A型不锈钢点焊结构车体强度、模态、稳定性和疲劳强度的研究
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摘要
由于不锈钢材料具有轻量化、良好的耐腐蚀性、耐磨性和强度高等特点,使得不锈钢材料在我国城市地铁中得到了日益广泛的应用,我国A型不锈钢点焊结构车体按照轻量化设计并且它的强度、稳定性和疲劳性能等方面采用了国际上的最高标准。因此它的可靠性,稳定性和抗疲劳性能等就变得愈加重要。本文以某城市地铁不锈钢点焊结构A型车体为研究对象,在车体的设计阶段,运用计算机数值模拟技术对车体进行性能仿真分析。具体内容如下：
首先,依据工厂提供的不锈钢车体的几何模型及焊接关系图纸对头车车体进行合理的简化,建立了仿真研究的力学模型。以《EN12663-2000铁路应用-铁道车辆车体结构要求》标准为基础并结合工厂提供的计算任务最终确定车体强度分析的8种载荷工况,并对8种载荷工况的计算结果做出分析,评价了车体主要部位的强度,并提出改进建议。
其次,应用ANSYS软件中Lanczos方法对钢结构车体和整备状态下车体进行模态分析,分别得到了车体一阶扭转频率和一阶垂向弯曲的自振频率,并做了对比分析。
然后,基于线性屈曲的算法原理,在车钩压缩力1500KN作用下对车体原始方案进行稳定性分析,车体前端地板,枕内波纹地板等多处屈曲因子小于1.0的部位不满足设计要求并进行了3次改进方案,依据改进方案3的计算结果,对车体提出改进建议,最终使车体达到工厂设计的要求。
最后,基于BS7608-1993标准,并根据工厂提供的疲劳计算任务确定垂向载荷工况1,横向载荷工况,纵向载荷工况和垂向工况2四种疲劳载荷工况对车体母材,角焊,点焊处进行疲劳强度分析,并计算累积损伤比,计算结果表明：车体各部位的疲劳强度均满足设计要求。
The stainless steel metro has been increasingly used in China cities, because of stainless steel has a lightweight, good corrosion resistance, wear resistance and high strength characteristics。A-type stainless steel spot welding structure of the body is in accordance with lightweight design, and its strength, stability and fatigue properties use the highest international standard。Therefore, its reliability, stability and fatigue resistance, etc. has become more important。Taking a subway car body of stainless steel welding structure of A-type as the research object, use the computer simulation technology to the body for performance simulation in the body of the design phase. The details are as follows:
First of all, according to the geometric model of the stainless steel body, provided by the factory, and car body welding drawing, establish the mechanical model for the simulation study。Determine the ultimate strength analysis of the 8 body loading conditions based on the"EN 12663-2000 Railway applications-Structural requirements of railway vehicle body, standard and combining the computing tasks provided by the factory, analyze the calculated results of the 8 body loading conditions, and make recommendations for improvement。
Secondly, apply the ANSYS software to do the modal analysis of the steel body and the body under the preparation, obtain the first torsion frequency and the first vertical bending natural frequency, and compare the results。
Then, based on the linear buckling theory, to do the stability analysis of the body's original scheme under the coupler compression force, which is 1500KN, to improve the program the 3 times in the parts, whose buckling factors is less than 1.0, such as the floor in the front of body, corrugated floor in the pillow and so on, based on the results, recommendations for improvement of the body, eventually make the design meet the requirements of the body。
Finally, basing on the BS7608-1993 standard, and according to the fatigue-task supplied by factories, determine the vertical load case 1, lateral load cases, longitudinal and vertical load case 2, four kinds of fatigue loading conditions, to analyze the fatigue strength of the body of base metal, corner welding, spot welding, and calculate the cumulative damage ratio, the results show that:the fatigue strength of various parts of the body are to meet the design requirements。
首先,依据工厂提供的不锈钢车体的几何模型及焊接关系图纸对头车车体进行合理的简化,建立了仿真研究的力学模型。以《EN12663-2000铁路应用-铁道车辆车体结构要求》标准为基础并结合工厂提供的计算任务最终确定车体强度分析的8种载荷工况,并对8种载荷工况的计算结果做出分析,评价了车体主要部位的强度,并提出改进建议。
其次,应用ANSYS软件中Lanczos方法对钢结构车体和整备状态下车体进行模态分析,分别得到了车体一阶扭转频率和一阶垂向弯曲的自振频率,并做了对比分析。
