动车组运行状态制动毂建模及应力分析
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摘要
制动毂是动车组制动系统的重要联接部件,由于目前在其强度校核与设计中仅考虑车辆制动状态,而忽略了正常运行状态,无法解释其早期疲劳失效的机理。通过车辆正常运行状态下的制动毂动力学分析,其主要受制动盘旋转及路谱冲击作用下的两种惯性力作用,建立了制动盘毂的力学模型;采用弹性力学和动力学的方法,通过模型简化,建立制动盘与毂的变形协调条件,进而提出制动毂齿的动应力分析方法,得出制动毂齿主要处于随机动拉应力状态的结论,阐述制动毂齿的主要失效形式为疲劳失效。最后以动车组制动毂为计算分析实例,对比分析了不同附加垂向加速度和运行速度下制动毂齿的合应力变化规律,结果表明,路谱冲击下的附加加速度及运行速度越大,制动毂齿的合应力也越大,并且由力学模型可知,制动盘毂的尺寸、质量都会影响制动毂齿的应力状态。
Brake hub(BH) is an important connecting part of EMU braking system. At present, it is difficult to explain the mechanism of early fatigue failure of BH, because only the brake state of vehicle is considered and the normal running state is always neglected. In this paper, the dynamic analysis of BH under normal running state shows that the BH is mainly subjected to two inertia forces of motion state, namely, the rotation of brake disc and the impact of road spectrum, then the mechanical model of BH is established. With the help of the methods of elastic mechanics and dynamics, the deformation coordination conditions of brake disc and hub(BDH) are proposed by modeling simplification. As the result, the dynamic stress analysis method of BH teeth is put forward, and the conclusion that BH teeth are mainly in the state of random dynamic tension stress is revealed, so the failure mode of BH teeth belongs to fatigue failure. Finally, taking the BH of EMU as an example of calculation and analysis, the resultant stress of the BH teeth varied with different additional vertical acceleration and running speed is analyzed. The results show that the greater the additional acceleration under the impact of road spectrum and running speed are, the greater the resultant stress of the BH teeth is. Furthermore, according to the mechanical model of the brake disc-hub(BDH), their size and quality can also affect the stress of the BH teeth.
Brake hub(BH) is an important connecting part of EMU braking system. At present, it is difficult to explain the mechanism of early fatigue failure of BH, because only the brake state of vehicle is considered and the normal running state is always neglected. In this paper, the dynamic analysis of BH under normal running state shows that the BH is mainly subjected to two inertia forces of motion state, namely, the rotation of brake disc and the impact of road spectrum, then the mechanical model of BH is established. With the help of the methods of elastic mechanics and dynamics, the deformation coordination conditions of brake disc and hub(BDH) are proposed by modeling simplification. As the result, the dynamic stress analysis method of BH teeth is put forward, and the conclusion that BH teeth are mainly in the state of random dynamic tension stress is revealed, so the failure mode of BH teeth belongs to fatigue failure. Finally, taking the BH of EMU as an example of calculation and analysis, the resultant stress of the BH teeth varied with different additional vertical acceleration and running speed is analyzed. The results show that the greater the additional acceleration under the impact of road spectrum and running speed are, the greater the resultant stress of the BH teeth is. Furthermore, according to the mechanical model of the brake disc-hub(BDH), their size and quality can also affect the stress of the BH teeth.
引文
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[3]金学松,郭俊,肖新标,等.高速列车安全运行研究的关键科学问题[C]//全国结构工程学术会议,广州,2009:8-22.JIN Xueson,GUO Jun,XIAO Xin,et al.Key scientific problems in study on running safety of high speed trains[C]//Proceedings of the 18th National Academic Conference on Structural Engineering,Guangzhou,2009:8-22.
[4]杨智勇,韩建民,李卫京,等.制动盘制动过程的热-机耦合仿真[J].机械工程学报,2010,46(2):114-118.YANG Zhiyong,HAN Jianmin,LI Weijing,et al.Thermo-mechanical coupling simulation of braking process of brake disc[J].Journal of Mechanical Engineering,2010,46(2):114-118.
[5]HEILIG J,WAUER J.Stability of a nonlinear brake system at high operating speeds[J].Nonlinear Dynamics,2003,34(3):235-247.
[6]TALBOT C,FIELDHOUSE J D.Animations of a disc brake generating noise[C]//Proceedings of the 19th Annual Brake Colloquium&Exhibition.New Orleans:SAE,2001:3126.
[7]石晓玲,李强,宋占勋,等.高速列车锻钢制动盘热疲劳裂纹耦合扩展特性研究[J].机械工程学报,2016,52(10):126-132.SHI Xiaoling,LI Qiang,SONG Zhanxun.Research on coupled extension characteristic of thermal fatigue cracks at forged brake disc for high speed train[J].Journal of Mechanical Engineering,2016,52(10):126-132.
[8]秦芳芳.制动毂齿部疲劳损伤机理及检测试验研究[D].北京:北京交通大学,2017.QIN Fangfang.Mechanism analysis and detecting experimental research on fatigue damage in brake hub teeth,master thesis[D].Beijing:Beijing Jiaotong University,2017.
[9]WU S C,ZHANG S Q,XU Z W.Thermal crack growth-based fatigue life prediction due to braking for a high-speed railway brake disc[J].International Journal of Fatigue,2016,87:359-369.
[10]CHO S K,CHOI J H,LEE Y M.Life evaluation of a disk brake of railway vehicles considering pressure distributions at a frictional surface[J].Key Engineering Materials,2007,353-358:303-306.
[11]SAWCZUK W.The application of vibration accelerations in the assessment of average friction coefficient of a railway brake disc[J].Measurement Science Review,2017,17(3):125-134.
[12]SUN Yu,ZHOU Jinsong,GONG Dao,et al.A new vibration absorber design for under-chassis device of a high-speed train[J].Shock and Vibration,2017,6:1-8.
[13]张龙,孙明月,李殿中.高速列车制动盘盘毂锻造工艺数值模拟[J].塑性工程学报,2012,19(4):56-61.ZHANG Long,SUN Mingyue,LI Dianzhong.Numerical simulation for die forging of high-speed railway brake disc hub[J].Journal of Plasticity Engineering,2012,19(4):56-61.
[14]TIMOSHENKO S P,GOODIER J N.弹性理论[M].3版.北京:清华大学出版社,2004.TIMOSHENKO S P,GOODIER J N.Theory of elasticity[M].3rd ed.Beijing:Tsinghua University Press,2004.
[15]陈传尧.疲劳与断裂[M].武汉:华中科技大学出版社,2002.CHEN Chuanyao.Fatigue&fracture[M].Wuhan:Huazhong University of Science&Technology Press,2002.