重载列车钩舌疲劳可靠性寿命分析
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摘要
车钩钩舌是货物列车中最重要的承载件之一,它直接关系着列车的运行安全和可靠性。随着我国铁路货运的重载化要求的不断提高,对车钩也提出了更高的要求。目前,大秦线重载列车的钩舌大量出现疲劳裂纹,其寿命远达不到设计的要求。因此,有必要对钩舌的疲劳可靠性进行研究,为提高钩舌的疲劳寿命提供依据。本文以我国大秦线上使用的国产16、17号车钩和美国产16、17号车钩为对象,分析了其可靠性,研究了二者的差异。
本文主要作了以下四个方面的工作:
1、建立小子样升降法数值仿真模型并进行大量模拟试验,为试验和准确处理数据提供依据。传统配对法求得的方差偏小,对计算结果影响较大。本文在数值模拟试验和已有数据的基础上,得出了关于小子样升降法应力级差、应力级数以及方差数据处理的一些结论。
2、用MTS试验机以及GPL-100高频疲劳试验机,测试了国产材料和美国材料的性能参数;结合模拟试验结论采用成组法与升降法测试了两种材料的p-S-N曲线。
3、通过考虑形状因素、尺寸效应和表面系数的影响,由材料的p-S-N曲线推导钩舌的p-S-N曲线。并且以尺寸效应为研究重点,分析总结了计算尺寸效应的各种方法。根据钩舌的受力状况,主要以有限元计算为基础,研究了尺寸效应的统计因素。
4、建立钩舌有限元模型,分析钩舌的受力与约束,用ANSYS进行加载计算。根据车钩载荷谱和试验所得的基本疲劳性能数据,计算了国产钩舌和美国钩舌的可靠性寿命。美国钩舌的疲劳寿命高于国产钩舌。
本文的研究结果将为我国重载列车钩舌的设计与应用提供技术保证与支持;本文的一些研究方法为同类型问题的研究提供参考。
Coupler knuckle is one of the most importent bearing weight parts of heavy haul train. Coupler knuckle is importent to the safety of the railway transport and the problem of coupler knuckle cracks has been serious with the development of railway transport.It is necessary to study the reliability of coupler knuckle's fatigue lifetime as fatigue cracks is more likely to appear on the coupler guard arm area. The object researched in this paper are the types of no.16 and no.17 coupler knuckles,which are used universally on heavy-load wagon of china.Two kinds of that coupler knuckles,the Chinese coupler knuckle and the American coupler knuckle, were studied and the difference has been find.
The contents of this paper can be summarized as follows:
1. Simulation model of small subsample fluctuation method is built and many tests have been carried out to service for the test and data processing. The finally calculation results will be very different as the dual small subsample fluctuation method gives a smaller variation.In this part some useful conclusions about test interval, the number of staircases of small subsample fluctuation method and the variation estimatent have been caried out based on numerical simulation and some test date.
2. The Chineae and American material properties have been tested by MTS and GPL-200 high frequency fatigue testing machine.Also combined with the conclusions obtained by numerical simulation ,fatigue limits and p-S-N curves have been tested using the group method and up-down method.
3. The coupler knuckle's p-S-N curves have been derived by deduction from the material's curves.Geometry effect,size effect and surface effect are considered in this process.the focus of this discussion is size effect. Methods of calculate size effect have been summarized in this part.according to the coupler guard arm area's stress,size effect has been calculated mostly by the Statistics factors based on the resuts of the finite element analysis.
4. Finite element analysis of the coupler knuckle is proposed.Finite element model of the coupler knuckle is built according to its entity, then is calculated by ANSYS based on its loads and constraints.Reliability analysis of fatigue lifetime of coupler guard arm area is proposed. It can program composition for caculating the reliability life of the coupler knuckle with the load spectrum date.the dispersion of coupler knuckle's fatigue strength can be simulated with the Monte-Carlo method. As the fatigue lifetime of American coupler knuckle is higher than the Chinese coupler knuckle,the main difference is the slope of the p-S-N curves.
