铁道车辆车轮CAD/CAE/CAM一体化技术研究
摘要
铁道车辆是我国主要的运输工具,车轮是车辆的关键部件,承担着车辆全部重量,且在轨道上高速运行。随着现代社会对铁路运输的要求越来越高,高速列车、重载列车得到了快速发展,因此,对车轮的设计与制造的要求也越来越高,采用现代CAD/CAE/CAM技术对车轮设计、制造和维修显得尤为必要。
本论文首先对车轮的结构形式、技术要求和制造工艺进行了分析研究。在此基础上,开展车轮三维实体造型及参数化设计方法的研究。并利用SolidWorks软件系统,建立了车轮三维CAD模型。对车轮关键几何尺寸进行了分析,通过建立EXECL系列参数表,实现了车轮的参数化设计。
针对传统设计方法无法精确计算车轮应力分布和最大应力问题,提出运用CAD/CAE集成技术的方法进行车轮结构强度分析计算。对CAD/CAE集成技术进行了分析,实现了车轮CAD模型与ANSYS间的数据共享。在分析车辆典型受力工况的基础上,建立了车轮的结构强度计算模型,采用有限元分析软件ANSYS对典型结构车轮进行了分析计算,给出了车轮强度的评定方法。
针对车轮踏面数控加工和CAD/CAM集成的需要,采用三维软件SolidWorks API和Visual C++.NET为开发工具,采用COM组件技术进行了车轮踏面数控加工编程软件的开发。该软件可利用车轮三维CAD几何模型直接获得车轮踏面的几何参数,并根据输入的加工参数自动生成车轮踏面数控加工代码。
Railway Vehicles are primary transportation tools in China, and wheels are key components of railway Vehicles, which support the all weight of vehicles and run in the high speed on rail. With increasing demands on the rail transport in the modern society, high-speed and heavy load trains are developed very rapidly, the demands on wheel design and manufacture has become higher and higher, so it is necessary to employ the CAD/CAE/CAM technology to ensure wheel design and manufacturing quality.
The paper first discusses wheel structure, technical demands and manufacturing process, and studies the approaches on wheel 3D solid modeling and the parametric design. A 3D wheel model is built up by CAD software SolidWorks. The key geometric dimensions of wheels are analyzed and wheel parametric design was realized by establishing an EXECL series parameter table.
Because the tradition design measure can not accurately calculate the wheel stress distribution and the largest stress, the paper proposes the way to carry on the wheel struction strength analysis by the CAD/CAE integration technology. The methods of CAD/CAE integration are analyzed, and data share is implemented between the wheel 3D solid model and ANSYS. On the basis of analyzing typical working condition of railway vehicles, the calculation model and evaluation method of the wheel intensity is proposed. The intensity of a wheel with typical construction was calculated by ANSYS software.
On the NC programming of wheel treadle and its CAD/CAM integration, an automatic NC program software of wheel tread was developed through SolidWorks API, Visual C++.NET and COM technology. The geometric parameters of a wheel tread are obtained directly from the wheel 3D modeling by the software, and the NC program can generated automatically according to manual defined machining parameters.
本论文首先对车轮的结构形式、技术要求和制造工艺进行了分析研究。在此基础上,开展车轮三维实体造型及参数化设计方法的研究。并利用SolidWorks软件系统,建立了车轮三维CAD模型。对车轮关键几何尺寸进行了分析,通过建立EXECL系列参数表,实现了车轮的参数化设计。
针对传统设计方法无法精确计算车轮应力分布和最大应力问题,提出运用CAD/CAE集成技术的方法进行车轮结构强度分析计算。对CAD/CAE集成技术进行了分析,实现了车轮CAD模型与ANSYS间的数据共享。在分析车辆典型受力工况的基础上,建立了车轮的结构强度计算模型,采用有限元分析软件ANSYS对典型结构车轮进行了分析计算,给出了车轮强度的评定方法。
针对车轮踏面数控加工和CAD/CAM集成的需要,采用三维软件SolidWorks API和Visual C++.NET为开发工具,采用COM组件技术进行了车轮踏面数控加工编程软件的开发。该软件可利用车轮三维CAD几何模型直接获得车轮踏面的几何参数,并根据输入的加工参数自动生成车轮踏面数控加工代码。
Railway Vehicles are primary transportation tools in China, and wheels are key components of railway Vehicles, which support the all weight of vehicles and run in the high speed on rail. With increasing demands on the rail transport in the modern society, high-speed and heavy load trains are developed very rapidly, the demands on wheel design and manufacture has become higher and higher, so it is necessary to employ the CAD/CAE/CAM technology to ensure wheel design and manufacturing quality.
