地铁车辆轴箱吊耳断裂机理和试验研究
|
摘要
地铁车辆在正常运营过程中发生轴箱吊耳断裂问题,采用有限元分析方法和线路试验开展断裂机理研究,并对吊耳振动水平进行评估。通过分析振动激扰源和结构响应特性,确定断裂原因和提出解决方案并进行试验验证。仿真表明吊耳第一阶固有模态为横向弯曲,主频约260 Hz;吊耳根部内圆弧处为强度薄弱点,与现场裂纹位置吻合。试验表明轴箱体、吊耳振动水平与线路区间相关,钢轨波磨是导致车辆振动水平激增的主因,波长61.5 mm;钢轨波磨波长、车辆常用速度共同作用导致波磨频率在吊耳固有模态频带内,导致结构共振从而引发疲劳破坏,提出钢轨打磨、优化吊耳结构设计和使用管理条件等解决措施。开展钢轨打磨效果验证性试验,表明钢轨打磨可显著降低吊耳加速度水平,使结构应力降低50%以上,但部分线路仍存在轻微波磨,可根据车辆振动数据特征对波磨路段进行定位从而再次进行打磨。
There is crack found on the safety hanger mounted on the axle-box of railway metro. The finite element(FE) Analysis and field measurement were performed to study the crack mechanism, then the vibration level of the hanger is thoroughly evaluated. The excitation and natural response of the structure are analyzed, and solutions are provided and validated by the field measurement. The FE analysis shows that the lateral bending mode has the lowest frequency around 260 Hz, and a weak area on the inner corner of the hanger bottom can be noticed. This shows a good agreement with the field crack propagation on the hanger. Field measurement illustrates that the vibration level of the axle-box and safety hanger are strongly dependent on the track segments. It is noticed that it is the rail corrugation with a wavelength of 61.5 mm that causes the serious vibration of vehicle. A resonance can be noticed by considering the natural mode of safety hanger and the track excitation frequency, which is dependent on the vehicle speed and corrugation wavelength. A fatigue problem can be encountered resulting from this resonance. Consequently, solutions for this structure failure issue are provided, such as the rail grinding, design a new safety hanger or specify the service conditions of this kind structure. Additionally, validation tests are conducted for the rail grinding solution which depicts that the rail grinding can significantly reduce the vibration level of vehicle, and the safety hanger stress reduces more than 50%. However, there still exist corrugations on some track segments. The vehicle dynamic responses can be used to identify the corrugation level and location on track for further track maintenance.
There is crack found on the safety hanger mounted on the axle-box of railway metro. The finite element(FE) Analysis and field measurement were performed to study the crack mechanism, then the vibration level of the hanger is thoroughly evaluated. The excitation and natural response of the structure are analyzed, and solutions are provided and validated by the field measurement. The FE analysis shows that the lateral bending mode has the lowest frequency around 260 Hz, and a weak area on the inner corner of the hanger bottom can be noticed. This shows a good agreement with the field crack propagation on the hanger. Field measurement illustrates that the vibration level of the axle-box and safety hanger are strongly dependent on the track segments. It is noticed that it is the rail corrugation with a wavelength of 61.5 mm that causes the serious vibration of vehicle. A resonance can be noticed by considering the natural mode of safety hanger and the track excitation frequency, which is dependent on the vehicle speed and corrugation wavelength. A fatigue problem can be encountered resulting from this resonance. Consequently, solutions for this structure failure issue are provided, such as the rail grinding, design a new safety hanger or specify the service conditions of this kind structure. Additionally, validation tests are conducted for the rail grinding solution which depicts that the rail grinding can significantly reduce the vibration level of vehicle, and the safety hanger stress reduces more than 50%. However, there still exist corrugations on some track segments. The vehicle dynamic responses can be used to identify the corrugation level and location on track for further track maintenance.
引文
[1]宋庆伟,李国栋,高纯友,等.北京地铁亦庄线车辆异常振动研究[J].铁道车辆,2014,52(5):5-8.SONG Qingwei,LI Guodong,GAO Chunyou,et al.Research on the abnormal vibration of vehicles on Yizhuang line of Beijing metro[J].Rolling Stock,2014,52(5):5-8.
[2]石怀龙,王建斌,戴焕云,等.联轴器不对中导致的车体振动研究[J].振动、测试与诊断,2015,35(4):626-631.SHI Huailong,WANG Jianbin,DAI Huanyun,et at.Car body vibration caused by the misalignment of rotor-shaft coupling of Metro[J].Journal of Vibration,Measurement&Diagnosis,2015,35(4):626-631.
[3]耿幸福,员华.地铁转向架构架疲劳开裂分析与改造方案[J].都市快轨交通,2010,23(6):90-93.GENG Xingfu,YUAN Hua.Fatigue crack analysis and restoration options for metro vehicle bogie frames[J].Urban Rapid Rail Transit,2010,23(6):90-93.