The research results of this paper can provide technical guarantee and support for the design and application of coupler knuckle of Chinese heavy haul train.Some research methods in this paper also can be used in the research of similar type problems.
本文主要作了以下四个方面的工作:
1、建立小子样升降法数值仿真模型并进行大量模拟试验,为试验和准确处理数据提供依据。传统配对法求得的方差偏小,对计算结果影响较大。本文在数值模拟试验和已有数据的基础上,得出了关于小子样升降法应力级差、应力级数以及方差数据处理的一些结论。
2、用MTS试验机以及GPL-100高频疲劳试验机,测试了国产材料和美国材料的性能参数;结合模拟试验结论采用成组法与升降法测试了两种材料的p-S-N曲线。
3、通过考虑形状因素、尺寸效应和表面系数的影响,由材料的p-S-N曲线推导钩舌的p-S-N曲线。并且以尺寸效应为研究重点,分析总结了计算尺寸效应的各种方法。根据钩舌的受力状况,主要以有限元计算为基础,研究了尺寸效应的统计因素。
4、建立钩舌有限元模型,分析钩舌的受力与约束,用ANSYS进行加载计算。根据车钩载荷谱和试验所得的基本疲劳性能数据,计算了国产钩舌和美国钩舌的可靠性寿命。美国钩舌的疲劳寿命高于国产钩舌。
本文的研究结果将为我国重载列车钩舌的设计与应用提供技术保证与支持;本文的一些研究方法为同类型问题的研究提供参考。
Coupler knuckle is one of the most importent bearing weight parts of heavy haul train. Coupler knuckle is importent to the safety of the railway transport and the problem of coupler knuckle cracks has been serious with the development of railway transport.It is necessary to study the reliability of coupler knuckle's fatigue lifetime as fatigue cracks is more likely to appear on the coupler guard arm area. The object researched in this paper are the types of no.16 and no.17 coupler knuckles,which are used universally on heavy-load wagon of china.Two kinds of that coupler knuckles,the Chinese coupler knuckle and the American coupler knuckle, were studied and the difference has been find.
The contents of this paper can be summarized as follows:
1. Simulation model of small subsample fluctuation method is built and many tests have been carried out to service for the test and data processing. The finally calculation results will be very different as the dual small subsample fluctuation method gives a smaller variation.In this part some useful conclusions about test interval, the number of staircases of small subsample fluctuation method and the variation estimatent have been caried out based on numerical simulation and some test date.
2. The Chineae and American material properties have been tested by MTS and GPL-200 high frequency fatigue testing machine.Also combined with the conclusions obtained by numerical simulation ,fatigue limits and p-S-N curves have been tested using the group method and up-down method.
3. The coupler knuckle's p-S-N curves have been derived by deduction from the material's curves.Geometry effect,size effect and surface effect are considered in this process.the focus of this discussion is size effect. Methods of calculate size effect have been summarized in this part.according to the coupler guard arm area's stress,size effect has been calculated mostly by the Statistics factors based on the resuts of the finite element analysis.
4. Finite element analysis of the coupler knuckle is proposed.Finite element model of the coupler knuckle is built according to its entity, then is calculated by ANSYS based on its loads and constraints.Reliability analysis of fatigue lifetime of coupler guard arm area is proposed. It can program composition for caculating the reliability life of the coupler knuckle with the load spectrum date.the dispersion of coupler knuckle's fatigue strength can be simulated with the Monte-Carlo method. As the fatigue lifetime of American coupler knuckle is higher than the Chinese coupler knuckle,the main difference is the slope of the p-S-N curves.
The research results of this paper can provide technical guarantee and support for the design and application of coupler knuckle of Chinese heavy haul train.Some research methods in this paper also can be used in the research of similar type problems.
