机车转向架构架疲劳寿命预测
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摘要
长期以来,构架作为铁道机车车辆系统的关键部件,其结构强度和疲劳寿命得到了广泛的关注。构架结构静强度在设计阶段可以通过计算,并结合相关理论进行评估从而得到保证。构架在动应力作用下的疲劳强度评估一般只有在其制造完成后,通过相应的疲劳测试试验来进行。如果测试结果表明构架的疲劳强度不满足设计和服务年限的要求,那么该构架就只得进行改进或重新设计。这显然与尽可能地缩短产品开发周期、最大限度地降低产品研制成本的现代化工业设计理念不符合。
本文结合国内外疲劳研究最新成果,通过机车多体系统动力学仿真、有限元法和疲劳寿命预测等多领域综合分析,以期实现设计阶段机车转向架构架的疲劳寿命评估。首先根据机车实际的结构参数,利用动力学仿真软件SIMPACK建立整车动力学模型,通过对机车典型运行工况下的动力学性能仿真,计算得出用于构架疲劳寿命分析的载荷时间历程;然后根据机车转向架构架的实际结构尺寸,利用三维制图软件SolidWorks建立详细的构架实体模型,并利用该软件与ANSYS之间的接口实现构架的有限元分析,包括静态应力分析、准静态应力分析和模态分析;最后确定母材和焊缝的S-N曲线,结合作用于构架上的载荷时间历程和有限元准静态应力分析结果,选择合适的疲劳寿命预测方法,采用相关疲劳寿命分析软件nSoft对构架进行疲劳寿命分析,得出构架结构最薄弱的结构部位,并对其进行详细的寿命分析。
这种基于虚拟样机技术的疲劳寿命分析方法,在构架结构设计阶段就能预测动应力分布状态,从而为构架结构的优化设计提供理论依据。
For a long time, bogie frame as a key structural component of railway vehicle system, the structural strength and fatigue life are widely concerned. The intensity of a frame can be ensured by the calculation combining with the corresponding theory at the design stage. The frame fatigue life assessment under dynamic loads is done by adopting fatigue test only after the completion of the manufacture. If the testing results show that the fatigue strength of this type frame doesn't satisfy design requirement or service life, the frame should be improved or redesigned. It's obviously incompatibe with modern design concepts which must shorten product development cycles and minimize the manufacturing cost.
Based on the latest fatigue research results at home and abroad, the paper is to achieve the locomotive bogie frame fatigue life assessment via the Multi-Body system dynamic simulation, the finite element method and fatigue life prediction at the design stage. Firstly, the whole locomotive dynamic model was established using the SIMPACK software according to the actual structural parameters. All the load histories, which were used to evaluate the bogie frame fatigue life, would be obtained by the dynamic performance simulation under the typical locomotive operation condtions. Secondly, the solid model of the frame was established using the 3D software SolidWorks. The finite element analysis of the frame was achieved through the connection between the 3D software and ANSYS software, including the static stress analysis, quasi-static stress analysis and modal analysis. Finally, combining the S - N curves of the material and weld, the load histories acting on the frame and the results of the quasi-static stress analysis, choosing the appropriate fatigue life prediction method, the frame fatigue life evaluation was done using the nSoft software. The most weakness position was confirmed and then the particular fatigue life analysis was done.
The above fatigue life prediction method based on the virtual techinique can predict the stress distribution at the design stage and provide the theory instruction for the structural optimization of the frame.
本文结合国内外疲劳研究最新成果,通过机车多体系统动力学仿真、有限元法和疲劳寿命预测等多领域综合分析,以期实现设计阶段机车转向架构架的疲劳寿命评估。首先根据机车实际的结构参数,利用动力学仿真软件SIMPACK建立整车动力学模型,通过对机车典型运行工况下的动力学性能仿真,计算得出用于构架疲劳寿命分析的载荷时间历程;然后根据机车转向架构架的实际结构尺寸,利用三维制图软件SolidWorks建立详细的构架实体模型,并利用该软件与ANSYS之间的接口实现构架的有限元分析,包括静态应力分析、准静态应力分析和模态分析;最后确定母材和焊缝的S-N曲线,结合作用于构架上的载荷时间历程和有限元准静态应力分析结果,选择合适的疲劳寿命预测方法,采用相关疲劳寿命分析软件nSoft对构架进行疲劳寿命分析,得出构架结构最薄弱的结构部位,并对其进行详细的寿命分析。
这种基于虚拟样机技术的疲劳寿命分析方法,在构架结构设计阶段就能预测动应力分布状态,从而为构架结构的优化设计提供理论依据。
For a long time, bogie frame as a key structural component of railway vehicle system, the structural strength and fatigue life are widely concerned. The intensity of a frame can be ensured by the calculation combining with the corresponding theory at the design stage. The frame fatigue life assessment under dynamic loads is done by adopting fatigue test only after the completion of the manufacture. If the testing results show that the fatigue strength of this type frame doesn't satisfy design requirement or service life, the frame should be improved or redesigned. It's obviously incompatibe with modern design concepts which must shorten product development cycles and minimize the manufacturing cost.
Based on the latest fatigue research results at home and abroad, the paper is to achieve the locomotive bogie frame fatigue life assessment via the Multi-Body system dynamic simulation, the finite element method and fatigue life prediction at the design stage. Firstly, the whole locomotive dynamic model was established using the SIMPACK software according to the actual structural parameters. All the load histories, which were used to evaluate the bogie frame fatigue life, would be obtained by the dynamic performance simulation under the typical locomotive operation condtions. Secondly, the solid model of the frame was established using the 3D software SolidWorks. The finite element analysis of the frame was achieved through the connection between the 3D software and ANSYS software, including the static stress analysis, quasi-static stress analysis and modal analysis. Finally, combining the S - N curves of the material and weld, the load histories acting on the frame and the results of the quasi-static stress analysis, choosing the appropriate fatigue life prediction method, the frame fatigue life evaluation was done using the nSoft software. The most weakness position was confirmed and then the particular fatigue life analysis was done.