[4]戴焕云.制动工况下机车车辆转向架颤振机理[J].交通运输工程学报,2005,5(3):5-7.DAI Huanyun.Chatter mechanism of railway vehicle bogie under braking condition[J].Journal of Traffic and Transportation Engineering,2005,5(3):5-7.
[5]王军.广州地铁APM线列车异常轻微抖动故障的分析与处理[J].轨道交通装备与技术,2015,34(4):34-36.WANG Jun.Analysis and solution for the abnormal vibration of Guangzhou Metro APM[J].Rail Transportation Equipment and Technology,2015,34(4):34-36.
[6]袁浩智.广州地铁三号线北延段列车一系钢弹簧断裂原因分析及处理[J].轨道交通装备与技术,2015,1(1):32-34.YUAN Haozhi.Analysis and solution for the primary steel spring crack of Guangzhou Metro Line 3[J].Rail Transportation Equipment and Technology,2015,1(1):32-34.
[7]张春玉,程亚军,邵俊捷.基于线路实测载荷谱的转向架部件振动疲劳分析[J].城市轨道交通研究,2017,20(2):46-47.ZHANG Chunyu,CHENG Yajun,SHAO Junjie.Vibration fatigue analysis of bogie components based on routine test load spectrum[J].Urban Mass Transit,2017,20(2):46-47.
[8]李伟,曾全君,朱士友,等.地铁钢轨波磨对车辆和轨道动态行为的影响[J].交通运输工程学报,2015,15(1):34-42.LI Wei,ZENG Quanjun,ZHU Shiyou,et al.Effect of metro rail corrugation on dynamic behaviors of vehicle and track[J].Journal of Traffic and Transportation Engineering,2015,15(1):34-42.
[9]刘维宁,任静,刘卫丰,等.北京地铁钢轨波磨测试分析[J].都市快轨交通,2011,24(3):6-9.LIU Weining,REN Jing,LIU Weifeng,et al.Tests and analysis on rail corrugation of Beijing Metro[J].Urban Rapid Rail Transit,2011,24(3):6-9.
[10]刘卫丰,刘维宁,吴宗臻,等.北京地铁剪切型减振器扣件钢轨波磨治理的试验研究[J].机械工程学报,2015,51(21):26-32.LIU Weifeng,LIU Weining,WU Zongzhen,et al.Test study on treating rail corrugation for egg fastener in Beijing metro[J].Journal of Mechanical Engineering,2015,51(21):26-32.
[11]EGANA J,VINOLAS J,SECO M.Investigation of the influence of rail pad stiffness on rail corrugation on a transit system[J].Wear,2006,261(2):216-224.
[12]GRASSIE S L.Rail corrugation:Characteristics,causes and treatments[J].Proceedings of the Institution of Mechanical Engineers,Part F:Journal of Rail and Rapid Transit,2009,223(6):581-596.
[13]JIN Xuesong,WEN Zefeng,WANG Kaiyun.Effect of track irregularities on initiation and evolution of rail corrugation[J].Journal of Sound and Vibration,2005,285(1-2):121-148.
[14]王建斌,邬平波,唐兆.车轮扁疤引发附加冲击力对车轴应力谱影响的研究[J].铁道学报,2006,28(1):39-43.WANG Jianbin,WU Pingbo,TANG Zhao.Research on the axle stress spectrum considering extra wheel flat impact forces[J].Journal of the China Railway Society,2006,28(1):39-43.
[15]肖守讷,李华丽,阳光武,等.轮轨冲击对构架疲劳的影响[J].交通运输工程学报,2008,8(3):6-9.XIAO Shoune,LI Huali,YANG Guangwu,et al.Influence of wheel-rail impact on fatigue of bogie frame[J].Journal of Traffic and Transportation Engineering,2008,8(3):6-9.
[16]吴圣川,吴玉程.断裂分析及CAE软件的现状与发展[J].计算机辅助工程,2011,20(1):1-2.WU Shengchuan,WU Yucheng.Review of the crack analysis and CAE software development[J].Computer Aided Engineering,2011,20(1):1-2.
[17]中华人民共和国国家质量监督检验检疫总局,中国国家标准化管理委员会.GB/T 700-2006碳素结构钢[S].北京:中国标准出版社,2006.General Administration of Quality Supervision,Inspection and Quarantine of the People’s Republic of China,Standardization Administration of the People’s Republic of China.GB/T 700-2006 Carbon structural steels[S].Beijing:Standards Press of China,2006.
[18]IEC61373.Railway applications-Rolling stock equipmentshock and vibration tests[S].International Electrotechnical Commission,1999.
[19]TOVO R.Cycle distribution and fatigue damage under broad-band random loading[J].International Journal of Fatigue,2002,24(11):1137-1147.
[2]石怀龙,王建斌,戴焕云,等.联轴器不对中导致的车体振动研究[J].振动、测试与诊断,2015,35(4):626-631.SHI Huailong,WANG Jianbin,DAI Huanyun,et at.Car body vibration caused by the misalignment of rotor-shaft coupling of Metro[J].Journal of Vibration,Measurement&Diagnosis,2015,35(4):626-631.