引文
[1]李舜酩.机械疲劳与可靠性设计.科学出版社,2006
[2]赵少汴,王忠保.抗疲劳设计--方法与数据.机械工业出版社,1997
[3]李明慧.重载列车钩舌断裂特性分析.北京.北京交通大学,2005
[4]严隽耄.车辆工程(第二版).北京:中国铁道出版社,1992
[5]姚卫星.结构疲劳寿命分析.北京:国防工业出版社,2003
[6]王勖成,邵敏,有限单元法基本原理和数值方法[M],清华大学出版社,1997
[7]陈俊生.提速重载后车钩分离事故增多的原因分析[J],铁道机车车辆,2002.1,第1期
[8]薛守义.有限单元法.中国建材工业出版社,2006
[9]罗桂琼.客车车钩缓冲装置裂纹成因分析及改进措施.铁道车辆,2006年8月,第44卷第8期
[10]高镇同.疲劳应用统计学.北京:国防工业出版社,1986
[11]曾春华,邹十践.疲劳分析方法及应用.北京:国防工业出版社,1991
[12]程育仁等.疲劳强度.北京:中国铁道出版社,1990
[13]徐灏等.机械设计手册第2卷第11篇.北京:机械工业出版社,1991
[14]林挺昌.典型焊接接头的疲劳可靠性分析.北京:北京交通大学,2006
[15]张建宇,汪大乐.测定疲劳强度的双细节串联升降法.实验力学,2006年10月,第21卷第5期
[16]傅惠民,殷刚.确定疲劳极限的极小样本方法.机械强度,1999年6月,第21卷第2期
[17]Dixon W J,Mood A M.A method for obtaining and analyzing sensitivity data.J.Amer.Statistical Assoc.1948,43:100-126
[18]Balry A Bolt.Design and estimation in small sample quantal response problems,a Mlonte Carlo study.AD- A208113,1989
[19]刘宝光.敏感吐数据分析与可靠吐评定.北京:国防工业出版社,1995
[20]陈玲,郭悦虹.疲劳极限升降法中应力增量选取的讨论.天津理工学院学报.1999年9月,第15卷第3期
[21]徐钟济.蒙特卡罗方法[M].上海:上海科学技术出版社,1985
[22]马海云,齐小军.蒙特卡罗仿真机及其应用.电脑与信息技术.2006年6月,第14卷第3期
[23]王正林.精通MATLAB科学计算.电子工业出版社,2007
[24]庄楚强,何春雄.应用数理统计基础.华南理工大学出版社,2005
[25]徐灏.机械强度的可靠性设计.北京:机械工业出版社,1984
[26]中华人民共和国国家标准GB-T228-2002.金属材料室温拉伸试验方法.2002
[27]Crossland B.Effect of large hydrostatic pressures on the torsional fatigue strength of an alloy steel.In:Proceeding of the international conference on fatigue of metals,London & New York.1956:p.138-49.ISBN 99-0981150-2
[28]Dang Van K.Macro-micro approach in high-cycle multiaxial fatigue.In:McDowell DL,Ellis R,editors.Advances in multiaxial fatigue.ASTM STP 1191.Philadelphia:Americann Society for Testing andMaterials.1993:p.120-30.ISSN 0066-0558
[29]Findley WN,Coleman JJ,Hanley BC.Theory for combined bending and torsion fatigue with data for SAE 4340 steel.In:Proceeding of the international conference on fatigue of metals.London & New York.1956:p.138-149.ISBN 99-0981150-2
[30]Matake T.An explanation on fatigue limit under combined stress.Bull Jpn Soc Mech Eng 1977.20(141):257-63.ISSN 0021-3764
[31]Papadopoulos Ⅳ.Long life fatigue under multiaxial loading.Int J Fatigue 2001.23(10):839-49
[32]郑楚鸿.高周疲劳设计方法--应力场强法的研究.北京:清华大学,1984
[33]靳东来,刘汝锋,陈章华.复合应力状态下裂纹形成行为.北京科技大学学报,1996年10月,第18卷第5期
[34]Papadopoulos Ⅳ,Panoskaltsis VP.Invariant formulation of a gradient dependent multiaxial high-cycle fatigue criterion.Eng Fract Moth,0013-7944 1996,55(4):513-28
[35]David Taylor,Geometrical effects in fatigue:a unifying theoretical model,International Journal of Fatigue 21(1999)413-420
[36]Mischke CR.A probabilistic model of size effect in the fatigue strength of rounds in bending and torsion.ASME Paper no 79-DE-16,1979
