG Tie-jun, GARBATOV Y, et al. Fatigue reliability assessment of riveted lap joint of aircraft structures[J]. International Journal of Fatigue, 2012, 43(1): 54-61.
[22] ALDERLIESTEN R C. Critical review on the assessment of fatigue and fracture in composite materials and structures[J]. Engineering Failure Analysis, 2013, 35: 370-379.
[23] FOONG C H, PAVLOVSKAIA E, WIERCIGROCH M, et al. Chaos caused by fatigue crack growth[J]. Chaos Solitons and Fractals, 2003, 5(16): 651-659.
[24] FOONG C H, WIERCIGROCH M, DEANS W F. Novel dynamic fatigue-testing device: design and measurements[J]. Measurement Science and Technology, 2006, 17(18): 2218-2226.
[25] 王文静,惠晓龙,马纪军.高速列车设备舱支架疲劳裂纹机理研究[J].机械工程学报,2015,51(6):142-147.WANG Wen-jing, HUI Xiao-long, MA Ji-jun. Fatigue crack mechanism research on high speed train equipment cabin frame[J]. Journal of Mechanical Engineering, 2015, 51(6): 142-147. (in Chinese)
[26] 陈智芳,姚建伟.高速万向轴式动力转向架体悬齿轮箱的研究[J].机车车辆工艺,2002(4):8-12.CHEN Zhi-fang, YAO Jian-wei. Development of suspended gearboxes for high speed cardan-shaft power bogies[J]. Locomotive and Rolling Stock Technology, 2002(4): 8-12. (in Chinese)
[27] 常程城.高速列车齿轮箱线路试验及振动传递关系研究[D].北京:北京交通大学,2015.CHANG Cheng-cheng. Research on transmission of vibration of high speed train gear box and gear box line test[D]. Beijing: Beijing Jiaotong University, 2015. (in Chinese)
[28] 任尊松,刘志明.高速动车组振动传递及频率分布规律[J].机械工程学报,2013,49(16):1-7.REN Zun-song, LIU Zhi-ming. Vibration and frequency domain characteristics of high speed EMU[J]. Journal of Mechanical Engineering, 2013, 49(16): 1-7. (in Chinese)
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