The paper first discusses wheel structure, technical demands and manufacturing process, and studies the approaches on wheel 3D solid modeling and the parametric design. A 3D wheel model is built up by CAD software SolidWorks. The key geometric dimensions of wheels are analyzed and wheel parametric design was realized by establishing an EXECL series parameter table.
Because the tradition design measure can not accurately calculate the wheel stress distribution and the largest stress, the paper proposes the way to carry on the wheel struction strength analysis by the CAD/CAE integration technology. The methods of CAD/CAE integration are analyzed, and data share is implemented between the wheel 3D solid model and ANSYS. On the basis of analyzing typical working condition of railway vehicles, the calculation model and evaluation method of the wheel intensity is proposed. The intensity of a wheel with typical construction was calculated by ANSYS software.
On the NC programming of wheel treadle and its CAD/CAM integration, an automatic NC program software of wheel tread was developed through SolidWorks API, Visual C++.NET and COM technology. The geometric parameters of a wheel tread are obtained directly from the wheel 3D modeling by the software, and the NC program can generated automatically according to manual defined machining parameters.
引文
[1]严隽耄.车辆工程.北京:中国铁道出版社,1992
[2]刘迎曦.轮轨两点接触的有限元分析.机械工程学报,2005,(11):121-125
[3]米彩盈,李芾.高速动力车车轮强度分析的工程方法.内燃机车,2005,(9):11-13
[4]刘会英,张澎湃,米彩盈.铁道车辆车轮强度设计方法探讨.铁道学报,2007,29(1):102-108.
[5]孙水鹏.KZ4A型机车车轮强度计算和轮对模态分析.电力机车与城轨车辆,2005,(9):27-30
[6]丁辉.铁道车辆车轮强度分析和评定方法.铁道车辆,2003,8:12-14
[7]崔胜民,高旭宏.车轮CAD/CAE/CAM一体化技术的研究.机械设计与制造,2004,(3):36-38
[8]崔胜民,杨占春.基于有限元分析的汽车车轮结构优化设计.机械设计,2001,(9):23-26
[9]米彩盈.有限元法基础和铁道车辆结构分析.成都:西南交通大学,2005
[10]陈胜利.铁道轮轴配合有限元分析.铁道车辆,2003,41(5):16-17
[11]余红英,樊永生.火车车轮非线性有限元热应力分析.华北工学院学报,2002,(1):25-27
[12]卢军.参数化设计火车车轮及模具CAD系统.机械工程师,1999,(9):41-42
[13]杨岳,罗意平.CAD/CAM原理与实践.北京:中国铁道出版社,2002
[14]陈世和.车辆修造工艺与装备.北京:中国铁道出版社.1999
[15]江洪.SolidWorks 2003二次开发基础与实例教程.北京:电子工业出版社,2003
[16]江洪,魏峥.SolidWorks二次开发实例解析.北京:机械工业出版社,2004
[17]Sai Kishore Sripriya.Visual C++.NET专业项目实例开发.北京:机械工业出版社,1999
