机车轮对轮箍加装扣环方案的力学性能分析
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摘要
为了防止内燃机车轮箍弛缓造成的机车脱轨事故,郑州铁路局机务处提出了给组装式机车轮对轮箍加装扣环的方案。机车轮对轮箍加装扣环后的运行实践证明,该方案可有效地防止因轮箍弛缓而造成的机车脱轨等重大事故,但轮箍加装扣环后由于结构发生了变化,存在以下几个方面的问题:轮辋与轮箍的配合面变短,轮辋受力中心外移导致轮辋弯曲变形;扣环槽部不可避免会有应力集中;轮箍的踏面和轮缘在使用过程中会发生磨损;恢复踏面和轮缘的线型时,需要对车轮进行车削修整,导致轮箍与轮缘变薄。因此,就加装扣环车轮在结构上的变化而引起车轮强度的变化进行分析与研究,在为机车轮对的结构设计提供理论依据,保证铁路机车安全运行等方面具有十分重要的意义。
本文以大型通用有限元分析软件ANSYS为分析工具,在装配应力、直线及曲线三种工况载荷下分别对加装扣环车轮及未加装扣环车轮进行了静力分析,并对计算结果进行了对比,确定了扣环槽对车轮结构的影响。此外,还对计算结果从静强度和疲劳强度两方面进行了评价。结果表明扣环槽对车轮局部的静强度产生一定影响,但这些影响主要是由于扣环槽的应力集中和轮箍轮辋配合面变窄引起的,对整个车轮的应力分布并没有多大影响,而且从应力数值上看,影响也很小的。
同时,对加装扣环车轮进行了模态分析,提取了前十阶固有频率和振动型态,与未加装扣环车轮的前十阶固有频率和振动型态进行对比,并在此基础上针对机车过过轨缝受到冲击的垂向动力学响应进行了分析,进一步确定扣环槽对车轮动力学性能的影响。结果表明无论是节点位移,节点力及节点应力均滞后于垂向动载荷的变化,扣环槽的存在对车轮动力学性能的影响较对静力学性能的影响要大一些,但并没有引起质的变化。
最后,针对铁道部提出的轮箍踏面禁用厚度,用穷举的方法对三组不同厚度(38mm,30mm,25mm)的踏面车轮在最恶劣工况载荷下进行分析计算,结果表明踏面厚度的变化并没有影响车轮整体的应力分布,而是将应力最大值由新轮的辐板弯曲处转移到轮箍上,仅从静强度和疲劳强度两方面考虑,加装扣环车轮在踏面厚度为30mm时运行是安全的。因此可以断言,轮箍加装扣环后铁道部原来规定的踏面与轮缘的禁用限度能够保障机车的安全运行。
For the purpose of preventing against relaxation of train wheels, Zhengzhou railway station brought forward the project of equipping coupling collar on train wheels, which could prevent against the serious accident after putting on practice. However, there are some problems that inevitably exist. First, the assemble face becomes narrower. Second, stress concentration is inevitably. Third, tread and wheel rim will be abraded. Forth, tread and wheel rim will become thinner after cutting and repairing. Therefore, it is very important to research on the project, which will provide theoretic evidence for the run security.Using the large general finite element analysis software ANS YS as analytic tool, and taking the geometric structure and boundary condition into consideration, the train wheel equipped with coupling collar and the wheel unequipped were analyzed and compared in static in three differ rent operating load. The result shows that equipping coupling collar only influence the local part of the wheel, the change of stress can also ignorant.The modal analysis was made for the wheels that equipped coupling collar and not, on the basis of which the transient dynamic analysis also was made when crossing the rail gap. The result show that no matter what the node displacement, node force and node stress, which all delayed compared to the change of vertical load, and the influence on dynamic capability made by coupling collar was more remarkable.At last, aimed at tread's forbidden thickness brought by railway department, three types of wheels in different tread thickness were analyzed in bad operating load, which will provide theoretic evidence in searching the security boundary. The result shows the change of treads' thickness made no effort on the wheel's stress distribution, just convert the stress maximum to tire. In addition, with the thickness becoming thinner to 25mm, stress maximum reach to 429MPa, which is beyond the yield limit.