然后,基于线性屈曲的算法原理,在车钩压缩力1500KN作用下对车体原始方案进行稳定性分析,车体前端地板,枕内波纹地板等多处屈曲因子小于1.0的部位不满足设计要求并进行了3次改进方案,依据改进方案3的计算结果,对车体提出改进建议,最终使车体达到工厂设计的要求。
最后,基于BS7608-1993标准,并根据工厂提供的疲劳计算任务确定垂向载荷工况1,横向载荷工况,纵向载荷工况和垂向工况2四种疲劳载荷工况对车体母材,角焊,点焊处进行疲劳强度分析,并计算累积损伤比,计算结果表明：车体各部位的疲劳强度均满足设计要求。
The stainless steel metro has been increasingly used in China cities, because of stainless steel has a lightweight, good corrosion resistance, wear resistance and high strength characteristics。A-type stainless steel spot welding structure of the body is in accordance with lightweight design, and its strength, stability and fatigue properties use the highest international standard。Therefore, its reliability, stability and fatigue resistance, etc. has become more important。Taking a subway car body of stainless steel welding structure of A-type as the research object, use the computer simulation technology to the body for performance simulation in the body of the design phase. The details are as follows:
First of all, according to the geometric model of the stainless steel body, provided by the factory, and car body welding drawing, establish the mechanical model for the simulation study。Determine the ultimate strength analysis of the 8 body loading conditions based on the"EN 12663-2000 Railway applications-Structural requirements of railway vehicle body, standard and combining the computing tasks provided by the factory, analyze the calculated results of the 8 body loading conditions, and make recommendations for improvement。
Secondly, apply the ANSYS software to do the modal analysis of the steel body and the body under the preparation, obtain the first torsion frequency and the first vertical bending natural frequency, and compare the results。
Then, based on the linear buckling theory, to do the stability analysis of the body's original scheme under the coupler compression force, which is 1500KN, to improve the program the 3 times in the parts, whose buckling factors is less than 1.0, such as the floor in the front of body, corrugated floor in the pillow and so on, based on the results, recommendations for improvement of the body, eventually make the design meet the requirements of the body。
Finally, basing on the BS7608-1993 standard, and according to the fatigue-task supplied by factories, determine the vertical load case 1, lateral load cases, longitudinal and vertical load case 2, four kinds of fatigue loading conditions, to analyze the fatigue strength of the body of base metal, corner welding, spot welding, and calculate the cumulative damage ratio, the results show that:the fatigue strength of various parts of the body are to meet the design requirements。
引文
[1]谢素明,隋明东,李晓峰,兆文忠.不锈钢点焊结构车体FEA建模方法[J].大连交通大学学报.2007,28(1)：18-22.
[2]李晓峰.基于虚拟疲劳试验的铁路车辆焊接结构疲劳寿命预测.大连交通大学博士论文.2008.5
[3]赵小宁.谈地铁不锈钢车体国产化及问题.工程建设与设计,2004,43：50-51
[4]员华,邹鹏.不锈钢车体与铝合金车体的现状及发展[J].都市快轨交通,2008(6),21(3)：89-91
[5]王炎金、丁国华、王俊玖.铝合金车体制造技术在中国的发展现状和展望.焊接,2004(10)：5-7
[6]冯伯欣.国产地铁车辆的发展及展望.铁道车辆,2000,38(1)：1-4
[7]徐灏.疲劳强度,北京：高等教育出版社,1990
[8]李兰,王成国,范忠胜等.城轨车辆轻量化不锈钢车体有限元分析.现代城市轨道交通,2006(6),38-41
[9]孙彰,贾宇,肖守讷.地铁车辆不锈钢车体的强度分析,2005(7)：32-34
[10]罗保发,罗震,王蕤,马迎兵等.低碳不锈钢点焊接头的耐腐蚀性能.焊接技术,2008(4)：21-24
[11]王歇成.有限单元法.北京：清华大学出版社,2003：117-124
[12]赵少汴.抗疲劳设计：方法与数据[M].北京：机械工业出版社,1997
[13]张罡,李建军,丁春辉.20g钢对接焊接接头循环应力-应变的特性.焊接学报.2001,22(2)：93-96
[14]杨新岐,张艳新,霍立兴等.焊接接头疲劳评定的局部法研究现状.焊接学报.2003,24(3)：82-86
[15]周张义,李芾,黄运华.基于热点应力的焊缝疲劳强度评定研究[J].内燃机车,2008(7)：1-5.