[18]陈坚.Visual C++.NET编程基础专家教程.北京:西安电子科技大学出版社,2002
[19]池勇.SolidWorks二次开发方法的研究.机械,2003,(3):38-40
[20]丁毓峰.用VisualC++6.0开发SolidWorks三维标准件库.计算机工程,2000,(7):52-54
[21]王军.MasterCAM Lathe在整体车轮数控加工程序设计中的应用.机械工人,2005,(3):77-79
[22]赵愉悦.新型车轮的数控加工.机械工人(冷加工),2002,(3):51-52
[23]周增文.机械加工工艺基础.长沙:中南大学出版社,2003
[24]叶炜成,余才佳.SolidWorks 2006实体建模与二次开发教程.北京:国防工学出版社,2006
[25]NIT公司.C#实用全书.北京:电子工业出版社,2002
[26]孙永强,戴锋.Visual C#.NET程序设计基础.北京:清华大学出版社,2002
[27]杨有君.数控技术.北京:机械工业出版社,2005
[28]秦国庆.车轮不同生产方式及特性分析.锻压技术,1999,(6):31-34
[29]王定标,郭茶秀,向飒.CAD/CAE/CAM技术与应用.北京:化学工业出版社,2005
[30]王宏林,李芾,黄运华.25t轴重重载货车车轮强度分析.铁道车辆,2007,45(12):1-3
[31]I.Y.Shevtsov,V.L.Markine,C.Esveld.Optimal design of wheel profile for railway vehicles.Wear,2005,258:1022-1030
[32]R.Fuoco,M.M.Ferreira,C.R.F.Azevedo.Failure analysis of a cast steel railway wheel.Engineering Failure Analysis,2004,(11):817-828
[33]Hamid Jahed,Behrooz Farshi,Mohammad A.Eshraghi,etal.A numerical optimization technique for design of wheel profiles.Wear,2008,264:1-10
[34]E.A.Gallardo-Hemandez,R.Lewis,R.S.Dwyer-Joyce.Temperature in a twin-disc wheel/rail contact simulation.Tribology International,2006,39:1653-1663
[35]MariaA,Heckl and I.D.Abrahamss.Curve Squeal of Train Wheels.Journal of Sound and Vibration,2000,229(3):709-735
[36]Wu Cai,Zefeng Wen,Xuesong Jin,etal.Dynamic stress analysis of rail joint with height difference defect using finite element method.Engineering Failure Analy-sis,2007,(14):1488-1499
[37]R.Fuoco,M.M.Ferreira,C.R.F.Azevedo.Failure analysis of a cast steel railway wheel.Engineering Failure Analysis,2004,(11):817-828
[38]Hakan Lane,Per Kettil,Nils-Erik Wiberg.Moving finite elements and dynamic vehicle interaction.European Journal of Mechanics,2007,(11):18-35
[39]Tanel Telliskivi,Ulf Olofsson.Wheel-rail wear simulation,science direct,2004,(11):1145-1153
[40]周力.车轮踏面数控加工系统的研究.[硕士学位论文].武汉:华中科技大学,2004
[41]铁道部标准计量所.铁道车辆用轮对型式与基本尺寸(TB/T 1001-2005).北京:铁道部科学研究院,2005
[42]钟斌,吴勇中,陈刚.国内外车轮生产工艺的对比分析.江西冶金.2003,23(4):12-15
[43]张斌,陈雷.我国铁路货车车轮技术发展.中国铁路.2006,(7):53-55
[2]刘迎曦.轮轨两点接触的有限元分析.机械工程学报,2005,(11):121-125
[3]米彩盈,李芾.高速动力车车轮强度分析的工程方法.内燃机车,2005,(9):11-13
[4]刘会英,张澎湃,米彩盈.铁道车辆车轮强度设计方法探讨.铁道学报,2007,29(1):102-108.