[37]Bohm J.Zur Vorhersage von Dauerschwingfestigkeiten ungekerbter und gekerbter Bauteile unter Beru cksichtigung des statististischen Gro¨sseneinflu¨sses.Dissertation,Technische Universitat Munchen,1979
[38]S.Norberg,M.Olsson b.The effect of loaded volume and stress gradient on the fatigue limit.ScienceDirect,International Journal of Fatigue 29(2007)2259-2272
[39]M.Makkonen.Statistical size effect in the fatigue limit of steel,International Journal of Fatigue 23(2001)395-402,2000
[40]M.Makkonen.Notch size effects in the fatigue limit of steel,International Journal of Fatigue 25(2003)17-26
[41]王少华,张质文.概率疲劳强度估算方法和疲劳尺寸效应的分析.机械强度,1992年9月
[42]Rajiv A.Naik,David B.Lanning,Theodore Nicholas,Alan R.Kallmeyer.A critical plane gradient approach for the prediction of notched HCF life,International Journal of Fatigue 27(2005)481-492
[43]Rajiv A.Naika,David B.Lanningb,Theodore Nicholasc,Alan R.Kallmeyer,A multiaxial criterion for notch high-cycle fatigue using a critical-point method,Engineering Fracture Mechanics 75(2008)1864-1874,2006
[44]Bohm J.Zur Vorhersage von Dauerschwingfestigkeiten ungekerbter und gekerbter Bauteile unter Beru"cksichtigung des statististischen Gro"sseneinflu"sses.Dissertation,Technische Universita"t Mu"nchen,1979
[45]AAR.货车的疲劳设计规范
[46]芮延年,傅戈雁.现代可靠性设计.北京:国防工业出版社.2007
[2]赵少汴,王忠保.抗疲劳设计--方法与数据.机械工业出版社,1997
[3]李明慧.重载列车钩舌断裂特性分析.北京.北京交通大学,2005
[4]严隽耄.车辆工程(第二版).北京:中国铁道出版社,1992
[5]姚卫星.结构疲劳寿命分析.北京:国防工业出版社,2003
[6]王勖成,邵敏,有限单元法基本原理和数值方法[M],清华大学出版社,1997
[7]陈俊生.提速重载后车钩分离事故增多的原因分析[J],铁道机车车辆,2002.1,第1期
[8]薛守义.有限单元法.中国建材工业出版社,2006
[9]罗桂琼.客车车钩缓冲装置裂纹成因分析及改进措施.铁道车辆,2006年8月,第44卷第8期
[10]高镇同.疲劳应用统计学.北京:国防工业出版社,1986
[11]曾春华,邹十践.疲劳分析方法及应用.北京:国防工业出版社,1991
[12]程育仁等.疲劳强度.北京:中国铁道出版社,1990
[13]徐灏等.机械设计手册第2卷第11篇.北京:机械工业出版社,1991
[14]林挺昌.典型焊接接头的疲劳可靠性分析.北京:北京交通大学,2006
[15]张建宇,汪大乐.测定疲劳强度的双细节串联升降法.实验力学,2006年10月,第21卷第5期
[16]傅惠民,殷刚.确定疲劳极限的极小样本方法.机械强度,1999年6月,第21卷第2期
[17]Dixon W J,Mood A M.A method for obtaining and analyzing sensitivity data.J.Amer.Statistical Assoc.1948,43:100-126
[18]Balry A Bolt.Design and estimation in small sample quantal response problems,a Mlonte Carlo study.AD- A208113,1989
[19]刘宝光.敏感吐数据分析与可靠吐评定.北京:国防工业出版社,1995
[20]陈玲,郭悦虹.疲劳极限升降法中应力增量选取的讨论.天津理工学院学报.1999年9月,第15卷第3期
[21]徐钟济.蒙特卡罗方法[M].上海:上海科学技术出版社,1985
[22]马海云,齐小军.蒙特卡罗仿真机及其应用.电脑与信息技术.2006年6月,第14卷第3期
[23]王正林.精通MATLAB科学计算.电子工业出版社,2007
[24]庄楚强,何春雄.应用数理统计基础.华南理工大学出版社,2005
[25]徐灏.机械强度的可靠性设计.北京:机械工业出版社,1984
[26]中华人民共和国国家标准GB-T228-2002.金属材料室温拉伸试验方法.2002
[27]Crossland B.Effect of large hydrostatic pressures on the torsional fatigue strength of an alloy steel.In:Proceeding of the international conference on fatigue of metals,London & New York.1956:p.138-49.ISBN 99-0981150-2