[16]基于虚拟疲劳试验的铁路车辆焊接结构疲劳寿命预测[D].大连交通大学博士论文,2008,5
[17]中华人民共和国铁道部.TB/T 3315-2005机车车辆动力学性能台架试验方法.中华人民共和国铁道行业标准,2005：6-7
[18]高速动车组拖车车体结构强度分析及优化设计[D].北京交通大学硕士论文,2010,6
[19]提高焊接结构疲劳寿命的刚度协调策略与应用[J].焊接学报,2007(12)：31-34
[20]车身结构中焊点布置的分区拓扑优化设计方法研究[J].计算力学学报,2010(8)：648-651
[21]岳译新,林文君,雷挺.地铁铝合金车体模态和稳定性有限元分析[J].机械,2008(4)：19-23
[22]雷成,肖守讷.铁路铝合金车体的结构设计和强度分析[J].机车传动,2006(1)：54-56
[23]霍立兴.焊接结构的断裂行为及评定[M].北京：机械工业出版社,2002.
[24]李晓峰,谢素明,时慧焯等.车辆焊接结构疲劳寿命评估方法研究[J],中国铁道科学,2007,28(3)：74-77.
[25]谢素明,程亚军,兆文忠.货车焊接结构疲劳寿命预测研究[J],铁道车辆,2006,44(6)：1-5.
[26]British Standard Institute (BSI).BS7608-1993 Fatigue design and assessment of steel structures[S]. BSI,1993
[27]IIW Joint Working Group XIII-XV. Recommen-dations for Fatigue Design of Welded Joints and Components[S]. IIW/IIS,2003
[28]The ASME B&PV Code, Section VIII, Division 2 and API 579-1/ASME FFS-1,2007
[29]P. Dong, J. K. Hong. Analysis of Recent Fatigue Data Using the Structural Stress Procedure in ASME Div 2 Rewrite[J]. Journal of Pressure Vessel Technology,2007,129:355-362
[30]Dong, P., Prager, M., Osage, D., "The Design Master S-N Curve in ASME Div 2 Rewrite and Its Validations," Int. Journal of IIW:Welding in the World, Vol.51, No.5/6,2007, pp.53-63
[31]DONG.P. A Robust Structural Stress Method for Fatigue Analysis of Ship Structures [C]. The 22nd International Conference on Offshore Mechanics and Arctic Engineering. Cancun:The American Society of Mechanical Engineers,2003:1-13.
[32]DONG.P, HONGJ.K. The Master S-N Curve Approach to Fatigue Evaluation of Offshore and Marine Structures [C]. The 23rd International Conference on Offshore Mechanics and Arctic Engineering. Vancouver:The American Society of Mechanical Engineers,2004:1-9
[33]DOERK.O, FRICKE.W, WEISSENBO.MC. Comparison of Different Calculation Method for Structural Sresses at Welded Joints [J]. International Journal of Fatigue,2003,25 (5):359-369.
[34]Pingsha Dong, Lecture Report "Fatigue of Welded Structures:Finite Element Based Design and Analysis Methods", Dalian Jiaotong University,2009.6
[35]Dong, P., Hong, J.K., and Cao, Z., "Stresses and Stress Intensities at Notches:'Anomalous Crack Growth'Revisited", International Journal of Fatigue,25 (2003), pp.811-825.