[3]耿幸福,员华.地铁转向架构架疲劳开裂分析与改造方案[J].都市快轨交通,2010,23(6):90-93.GENG Xingfu,YUAN Hua.Fatigue crack analysis and restoration options for metro vehicle bogie frames[J].Urban Rapid Rail Transit,2010,23(6):90-93.
[4]戴焕云.制动工况下机车车辆转向架颤振机理[J].交通运输工程学报,2005,5(3):5-7.DAI Huanyun.Chatter mechanism of railway vehicle bogie under braking condition[J].Journal of Traffic and Transportation Engineering,2005,5(3):5-7.
[5]王军.广州地铁APM线列车异常轻微抖动故障的分析与处理[J].轨道交通装备与技术,2015,34(4):34-36.WANG Jun.Analysis and solution for the abnormal vibration of Guangzhou Metro APM[J].Rail Transportation Equipment and Technology,2015,34(4):34-36.
[6]袁浩智.广州地铁三号线北延段列车一系钢弹簧断裂原因分析及处理[J].轨道交通装备与技术,2015,1(1):32-34.YUAN Haozhi.Analysis and solution for the primary steel spring crack of Guangzhou Metro Line 3[J].Rail Transportation Equipment and Technology,2015,1(1):32-34.
[7]张春玉,程亚军,邵俊捷.基于线路实测载荷谱的转向架部件振动疲劳分析[J].城市轨道交通研究,2017,20(2):46-47.ZHANG Chunyu,CHENG Yajun,SHAO Junjie.Vibration fatigue analysis of bogie components based on routine test load spectrum[J].Urban Mass Transit,2017,20(2):46-47.
[8]李伟,曾全君,朱士友,等.地铁钢轨波磨对车辆和轨道动态行为的影响[J].交通运输工程学报,2015,15(1):34-42.LI Wei,ZENG Quanjun,ZHU Shiyou,et al.Effect of metro rail corrugation on dynamic behaviors of vehicle and track[J].Journal of Traffic and Transportation Engineering,2015,15(1):34-42.
[9]刘维宁,任静,刘卫丰,等.北京地铁钢轨波磨测试分析[J].都市快轨交通,2011,24(3):6-9.LIU Weining,REN Jing,LIU Weifeng,et al.Tests and analysis on rail corrugation of Beijing Metro[J].Urban Rapid Rail Transit,2011,24(3):6-9.
[10]刘卫丰,刘维宁,吴宗臻,等.北京地铁剪切型减振器扣件钢轨波磨治理的试验研究[J].机械工程学报,2015,51(21):26-32.LIU Weifeng,LIU Weining,WU Zongzhen,et al.Test study on treating rail corrugation for egg fastener in Beijing metro[J].Journal of Mechanical Engineering,2015,51(21):26-32.
[11]EGANA J,VINOLAS J,SECO M.Investigation of the influence of rail pad stiffness on rail corrugation on a transit system[J].Wear,2006,261(2):216-224.
[12]GRASSIE S L.Rail corrugation:Characteristics,causes and treatments[J].Proceedings of the Institution of Mechanical Engineers,Part F:Journal of Rail and Rapid Transit,2009,223(6):581-596.
[13]JIN Xuesong,WEN Zefeng,WANG Kaiyun.Effect of track irregularities on initiation and evolution of rail corrugation[J].Journal of Sound and Vibration,2005,285(1-2):121-148.
[14]王建斌,邬平波,唐兆.车轮扁疤引发附加冲击力对车轴应力谱影响的研究[J].铁道学报,2006,28(1):39-43.WANG Jianbin,WU Pingbo,TANG Zhao.Research on the axle stress spectrum considering extra wheel flat impact forces[J].Journal of the China Railway Society,2006,28(1):39-43.
[15]肖守讷,李华丽,阳光武,等.轮轨冲击对构架疲劳的影响[J].交通运输工程学报,2008,8(3):6-9.XIAO Shoune,LI Huali,YANG Guangwu,et al.Influence of wheel-rail impact on fatigue of bogie frame[J].Journal of Traffic and Transportation Engineering,2008,8(3):6-9.
[16]吴圣川,吴玉程.断裂分析及CAE软件的现状与发展[J].计算机辅助工程,2011,20(1):1-2.WU Shengchuan,WU Yucheng.Review of the crack analysis and CAE software development[J].Computer Aided Engineering,2011,20(1):1-2.
[17]中华人民共和国国家质量监督检验检疫总局,中国国家标准化管理委员会.GB/T 700-2006碳素结构钢[S].北京:中国标准出版社,2006.General Administration of Quality Supervision,Inspection and Quarantine of the People’s Republic of China,Standardization Administration of the People’s Republic of China.GB/T 700-2006 Carbon structural steels[S].Beijing:Standards Press of China,2006.
[18]IEC61373.Railway applications-Rolling stock equipmentshock and vibration tests[S].International Electrotechnical Commission,1999.
[19]TOVO R.Cycle distribution and fatigue damage under broad-band random loading[J].International Journal of Fatigue,2002,24(11):1137-1147.