本文以大型通用有限元分析软件ANSYS为分析工具,在装配应力、直线及曲线三种工况载荷下分别对加装扣环车轮及未加装扣环车轮进行了静力分析,并对计算结果进行了对比,确定了扣环槽对车轮结构的影响。此外,还对计算结果从静强度和疲劳强度两方面进行了评价。结果表明扣环槽对车轮局部的静强度产生一定影响,但这些影响主要是由于扣环槽的应力集中和轮箍轮辋配合面变窄引起的,对整个车轮的应力分布并没有多大影响,而且从应力数值上看,影响也很小的。
同时,对加装扣环车轮进行了模态分析,提取了前十阶固有频率和振动型态,与未加装扣环车轮的前十阶固有频率和振动型态进行对比,并在此基础上针对机车过过轨缝受到冲击的垂向动力学响应进行了分析,进一步确定扣环槽对车轮动力学性能的影响。结果表明无论是节点位移,节点力及节点应力均滞后于垂向动载荷的变化,扣环槽的存在对车轮动力学性能的影响较对静力学性能的影响要大一些,但并没有引起质的变化。
最后,针对铁道部提出的轮箍踏面禁用厚度,用穷举的方法对三组不同厚度(38mm,30mm,25mm)的踏面车轮在最恶劣工况载荷下进行分析计算,结果表明踏面厚度的变化并没有影响车轮整体的应力分布,而是将应力最大值由新轮的辐板弯曲处转移到轮箍上,仅从静强度和疲劳强度两方面考虑,加装扣环车轮在踏面厚度为30mm时运行是安全的。因此可以断言,轮箍加装扣环后铁道部原来规定的踏面与轮缘的禁用限度能够保障机车的安全运行。
For the purpose of preventing against relaxation of train wheels, Zhengzhou railway station brought forward the project of equipping coupling collar on train wheels, which could prevent against the serious accident after putting on practice. However, there are some problems that inevitably exist. First, the assemble face becomes narrower. Second, stress concentration is inevitably. Third, tread and wheel rim will be abraded. Forth, tread and wheel rim will become thinner after cutting and repairing. Therefore, it is very important to research on the project, which will provide theoretic evidence for the run security.Using the large general finite element analysis software ANS YS as analytic tool, and taking the geometric structure and boundary condition into consideration, the train wheel equipped with coupling collar and the wheel unequipped were analyzed and compared in static in three differ rent operating load. The result shows that equipping coupling collar only influence the local part of the wheel, the change of stress can also ignorant.The modal analysis was made for the wheels that equipped coupling collar and not, on the basis of which the transient dynamic analysis also was made when crossing the rail gap. The result show that no matter what the node displacement, node force and node stress, which all delayed compared to the change of vertical load, and the influence on dynamic capability made by coupling collar was more remarkable.At last, aimed at tread's forbidden thickness brought by railway department, three types of wheels in different tread thickness were analyzed in bad operating load, which will provide theoretic evidence in searching the security boundary. The result shows the change of treads' thickness made no effort on the wheel's stress distribution, just convert the stress maximum to tire. In addition, with the thickness becoming thinner to 25mm, stress maximum reach to 429MPa, which is beyond the yield limit.
