机车轮对轮轴冷压工艺仿真与试验研究
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摘要
机车轮对作为机车走行部的关键件,其制造质量,尤其是车轴、车轮组装质量直接影响机车的行车安全,目前国内机车轮对的轮轴组装方式主要为热套和注油压装。HXN5型交流传动货运内燃机车为南车戚墅堰机车有限公司与美国通用电气公司为中国干线铁路设计的一种新型重型机车,设计要求轮对轮轴组装采用冷压工艺。国内对机车轮对冷压工艺可借鉴经验较少。本文针对新型的机车轮对特点,开展轮轴冷压工艺的仿真和试验研究,选题具有重要的工程实用价值。
论文首先分析了机车转向架及轮对的结构特点,采用ABAQUS软件对轮对装配进行有限元建模,分析装配过程中的应力分布特点以及油槽设计位置对压装曲线和应力分布的影响,研究关键参数如过盈量、摩擦系数等对压装曲线的影响规律,提出了装配工艺控制点;基于实际的压装数据,筛选出影响压装质量的关键变量,采用四参数两水平正交试验方法进行试验设计,确定了合理的参数范围。上述研究成果应用于实际轮对压装,合格率达98%以上,较好地完成该车的国产化任务。也为以后南车戚墅堰机车有限公司出口机车符合AAR标准进行了工艺储备。
As an important part of the locomotives, the manufacture quality of the wheelset, particularly wheel and shaft assembling quality directly influence safety of locomotive . Now the two main fitting processes in China are hot jacket and oil injection press mounting. A new heavy locomotive-- HXN5 exchange transmission freight transportation diesel locomotive is designed by CSR Qishuyan Locomotive Co., Ltd. and GE for the Chinese Mainline railroad , A fitting press method is required. But there are little experience in fitting process in CSR Qishuyan Locomotive Co., Ltd..
In this research, the locomotive wheelset fitting process is simulated used ABAQUS software, some key parameters are studied via Orthogonal experiments method. The research will provide more valuable information in wheelset fitting process.
Firstly, the paper analyzed the structures and features of the wheelsets.
Secondly, then a finite element modeling was established, The characters of stress distribution along the contact surface in the total fitting prccess and the oil groove positions were analyzed. The influence of the friction coefficient and small or large interferences was studied, the fitting process controlling points were proposed.
Finally, based on the actual press mounting data, the key parameters were selected. A DOE mothod was used to determined the reasonable parameter range. The above results are applied in the real fitting process and a good qualified rate above 98% is achieved.
论文首先分析了机车转向架及轮对的结构特点,采用ABAQUS软件对轮对装配进行有限元建模,分析装配过程中的应力分布特点以及油槽设计位置对压装曲线和应力分布的影响,研究关键参数如过盈量、摩擦系数等对压装曲线的影响规律,提出了装配工艺控制点;基于实际的压装数据,筛选出影响压装质量的关键变量,采用四参数两水平正交试验方法进行试验设计,确定了合理的参数范围。上述研究成果应用于实际轮对压装,合格率达98%以上,较好地完成该车的国产化任务。也为以后南车戚墅堰机车有限公司出口机车符合AAR标准进行了工艺储备。
As an important part of the locomotives, the manufacture quality of the wheelset, particularly wheel and shaft assembling quality directly influence safety of locomotive . Now the two main fitting processes in China are hot jacket and oil injection press mounting. A new heavy locomotive-- HXN5 exchange transmission freight transportation diesel locomotive is designed by CSR Qishuyan Locomotive Co., Ltd. and GE for the Chinese Mainline railroad , A fitting press method is required. But there are little experience in fitting process in CSR Qishuyan Locomotive Co., Ltd..
In this research, the locomotive wheelset fitting process is simulated used ABAQUS software, some key parameters are studied via Orthogonal experiments method. The research will provide more valuable information in wheelset fitting process.
Firstly, the paper analyzed the structures and features of the wheelsets.
Secondly, then a finite element modeling was established, The characters of stress distribution along the contact surface in the total fitting prccess and the oil groove positions were analyzed. The influence of the friction coefficient and small or large interferences was studied, the fitting process controlling points were proposed.