[5]孙水鹏.KZ4A型机车车轮强度计算和轮对模态分析.电力机车与城轨车辆,2005,(9):27-30
[6]丁辉.铁道车辆车轮强度分析和评定方法.铁道车辆,2003,8:12-14
[7]崔胜民,高旭宏.车轮CAD/CAE/CAM一体化技术的研究.机械设计与制造,2004,(3):36-38
[8]崔胜民,杨占春.基于有限元分析的汽车车轮结构优化设计.机械设计,2001,(9):23-26
[9]米彩盈.有限元法基础和铁道车辆结构分析.成都:西南交通大学,2005
[10]陈胜利.铁道轮轴配合有限元分析.铁道车辆,2003,41(5):16-17
[11]余红英,樊永生.火车车轮非线性有限元热应力分析.华北工学院学报,2002,(1):25-27
[12]卢军.参数化设计火车车轮及模具CAD系统.机械工程师,1999,(9):41-42
[13]杨岳,罗意平.CAD/CAM原理与实践.北京:中国铁道出版社,2002
[14]陈世和.车辆修造工艺与装备.北京:中国铁道出版社.1999
[15]江洪.SolidWorks 2003二次开发基础与实例教程.北京:电子工业出版社,2003
[16]江洪,魏峥.SolidWorks二次开发实例解析.北京:机械工业出版社,2004
[17]Sai Kishore Sripriya.Visual C++.NET专业项目实例开发.北京:机械工业出版社,1999
[18]陈坚.Visual C++.NET编程基础专家教程.北京:西安电子科技大学出版社,2002
[19]池勇.SolidWorks二次开发方法的研究.机械,2003,(3):38-40
[20]丁毓峰.用VisualC++6.0开发SolidWorks三维标准件库.计算机工程,2000,(7):52-54
[21]王军.MasterCAM Lathe在整体车轮数控加工程序设计中的应用.机械工人,2005,(3):77-79
[22]赵愉悦.新型车轮的数控加工.机械工人(冷加工),2002,(3):51-52
[23]周增文.机械加工工艺基础.长沙:中南大学出版社,2003
[24]叶炜成,余才佳.SolidWorks 2006实体建模与二次开发教程.北京:国防工学出版社,2006
[25]NIT公司.C#实用全书.北京:电子工业出版社,2002
[26]孙永强,戴锋.Visual C#.NET程序设计基础.北京:清华大学出版社,2002
[27]杨有君.数控技术.北京:机械工业出版社,2005
[28]秦国庆.车轮不同生产方式及特性分析.锻压技术,1999,(6):31-34
[29]王定标,郭茶秀,向飒.CAD/CAE/CAM技术与应用.北京:化学工业出版社,2005
[30]王宏林,李芾,黄运华.25t轴重重载货车车轮强度分析.铁道车辆,2007,45(12):1-3
[31]I.Y.Shevtsov,V.L.Markine,C.Esveld.Optimal design of wheel profile for railway vehicles.Wear,2005,258:1022-1030
[32]R.Fuoco,M.M.Ferreira,C.R.F.Azevedo.Failure analysis of a cast steel railway wheel.Engineering Failure Analysis,2004,(11):817-828
[33]Hamid Jahed,Behrooz Farshi,Mohammad A.Eshraghi,etal.A numerical optimization technique for design of wheel profiles.Wear,2008,264:1-10
[34]E.A.Gallardo-Hemandez,R.Lewis,R.S.Dwyer-Joyce.Temperature in a twin-disc wheel/rail contact simulation.Tribology International,2006,39:1653-1663
[35]MariaA,Heckl and I.D.Abrahamss.Curve Squeal of Train Wheels.Journal of Sound and Vibration,2000,229(3):709-735
[36]Wu Cai,Zefeng Wen,Xuesong Jin,etal.Dynamic stress analysis of rail joint with height difference defect using finite element method.Engineering Failure Analy-sis,2007,(14):1488-1499
[37]R.Fuoco,M.M.Ferreira,C.R.F.Azevedo.Failure analysis of a cast steel railway wheel.Engineering Failure Analysis,2004,(11):817-828
[38]Hakan Lane,Per Kettil,Nils-Erik Wiberg.Moving finite elements and dynamic vehicle interaction.European Journal of Mechanics,2007,(11):18-35
[39]Tanel Telliskivi,Ulf Olofsson.Wheel-rail wear simulation,science direct,2004,(11):1145-1153
[40]周力.车轮踏面数控加工系统的研究.[硕士学位论文].武汉:华中科技大学,2004
[41]铁道部标准计量所.铁道车辆用轮对型式与基本尺寸(TB/T 1001-2005).北京:铁道部科学研究院,2005
[42]钟斌,吴勇中,陈刚.国内外车轮生产工艺的对比分析.江西冶金.2003,23(4):12-15
[43]张斌,陈雷.我国铁路货车车轮技术发展.中国铁路.2006,(7):53-55