引文
[1] 萨殊利编著.机车总体与走行部.北方交通大学出版社.2004
[2] 李述松,唐东平,宋春如.DF系列机车轮对轮箍加装扣环方案可行性分析.内燃机车.2003(5):18-19
[3] 曾攀.有限元分析及应用.清华大学出版社.2004
[4] 刘涛,杨凤鹏主编.精通ANSYS.清华大学出版社.2002
[5] 任辉启编著.ANSYS7.0工程分析实例详解.2003
[6] 倪栋,段进,徐久成等编著.通用有限元分析ANSYS7.0实例精解.电子工业出版社.2003
[7] 李小村主编.内燃机车总体.中国铁道出版社,2002,112
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[9] 沙杜尔[苏]著.苏宝瑛等译.车辆构造理论与计算.中国铁道出版社.1980,74
[10] 张中央主编.列车牵引计算.中国铁道出版社.2002,36
[11] 温泽峰,金学松,张卫华.钢轨轨缝接触—冲击的有限元分析.摩擦学学报.2003,23(3):240-244
[12] 实威科技编著.SolidWorks原厂教育训练手册.清华大学出版社,2002
[13] 陈胜利.铁路轮轴配合有限元分析.铁道车辆.2003,41(5):16-18
[14] 丁辉.铁道车辆车轮强度分析和评定方法。铁道机车车辆.2003,23(4):12-14
[15] 缪炳荣,肖守纳.机车车体结构模态的有限元分析.机械与电子.2002(5):58-60
[16] 胡用生,谭复兴,陆正刚.TBDS轮轨耦合模型的仿真验证及其应用.铁道学报.1996,18(3):29-36
[17] 金学松,刘启跃.轮轨摩擦学.中国铁道出版社.2004
[18] 王家玉,王顺福.机车磨耗型踏面与踏面剥离.铁路运营技术.2004,10(4):26-28
[19] 佐藤荣作[日].车轮踏面形状设计的科学化.车外内燃机车.2000
[20] 刘达德主编.东风_(4B)型内燃机车结构—原理—检修.中国铁道出版社.2002,4
[21] 刘建新.无孔辐板轮对的结构强度分析.电力机车技术.2000(1):17-21
[22] 王宗彦,余红英,刘卫玲,王爱玲.复杂载荷下火车轮轴的有限元分析.华北工学院学报.2002,23(5):318-321
[23] 赵华,何翠微,刘建新.机车轮对装配应力的数值分析.铁道学报.1998,20(1):45-51
[24] 傅立东,肖峰.车轮与有限元计算.哈铁科技情报.2003(3)
[25] 许小强,赵洪伦.铁道车辆轮轴装配应力的接触非线性有限元分析.上海铁道大学学报.1999,20(12):76-79
[26] 许小强,赵洪伦.过盈配合应力的接触非线性有限元分析.上海铁道大学学报.2000(1):33-35
[27] 李俊,金咸定,李维扬.瞬态接触—冲击问题的有限元分析.上海交通大学学报. 1997,31(11):78-81
[28] 雷晓燕.轮轨相互作用有限元分析.铁道学报.1994,16(1):7-16
[29] 张焱,孔祥安,金学松.轮轨三维弹塑性接触应力的算法研究.力学与实践.2000,22(1):23-26
[30] K laus Knothe,等[德].轮轨接触力学的最新发展.国外铁道车辆.2002,39(5):27-33
[31] 吴昌华,张军.轮轨接触的有限元研究.大连铁道学院学报.1997,18(4):25-30
[32] 王忠东,张承志,谷中秋.有限元法在具有摩擦的有限变形接触问题中的应用.吉林大学自然科学学报.1995,8(3):12-18
[33] 汪召华,高莲士,宋文晶.二维摩擦接触的有限元分析.清华大学学报(自然科学版).2002,42(S1):25-28
[34] 欧垣安,李润方.三维冲击—动力接触问题的有限元混合算法.重庆大学学报.1994,17(2):52-57
[35] 向俊.机车车辆随机振动分析的有限单元法研究.长沙铁道学院学报.1995,13(4):38-45
[36] 张治国,郑明军,谢基龙.弹性车轮瞬态动力响应的有限元仿真方法研究.北方交通大学学报.2003,27(1):25-35
[37] 王珍君,侯炳麟.钢轨轨头三维应力有限元分析.中国铁道科学.2000,21(4):66-72
[38] 陆辉,孙国瑛.非椭圆接触面下钢轨三维弹塑性应力分析.西南交通大学学报.2000,35(4):340-345
[39] Ullah I, Kota S.Optimal Synthesis of mechanisms of path generation using fourier descriptors and gloabal search methods. ASME Journal of Mechaniacl Design, 1997, 119(4):504-510
[40] Amanan L, Krishna Kumar R, Sriraman R. Thermo-mechanical finite element analysis is of a rail wheel[J]. International Journal of Mechanical Science, 1999, 41: 487-505
[41] Lunden R. Crack in railway wheels under rolling contact[A]. Proceedings of 10th International wheelset Congress[C], Sydney, October, 1992.163
[42] Ikeda K, Sumi T, Sasaki S. Characteristics of irregular inclination of rail vibration in the rail joint[C]. In: Proceedings of the Western Branch in JSCE, 1998, 136-138.