Finally, based on the actual press mounting data, the key parameters were selected. A DOE mothod was used to determined the reasonable parameter range. The above results are applied in the real fitting process and a good qualified rate above 98% is achieved.
引文
[1]郝金伟,HXN5型大功率交流传动内燃机车及其技术创新性,戚机科技,2009.2,16-22
[2]凃富田，关于车轴轮座、车轮轮毂孔的圆柱度公差和压装曲线分析，铁道车辆，2006.3,24-27
[3]陈炜,影响DF11型内燃机车轮对压装质量的因素及措施,机车车辆工艺,2002.4,37-38,40
[4]Association of American Railroads, AAR G-Ⅱ-2008 WHEEL AND AXLE MANUAL,U.S.A.
[5]赵景思,刘力琼,杨夏沙,关于轮轴注油压装标准的应用及建议,电力机车与城轨车辆,2004.6,28-29
[6]张元涛,张顺启,关于轮对压装工艺参数优化设计的探讨,铁道车辆,2006.7,29-30
[7]周兰英,轮对压装曲线不合格的原因及对策,铁道机车车辆工人,2001.1,2-5
[8]王涛,对轮对压装曲线中几个限度的探讨,机车车辆工艺,2007.6,43-44
[9]张建路,可靠的轮轴冷压装参数计算与工艺,新技术新工艺,2005.12,28-29
[10]岳立峰,窦广旭,轮对压装工艺分析,机车车辆工艺,2005.3,7-9
[11]贾建峰,延长轮对使用寿命的研究与探讨,铁道机车车辆,2005.6,56-57
[12]项彬,宋子濂,孙铜山,轮轴压装损伤的宏、微观特征和形成机理,铁道机车车辆,2006.1,17-23
[13]刘红生,提高轮对压装质量的途径,机车车辆工艺,2001.2,16-18
[14]张剑,魏伟,车辆轮对压装过程的仿真,大连铁道学院学报,2002.2,40-42
[15]王少峰,轮对压装中轴端变形的对策,机车车辆工艺,2001.3,18-19
[16]龙喜宝,洪常勤,刘庚武,上海地铁车辆车轴轮对压装工艺验证,电力机车与城轨车辆,2006.5,33-34
[17]赵凤兰,李健,电力机车整体辗钢车轮压装过盈量的研究,铁道机车车辆,2000.3,22-24
[18]徐礼钟,关于DF4、DF8型机车轮对大修冷态压装一次成功的探讨,内燃机车,2002.3,16-17
[19]张桂利,轮对压装曲线末端平直降吨原因分析,机车车辆工艺,2004.1,34-36
[20]赵坤德,保证RD2型轮对压装尺寸的方法,机车车辆工艺,2000.4,5-6
[21]魏延刚,宋亚昕,机车轮对压装过程弹塑性模拟,机械设计,2004.9,46-48
[22]王献红,用冷冻植物油解决轮对压装中的跳顿问题,长春客车厂,1999
[23]李英杰,陈光满,D型轮对压装不合格的原因及改进方法,大连机车车辆厂,1999
[24]王彦豪,客车轮对压装问题探讨,长春客车厂
[25]陈辉刚,管玉山,轮对压装实现互换的可行性分析,四方机车车辆厂,1997
[26]于中南,智能型轮轴压装记录仪信息管理系统,铁道技术监督,2003.3,31-32
[27]袁旭芳,铁路车辆轮对压装曲线陡跳工艺探讨,煤矿机械,2005.5,91-92
[28]德国Thom asKU T TN ER等作,云济译,避免轮对压装压伤的经济方法-离子注入,国外机车车辆工艺,2003.5,12-18
[29]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
[30]王勖成邵敏,有限单元法基本原理和数值方法(第二版),北京:清华大学出版社,1997
[31]陈魁,应用概率统计,北京:清华大学出版社,2000
[32]孙玲芳,机车轮对有限元分析及优化设计,[学位论文],大连交通大学,2005
[33]刘宝庆,过盈联接摩擦系数的理论及试验研究,[学位论文],大连理工大学,2008
[34]中国南车集团戚墅堰机车车辆工艺研究所,TB/T1463-2006机车轮对组装技术条件,北京:中华人民共和国铁道部,2006
[2]凃富田，关于车轴轮座、车轮轮毂孔的圆柱度公差和压装曲线分析，铁道车辆，2006.3,24-27
[3]陈炜,影响DF11型内燃机车轮对压装质量的因素及措施,机车车辆工艺,2002.4,37-38,40
[4]Association of American Railroads, AAR G-Ⅱ-2008 WHEEL AND AXLE MANUAL,U.S.A.