[36]The ASME B&PV Code, Section VIII, Division 2 and API 579-1/ASME FFS-1,2007
[2]李晓峰.基于虚拟疲劳试验的铁路车辆焊接结构疲劳寿命预测.大连交通大学博士论文.2008.5
[3]赵小宁.谈地铁不锈钢车体国产化及问题.工程建设与设计,2004,43：50-51
[4]员华,邹鹏.不锈钢车体与铝合金车体的现状及发展[J].都市快轨交通,2008(6),21(3)：89-91
[5]王炎金、丁国华、王俊玖.铝合金车体制造技术在中国的发展现状和展望.焊接,2004(10)：5-7
[6]冯伯欣.国产地铁车辆的发展及展望.铁道车辆,2000,38(1)：1-4
[7]徐灏.疲劳强度,北京：高等教育出版社,1990
[8]李兰,王成国,范忠胜等.城轨车辆轻量化不锈钢车体有限元分析.现代城市轨道交通,2006(6),38-41
[9]孙彰,贾宇,肖守讷.地铁车辆不锈钢车体的强度分析,2005(7)：32-34
[10]罗保发,罗震,王蕤,马迎兵等.低碳不锈钢点焊接头的耐腐蚀性能.焊接技术,2008(4)：21-24
[11]王歇成.有限单元法.北京：清华大学出版社,2003：117-124
[12]赵少汴.抗疲劳设计：方法与数据[M].北京：机械工业出版社,1997
[13]张罡,李建军,丁春辉.20g钢对接焊接接头循环应力-应变的特性.焊接学报.2001,22(2)：93-96
[14]杨新岐,张艳新,霍立兴等.焊接接头疲劳评定的局部法研究现状.焊接学报.2003,24(3)：82-86
[15]周张义,李芾,黄运华.基于热点应力的焊缝疲劳强度评定研究[J].内燃机车,2008(7)：1-5.
[16]基于虚拟疲劳试验的铁路车辆焊接结构疲劳寿命预测[D].大连交通大学博士论文,2008,5
[17]中华人民共和国铁道部.TB/T 3315-2005机车车辆动力学性能台架试验方法.中华人民共和国铁道行业标准,2005：6-7
[18]高速动车组拖车车体结构强度分析及优化设计[D].北京交通大学硕士论文,2010,6
[19]提高焊接结构疲劳寿命的刚度协调策略与应用[J].焊接学报,2007(12)：31-34
[20]车身结构中焊点布置的分区拓扑优化设计方法研究[J].计算力学学报,2010(8)：648-651
[21]岳译新,林文君,雷挺.地铁铝合金车体模态和稳定性有限元分析[J].机械,2008(4)：19-23
[22]雷成,肖守讷.铁路铝合金车体的结构设计和强度分析[J].机车传动,2006(1)：54-56
[23]霍立兴.焊接结构的断裂行为及评定[M].北京：机械工业出版社,2002.
[24]李晓峰,谢素明,时慧焯等.车辆焊接结构疲劳寿命评估方法研究[J],中国铁道科学,2007,28(3)：74-77.
[25]谢素明,程亚军,兆文忠.货车焊接结构疲劳寿命预测研究[J],铁道车辆,2006,44(6)：1-5.
[26]British Standard Institute (BSI).BS7608-1993 Fatigue design and assessment of steel structures[S]. BSI,1993
[27]IIW Joint Working Group XIII-XV. Recommen-dations for Fatigue Design of Welded Joints and Components[S]. IIW/IIS,2003
[28]The ASME B&PV Code, Section VIII, Division 2 and API 579-1/ASME FFS-1,2007
[29]P. Dong, J. K. Hong. Analysis of Recent Fatigue Data Using the Structural Stress Procedure in ASME Div 2 Rewrite[J]. Journal of Pressure Vessel Technology,2007,129:355-362
[30]Dong, P., Prager, M., Osage, D., "The Design Master S-N Curve in ASME Div 2 Rewrite and Its Validations," Int. Journal of IIW:Welding in the World, Vol.51, No.5/6,2007, pp.53-63
[31]DONG.P. A Robust Structural Stress Method for Fatigue Analysis of Ship Structures [C]. The 22nd International Conference on Offshore Mechanics and Arctic Engineering. Cancun:The American Society of Mechanical Engineers,2003:1-13.
[32]DONG.P, HONGJ.K. The Master S-N Curve Approach to Fatigue Evaluation of Offshore and Marine Structures [C]. The 23rd International Conference on Offshore Mechanics and Arctic Engineering. Vancouver:The American Society of Mechanical Engineers,2004:1-9
[33]DOERK.O, FRICKE.W, WEISSENBO.MC. Comparison of Different Calculation Method for Structural Sresses at Welded Joints [J]. International Journal of Fatigue,2003,25 (5):359-369.
[34]Pingsha Dong, Lecture Report "Fatigue of Welded Structures:Finite Element Based Design and Analysis Methods", Dalian Jiaotong University,2009.6
[35]Dong, P., Hong, J.K., and Cao, Z., "Stresses and Stress Intensities at Notches:'Anomalous Crack Growth'Revisited", International Journal of Fatigue,25 (2003), pp.811-825.
[36]The ASME B&PV Code, Section VIII, Division 2 and API 579-1/ASME FFS-1,2007