[28]Dang Van K.Macro-micro approach in high-cycle multiaxial fatigue.In:McDowell DL,Ellis R,editors.Advances in multiaxial fatigue.ASTM STP 1191.Philadelphia:Americann Society for Testing andMaterials.1993:p.120-30.ISSN 0066-0558
[29]Findley WN,Coleman JJ,Hanley BC.Theory for combined bending and torsion fatigue with data for SAE 4340 steel.In:Proceeding of the international conference on fatigue of metals.London & New York.1956:p.138-149.ISBN 99-0981150-2
[30]Matake T.An explanation on fatigue limit under combined stress.Bull Jpn Soc Mech Eng 1977.20(141):257-63.ISSN 0021-3764
[31]Papadopoulos Ⅳ.Long life fatigue under multiaxial loading.Int J Fatigue 2001.23(10):839-49
[32]郑楚鸿.高周疲劳设计方法--应力场强法的研究.北京:清华大学,1984
[33]靳东来,刘汝锋,陈章华.复合应力状态下裂纹形成行为.北京科技大学学报,1996年10月,第18卷第5期
[34]Papadopoulos Ⅳ,Panoskaltsis VP.Invariant formulation of a gradient dependent multiaxial high-cycle fatigue criterion.Eng Fract Moth,0013-7944 1996,55(4):513-28
[35]David Taylor,Geometrical effects in fatigue:a unifying theoretical model,International Journal of Fatigue 21(1999)413-420
[36]Mischke CR.A probabilistic model of size effect in the fatigue strength of rounds in bending and torsion.ASME Paper no 79-DE-16,1979
[37]Bohm J.Zur Vorhersage von Dauerschwingfestigkeiten ungekerbter und gekerbter Bauteile unter Beru cksichtigung des statististischen Gro¨sseneinflu¨sses.Dissertation,Technische Universitat Munchen,1979
[38]S.Norberg,M.Olsson b.The effect of loaded volume and stress gradient on the fatigue limit.ScienceDirect,International Journal of Fatigue 29(2007)2259-2272
[39]M.Makkonen.Statistical size effect in the fatigue limit of steel,International Journal of Fatigue 23(2001)395-402,2000
[40]M.Makkonen.Notch size effects in the fatigue limit of steel,International Journal of Fatigue 25(2003)17-26
[41]王少华,张质文.概率疲劳强度估算方法和疲劳尺寸效应的分析.机械强度,1992年9月
[42]Rajiv A.Naik,David B.Lanning,Theodore Nicholas,Alan R.Kallmeyer.A critical plane gradient approach for the prediction of notched HCF life,International Journal of Fatigue 27(2005)481-492
[43]Rajiv A.Naika,David B.Lanningb,Theodore Nicholasc,Alan R.Kallmeyer,A multiaxial criterion for notch high-cycle fatigue using a critical-point method,Engineering Fracture Mechanics 75(2008)1864-1874,2006
[44]Bohm J.Zur Vorhersage von Dauerschwingfestigkeiten ungekerbter und gekerbter Bauteile unter Beru"cksichtigung des statististischen Gro"sseneinflu"sses.Dissertation,Technische Universita"t Mu"nchen,1979
[45]AAR.货车的疲劳设计规范
[46]芮延年,傅戈雁.现代可靠性设计.北京:国防工业出版社.2007