[5]赵景思,刘力琼,杨夏沙,关于轮轴注油压装标准的应用及建议,电力机车与城轨车辆,2004.6,28-29
[6]张元涛,张顺启,关于轮对压装工艺参数优化设计的探讨,铁道车辆,2006.7,29-30
[7]周兰英,轮对压装曲线不合格的原因及对策,铁道机车车辆工人,2001.1,2-5
[8]王涛,对轮对压装曲线中几个限度的探讨,机车车辆工艺,2007.6,43-44
[9]张建路,可靠的轮轴冷压装参数计算与工艺,新技术新工艺,2005.12,28-29
[10]岳立峰,窦广旭,轮对压装工艺分析,机车车辆工艺,2005.3,7-9
[11]贾建峰,延长轮对使用寿命的研究与探讨,铁道机车车辆,2005.6,56-57
[12]项彬,宋子濂,孙铜山,轮轴压装损伤的宏、微观特征和形成机理,铁道机车车辆,2006.1,17-23
[13]刘红生,提高轮对压装质量的途径,机车车辆工艺,2001.2,16-18
[14]张剑,魏伟,车辆轮对压装过程的仿真,大连铁道学院学报,2002.2,40-42
[15]王少峰,轮对压装中轴端变形的对策,机车车辆工艺,2001.3,18-19
[16]龙喜宝,洪常勤,刘庚武,上海地铁车辆车轴轮对压装工艺验证,电力机车与城轨车辆,2006.5,33-34
[17]赵凤兰,李健,电力机车整体辗钢车轮压装过盈量的研究,铁道机车车辆,2000.3,22-24
[18]徐礼钟,关于DF4、DF8型机车轮对大修冷态压装一次成功的探讨,内燃机车,2002.3,16-17
[19]张桂利,轮对压装曲线末端平直降吨原因分析,机车车辆工艺,2004.1,34-36
[20]赵坤德,保证RD2型轮对压装尺寸的方法,机车车辆工艺,2000.4,5-6
[21]魏延刚,宋亚昕,机车轮对压装过程弹塑性模拟,机械设计,2004.9,46-48
[22]王献红,用冷冻植物油解决轮对压装中的跳顿问题,长春客车厂,1999
[23]李英杰,陈光满,D型轮对压装不合格的原因及改进方法,大连机车车辆厂,1999
[24]王彦豪,客车轮对压装问题探讨,长春客车厂
[25]陈辉刚,管玉山,轮对压装实现互换的可行性分析,四方机车车辆厂,1997
[26]于中南,智能型轮轴压装记录仪信息管理系统,铁道技术监督,2003.3,31-32
[27]袁旭芳,铁路车辆轮对压装曲线陡跳工艺探讨,煤矿机械,2005.5,91-92
[28]德国Thom asKU T TN ER等作,云济译,避免轮对压装压伤的经济方法-离子注入,国外机车车辆工艺,2003.5,12-18
[29]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
[30]王勖成邵敏,有限单元法基本原理和数值方法(第二版),北京:清华大学出版社,1997
[31]陈魁,应用概率统计,北京:清华大学出版社,2000
[32]孙玲芳,机车轮对有限元分析及优化设计,[学位论文],大连交通大学,2005
[33]刘宝庆,过盈联接摩擦系数的理论及试验研究,[学位论文],大连理工大学,2008
[34]中国南车集团戚墅堰机车车辆工艺研究所,TB/T1463-2006机车轮对组装技术条件,北京:中华人民共和国铁道部,2006