[43] Cannon D F, Sinclair J, Sharp K A. Improving the fatigue performance of bolt holes in railway rails by cold expansion[C]. In: The International Conference on Fatigue Correction Cracking, Fracture Mechanics and Failure Analysis, Salt Lake City, USA, December, 1985
[44] John O Hallquist. LS-DYNA User's Manual-Version 940[M]. Livermore: Livermore Sofeware Technology Corporation, 1997.
[45] Clark R A, Dean P A, Elkins J A, etal. An investigation into the dynamic effects of railway vehicle running on corrugated rails[J]. Journal of Mechanical Engineering Science, 1992, 24(2): 65-76
[46] Jenkins H H, The effects of track and vehicle parameters on wheel/rail vertical dynamic forces[J]. Railway Engineering Journal, 1994, 3(1):2-16
[47] Scurria N V, Doyle J F. Photoelastic analysis of contact stresses in the presence of maching irregulaties. Experimental Mechanics, 1992,(22):342-347
[48] Grimm T R, Chiu A C. Design of hubs to minimize interference stresses-A finite elelment study. Computers in Engineering 1988-Proceedings, San Franciso, ASME, 1988,85-91
[49] Kags H. Stress analysis of a tire undervertical load by a finite element method[J]. Tire Science & Technology, TSTCA, 1997,5(2): 102-118
[2] 李述松,唐东平,宋春如.DF系列机车轮对轮箍加装扣环方案可行性分析.内燃机车.2003(5):18-19
[3] 曾攀.有限元分析及应用.清华大学出版社.2004
[4] 刘涛,杨凤鹏主编.精通ANSYS.清华大学出版社.2002
[5] 任辉启编著.ANSYS7.0工程分析实例详解.2003
[6] 倪栋,段进,徐久成等编著.通用有限元分析ANSYS7.0实例精解.电子工业出版社.2003
[7] 李小村主编.内燃机车总体.中国铁道出版社,2002,112
[8] 孙竹生,鲍维千.内燃机车总体及走行部.中国铁道出版社,1980,136
[9] 沙杜尔[苏]著.苏宝瑛等译.车辆构造理论与计算.中国铁道出版社.1980,74
[10] 张中央主编.列车牵引计算.中国铁道出版社.2002,36
[11] 温泽峰,金学松,张卫华.钢轨轨缝接触—冲击的有限元分析.摩擦学学报.2003,23(3):240-244
[12] 实威科技编著.SolidWorks原厂教育训练手册.清华大学出版社,2002
[13] 陈胜利.铁路轮轴配合有限元分析.铁道车辆.2003,41(5):16-18
[14] 丁辉.铁道车辆车轮强度分析和评定方法。铁道机车车辆.2003,23(4):12-14
[15] 缪炳荣,肖守纳.机车车体结构模态的有限元分析.机械与电子.2002(5):58-60
[16] 胡用生,谭复兴,陆正刚.TBDS轮轨耦合模型的仿真验证及其应用.铁道学报.1996,18(3):29-36
[17] 金学松,刘启跃.轮轨摩擦学.中国铁道出版社.2004
[18] 王家玉,王顺福.机车磨耗型踏面与踏面剥离.铁路运营技术.2004,10(4):26-28
[19] 佐藤荣作[日].车轮踏面形状设计的科学化.车外内燃机车.2000
[20] 刘达德主编.东风_(4B)型内燃机车结构—原理—检修.中国铁道出版社.2002,4
[21] 刘建新.无孔辐板轮对的结构强度分析.电力机车技术.2000(1):17-21
[22] 王宗彦,余红英,刘卫玲,王爱玲.复杂载荷下火车轮轴的有限元分析.华北工学院学报.2002,23(5):318-321
[23] 赵华,何翠微,刘建新.机车轮对装配应力的数值分析.铁道学报.1998,20(1):45-51
[24] 傅立东,肖峰.车轮与有限元计算.哈铁科技情报.2003(3)
[25] 许小强,赵洪伦.铁道车辆轮轴装配应力的接触非线性有限元分析.上海铁道大学学报.1999,20(12):76-79
[26] 许小强,赵洪伦.过盈配合应力的接触非线性有限元分析.上海铁道大学学报.2000(1):33-35