The above fatigue life prediction method based on the virtual techinique can predict the stress distribution at the design stage and provide the theory instruction for the structural optimization of the frame.
引文
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[2] M.Haiba, D.C.Barton, P.C.Brooks, M.C.Levesley. Review of life assessment techniques applied to dynamically loaded automotive components. Computers and structures,2002(80):481 -494
[3] Johan Martinsson. Fatigue assessment of complex welding steel structures. Ph.D.Royal institute of technology, Stockholm,2005,2
[4] R.KXuo, B.L.Gabbitas, B.V.Brickle. Fatigue life evaluation of a railway vehicle bogie using an integrated dynamic simulation. Proc Instn Mech Engrs,1994(208):23-132
[5] R.K.Luo, B.L.Gabbitas, B.V.Brickle, W.X.Wu. Fatigue damage evaluation for a railway vehicle bogie using appropriate sampling frequenciese. Vehicle System Dynamics,1998(28):405-415
[6] R.KXuo, B.L.Gabbitas, B.V.Brickle. An intergrated dynamic simulation of metro vehicle in a real operating environment. Vehicle System Dynamics, 1993(23):335-345
[7] P.K.Luo, B.L.Gabbitas, B.V.Brickle. Fatigue design in railway vehicle bogies based on dynamic simulation. Vehicle System Dynamics, 1996(25):449-459
[8] Stefan Dietz, Helmuth Netter, Sachau. Fatigue life prediction of a railway bogie under dynamic loads through simulation. Vehicle System Dynamics,1998(29):385-402
[9] Su Hong. Automotive CAE Durability Analysis Using Random Vibration Approach. MSC 2nd Worldwide Automotive Conference, Dearborn,MI,2000,10
[10] S.DIETZ, K.KNOTHE, W.KORTUM (Germany). Fatigue Life Simulations Applied to Railway Bogies. The 4TH International Conference on railway bogies and running gears, 1998,9
[11] H.Riener, D.Peiskammer, W.Witteveen. Modal Durability analysis of a passenger cars front suppoting frame due to full vehicle simulation loads.Adams user conference,North America,2001
[12]K.S.Kim,H.J.Yim,C.B.Kim.Computational durability prediction of body structure in propotype vehicle.International Journal of automotive technology,2002(3):129-136
[13]Shinichi CHIBA,Kimihiko AOYAMA,Kenji YANABU.Fatigue Strength Prediction of Truck Cab by CAE.Technical review,2003(15):53-58
[14]孟广伟,王成国,刘敬辉,原亮明.用虚拟疲劳样机技术分析转8A型转向架侧架的疲劳寿命.中国铁道科学,2002,23(4):8-11
[15]刘德刚,候卫星,王凤州等.基于有限元技术的构件疲劳寿命计算.铁道学报,2004,26(2):47-51
[16]缪炳荣.基于多体动力学和有限元法的机车车体结构疲劳仿真研究.西南交通大学,博士学位论文.成都,2006,10
[17]阳光武.机车车辆零部件的疲劳寿命预测仿真.西南交通大学,博士论文.成都,2005,7
[18]曾仲谋.电力机车车体关键部位疲劳寿命预测.西南交通大学,硕士论文.成都,2004,3
[19]Sung I1 SEO,Choon PARK,Ki Hwan KIM.Fatigue strength evaluation of the aluminum carbody of urban transit unit by large scale dynamic load test.JSME international journal,Vol.48(1),2005
[20]缪龙秀,孙守光,吕澎民,刘志明,李强.提速客车转向架焊接构架应力谱的试验研究.铁道车辆,1998,36(12):30-34
[21]吕澎民,赵邦华.车辆振动系统结构疲劳寿命预测方法及应用.兰州铁道学院学报,1996,15(3):46-53
[22]吕澎民,严隽耄.焊接转向架结构可靠性疲劳寿命预估方法研究.兰州铁道学院学报,1995,14(3):80-85
[23]吕澎民,赵邦华,王明复,孟广甫.货车铸钢侧架随机载荷谱下的疲劳寿命预估研究.铁道学报,1994,16(1):101-107
[24]刘志明.随机载荷下焊接构架疲劳寿命及可靠性研究.北方交通大学,博士学位论文.北京,2001,3
[25]王成国,孟广伟,原亮明,刘敬辉.新型高速客车技术构架的疲劳寿命数值仿真分析.中国铁道科学,2001,22(3):91-94
[26]虞丽娟,李元君,沈钢.机车构件疲劳寿命仿真分析.铁道学报,1998,20(3):120-126
[27]于慧,王文斌,虞丽娟,赵洪伦.基于疲劳设计的高速客车转向架构架优化设计.铁道车辆,2001,39(8):9-11,37
[28]赵文礼,赵邦华,何钟韬.客车车辆随机动态响应与车轴强度的结合研究.甘肃科学学报,1994(3):48-54
[29]赵文礼,赵邦华.客车车轴的应力谱分析与疲劳寿命估算.甘肃科学学报,1994(1):53-57
[30]涂善东,赵永翔.机械强度学科发展趋势.机械强度,2005,27(4):555-559
[31]米彩盈.机车转向架焊接构架轻量化评定和疲劳强度分析.西南交通大学学报.1999,34(1):104-108
[32]梁红琴,邬平波,关雪梅.随机载荷作用下货车车轴的疲劳应力计算.机械,2004,31(4):36-39
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