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高速列车结构热点应力疲劳评定方法及应用研究
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摘要
我国铁路运输正向着高速、重载、轻量化的方向不断快速发展,这对车辆结构的疲劳强度提出了更高的要求。目前,我国提速、高速客车转向架构架及车体均采用钢板焊接结构和铝合金焊接结构,这样可大大降低车辆结构的自重。但是,运行速度的提高、载荷的增加以及复杂的焊接接头形式使得车辆的承载状况变得十分恶劣;同时,各种新型材料也不断应用于我国高速列车转向架与车体的结构中。焊接结构在交变应力作用下主要产生疲劳破坏,其疲劳破坏部位大多数在焊接接头上,焊接接头的疲劳强度制约着高速列车的运营安全性,因此,研究焊接接头的疲劳评定方法日益突显出来。国外目前绝大多数情况下的疲劳评定采用的是传统的名义应力评定方法,我国在焊接结构与车体疲劳评定中也主要考虑接头名义应力的影响,然而既有焊接接头的名义应力方法忽略焊接结构细节的变化,当焊接结构的细节与其承载复杂时,或者说当某一种焊接细节无法与典型焊接接头相对应时,就很难确定这些情况下的名义应力。因此,需要在获取所用材料焊接接头名义应力一寿命曲线的基础上,研究采用更为可靠的评定方法。
     热点应力方法由于其应力—寿命曲线受焊件几何细节与载荷形式的影响较小,其值更接近于焊件实际应力而使得评定结果更为准确、可靠,从而更适应我国高速列车疲劳评定的需要。目前针对高速列车用焊接接头进行热点应力疲劳评定的研究报道甚少。本文以高速列车用典型焊接接头为基本研究对象,以热点应力理论为基础,对焊接接头热点应力有限元计算方法与影响因素进行了系统研究,并测试了我国高速列车用新型材料焊接接头疲劳性能数据,建立高速列车焊接结构热点应力疲劳评定的基础;研究使用热点应力进行高速列车焊接结构疲劳评定的方法。论文主要进行了以下方面的研究工作:
     1、建立典型焊接接头有限元模型,解决了热点应力中有限元计算的单元划分方法与外推方法,分析不同承载条件下的热点应力计算方法和热点应力集中系数。
     2、分析了对接接头焊缝高度和底板厚度与角接接头焊缝尺寸、底板厚度、角接角度及立板厚度等几何参数对热点应力集中系数的影响;提出采用热点应力特征量来描述焊接接头几何参数变化对热点应力集中系数的影响;研究了载荷形式对焊接接头热点应力的影响。
     3、试验研究了高速列车用结构钢与铝合金焊接接头名义应力及热点应力疲劳性能,得到了AQ400NH钢、SMA490BW钢以及铝合金6005三种材质对接与角接接头的名义应力S-N曲线,结合相应接头形式的热点应力集中系数,得到相应焊接接头的热点应力S-N曲线。这些焊接接头热点应力疲劳性能,为开展高速列车焊接结构热点应力疲劳评定提供了基础数据。
     4、根据UIC615-4规程,计算高速转向架焊接构架上的名义应力进行疲劳强度评定;又以构架横向止挡座与侧梁上盖板连接部、牵引拉杆座与横梁下盖板连接部两处典型角接接头为研究对象,采用子模型方法将关键部位从整体结构中分离并建立实体模型进行分析,通过对带孔的槽钢子模型的计算分析,验证了子模型方法的正确性,因此实现了对焊接构架进行热点应力疲劳评定。
     5、根据铝合金6005车体牵引梁与盖板连接部、抗蛇行减振器座与车体底架连接部实测名义应力谱,计算其等效名义应力幅。通过该部位焊接接头热点应力特征量,计算等效热点应力幅,以此判定其热点应力疲劳强度,建立高速铝合金车体的热点应力疲劳评定方法。
The railway transportation in China is developing quickly with the aims that are high-speed,heavy load and light weight.This will cause much more requirements for the fatigue strength of the vehicle.The bogie frames and carbodies which belong to the raised-speed and high-speed vehicle are made from welded steel plate and aluminium alloy plate.This help reducing sole weight of the vehicle widely.However,raised speed, heavier load and duplicated forms of welded joints will make the load-bearing condition formidable for the vehicle.At the same time,various new materials are applied by bogie frames and carbodies continiously.Fatigue breakdown is the primary form of the welded structures under alternating load,and the mainly parts which breakdown are the welded joints.Therefore,the fatigue strength of welded joints confines the operating safety of the vehicle and researching fatigue evaluation approach becomes more important.The traditional nominal stress method is the main fatigue evaluation approach abroad.And the nominal stress is the most important approach while determine the fatigue strength of welded structure and carbody in our country.However, existing nominal stress approach of welded joint ignores the variety of welding details. The nominal stress will be difficult to be determined while the welding details are complicated,or some welding details do not belong to traditional welded joint. Consequently,the more reliable approach must to be brought forward on the basis that nominal stress S-N curve is got.
     Hot spot stress(HSS) approach is more applicable for high-speed vehicle fatigue evaluation,because its evaluation result is independent on the welding details and load form.Evaluation result by HSS is closer to real stress of welded joint than nominal stress approach;the result is much more exact and reliable therefore.Reports about fatigue evaluation by HSS for high-speed vehicle are quite few.In this paper,HSS calculation method by finite element and influencing factors are studied by the numbers. During this process,the welded joint belongs to high-speed car is the basis studying object,and the HSS theory is the basis flat.The fatigue capability data of new material welded joints applied for high-speed car are tested,which is the foundation for high-speed car fatigue evaluation by HSS approach.The fatigue evaluation by HSS approach for high-speed car is studied.The main research works in this paper are as follows:
     1.Finite element model of typical weled joint is constituted;the element size and extrapolating method are resolved.The HSS calculation method and HSS concentration factor under different load form are analyzed.
     2.Geometry factors and welding details which maybe influence the HSS concentration factor are analyzed.The factors are:for butt joint,there are the height of welding seam and plate thickness,and for fillet welded joint,there are the size of welding seam,plate thickness,welding angle and erect board thickness.HSS eigenvalue is brought forward which is used to describe the influence to HSS concentration factor caused by geometry factors and welding details.Influence from load form is calculated.
     3.The nominal stress S-N and HSS S-N for fillet welded joint and butt joint of AQ400NH steel,SMA490BW steel and aluminum alloy 6005 are got.These three materials are applied to high-speed car in China.The fatigue capability data provide the basis for fatigue evaluation by HSS for high-speed vehicle.
     4.In practical application item,UIC615-4 Code is applied for analyzing the complete welded AQ400NH bogie frame by finite element method.And the bogie frame fatigue strength is evaluated by nominal stress.As the studid objects,two typical fillet welded joints which are connection area beween side beam top cover plate and lateral stopper of bogie frame and connection area beween lateral beam bottom cover plate and traction bar support, are evaluated by HSS approach.During the analysis,the sub-model technology is applied to separate the fillet parts from whole model,then the solid element models are established.On the basis of analysizing the box iron with rectangle hole,the sub-model method is validated.Then the fatigue evaluation by HSS approach for welded bogie frame is achieved.
     5.According to tested nominal stress spectrum of connection area beween cover plate and traction beam of carbody,and the nominal stress spectrum of connection area beween underframe of carbody and unti-hunting damper support,the equivalent HSS spectru are got by HSS eigenvalue of these two parts.Using HSS spectrum,the HSS fatigue strength can be evaluated.The fatigue evaluation by HSS approach for high-speed aluminium alloy car body is established then.
引文
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