[27] 李俊,金咸定,李维扬.瞬态接触—冲击问题的有限元分析.上海交通大学学报. 1997,31(11):78-81
[28] 雷晓燕.轮轨相互作用有限元分析.铁道学报.1994,16(1):7-16
[29] 张焱,孔祥安,金学松.轮轨三维弹塑性接触应力的算法研究.力学与实践.2000,22(1):23-26
[30] K laus Knothe,等[德].轮轨接触力学的最新发展.国外铁道车辆.2002,39(5):27-33
[31] 吴昌华,张军.轮轨接触的有限元研究.大连铁道学院学报.1997,18(4):25-30
[32] 王忠东,张承志,谷中秋.有限元法在具有摩擦的有限变形接触问题中的应用.吉林大学自然科学学报.1995,8(3):12-18
[33] 汪召华,高莲士,宋文晶.二维摩擦接触的有限元分析.清华大学学报(自然科学版).2002,42(S1):25-28
[34] 欧垣安,李润方.三维冲击—动力接触问题的有限元混合算法.重庆大学学报.1994,17(2):52-57
[35] 向俊.机车车辆随机振动分析的有限单元法研究.长沙铁道学院学报.1995,13(4):38-45
[36] 张治国,郑明军,谢基龙.弹性车轮瞬态动力响应的有限元仿真方法研究.北方交通大学学报.2003,27(1):25-35
[37] 王珍君,侯炳麟.钢轨轨头三维应力有限元分析.中国铁道科学.2000,21(4):66-72
[38] 陆辉,孙国瑛.非椭圆接触面下钢轨三维弹塑性应力分析.西南交通大学学报.2000,35(4):340-345
[39] Ullah I, Kota S.Optimal Synthesis of mechanisms of path generation using fourier descriptors and gloabal search methods. ASME Journal of Mechaniacl Design, 1997, 119(4):504-510
[40] Amanan L, Krishna Kumar R, Sriraman R. Thermo-mechanical finite element analysis is of a rail wheel[J]. International Journal of Mechanical Science, 1999, 41: 487-505
[41] Lunden R. Crack in railway wheels under rolling contact[A]. Proceedings of 10th International wheelset Congress[C], Sydney, October, 1992.163
[42] Ikeda K, Sumi T, Sasaki S. Characteristics of irregular inclination of rail vibration in the rail joint[C]. In: Proceedings of the Western Branch in JSCE, 1998, 136-138.
[43] Cannon D F, Sinclair J, Sharp K A. Improving the fatigue performance of bolt holes in railway rails by cold expansion[C]. In: The International Conference on Fatigue Correction Cracking, Fracture Mechanics and Failure Analysis, Salt Lake City, USA, December, 1985
[44] John O Hallquist. LS-DYNA User's Manual-Version 940[M]. Livermore: Livermore Sofeware Technology Corporation, 1997.
[45] Clark R A, Dean P A, Elkins J A, etal. An investigation into the dynamic effects of railway vehicle running on corrugated rails[J]. Journal of Mechanical Engineering Science, 1992, 24(2): 65-76
[46] Jenkins H H, The effects of track and vehicle parameters on wheel/rail vertical dynamic forces[J]. Railway Engineering Journal, 1994, 3(1):2-16
[47] Scurria N V, Doyle J F. Photoelastic analysis of contact stresses in the presence of maching irregulaties. Experimental Mechanics, 1992,(22):342-347
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