铁路货车滚动轴承压装系统仿真分析与试验研究
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摘要
滚动轴承压装机是铁路货车滚动轴承检修的关键设备,它可以完成滚动轴承的压装工作,广泛应用于铁路系统轴承检修车间。作为一种铁路通用设备,其机体的强度和刚度直接影响到滚动轴承的压装质量,进而影响铁路货车滚动轴承的使用寿命。在当前铁路系统跨越式发展,列车行驶速度进一步提高的情况下,进一步提高滚动轴承的压装质量显得尤为重要。本文以压装机系统这一特定分析对象,运用现代设计理论和方法,采用流行有限元分析软件对压装机及轴承压装过程进行了分析。
在对压装机进行了整体建模仿真的基础上,针对压装机整体建模存在的误差问题,本文提出了一种改进的弹簧单元和薄层实体单元混合建模的方法,并依此设计了螺栓结合面静刚度测试试验,通过试验获得了建模所需的参数。混合建模方法和以往建模方法相比,它综合考虑了结合面刚度和对应力分布的影响,具有更高的精度。利用新的混合建模方法对压装机整体进行重新建模分析,其仿真结果和实测结果比较吻合,精度比整体建模方法提高了30%左右。最后根据分析结果对结构改进提出了理论意见。
轴承压装质量对轴承疲劳寿命和铁路货车安全运行有重大影响,当前因为压装完毕之后的微观过盈配合接触应力无法测量,铁道部仅以宏观压装力作为轴承压装质量检查的标准,而过盈配合接触应力轴承疲劳寿命有很大影响。本文正是针对轴承压装过程的复杂性和不可测性,首先进行了压装力的理论计算,并利用非线性有限元仿真软件MSC.Marc对压装过程进行了非线性弹塑仿真,研究了摩擦系数、过盈量和轴颈锥形误差对压装力和过盈配合接触应力分布的影响规律,为轴承压装质量检查和轴承选配流程提供了理论指导。
The rolling bearing press-mounting machines are the key equipment for the overhaul of the rolling bearing of the freight train. They are widely used to execute the press-mounting tasks of the rolling bearing in the bearing overhaul workshop of the railway system. As a general equipment of the railway system, the structure strength and stiffness directly impact the press-mounting quality of the rolling bearings. Furthermore, they impact the life-cycle of the rolling bearings. As the railway system develops quickly and the train speed is being enhanced, it appears to be really important to improve the press-mounting quality of the rolling bearing. Based on the special analysis object of press-mounting system, using the modern design theory and method, this thesis adopts the popular mechanical finite element analysis software to analyze the press-mounting machine and the process of the press-mounting.
On the basis of the finite element analysis of the press-mounting machine, to solve the modeling error of the previous modeling method, a new mixed-model method using the spring element and thin-layer solid element was introduced in this thesis. An experiment designed to test the interface static stiffness was carried out and the needed modeling datum was obtained. Compared to traditional modeling method, the new mixed-model method considers the stiffness of the interface and its influence to stress distribution. It is more accurate. Using the new modeling method, the finite element model of the press-mounting machine was revised and re-analyzed. And the simulation results are closed to the test results. The results accuracy raised 30% compared to the traditional method. At last some revise suggestions to the structure are given based on the simulation results.
The press-mounting quality of the rolling bearing has big influence to the rolling bearing fatigue life and safe operation of the freight train. Because it is impossible to measure the micro interference fitting contact stress after press-mounting, the Department of railway system just uses the press-force as the criteria of the press-mounting quality. But the interference fitting contact stress has big influence to the rolling bearing fatigue life. Considering the complexity
在对压装机进行了整体建模仿真的基础上,针对压装机整体建模存在的误差问题,本文提出了一种改进的弹簧单元和薄层实体单元混合建模的方法,并依此设计了螺栓结合面静刚度测试试验,通过试验获得了建模所需的参数。混合建模方法和以往建模方法相比,它综合考虑了结合面刚度和对应力分布的影响,具有更高的精度。利用新的混合建模方法对压装机整体进行重新建模分析,其仿真结果和实测结果比较吻合,精度比整体建模方法提高了30%左右。最后根据分析结果对结构改进提出了理论意见。
轴承压装质量对轴承疲劳寿命和铁路货车安全运行有重大影响,当前因为压装完毕之后的微观过盈配合接触应力无法测量,铁道部仅以宏观压装力作为轴承压装质量检查的标准,而过盈配合接触应力轴承疲劳寿命有很大影响。本文正是针对轴承压装过程的复杂性和不可测性,首先进行了压装力的理论计算,并利用非线性有限元仿真软件MSC.Marc对压装过程进行了非线性弹塑仿真,研究了摩擦系数、过盈量和轴颈锥形误差对压装力和过盈配合接触应力分布的影响规律,为轴承压装质量检查和轴承选配流程提供了理论指导。
The rolling bearing press-mounting machines are the key equipment for the overhaul of the rolling bearing of the freight train. They are widely used to execute the press-mounting tasks of the rolling bearing in the bearing overhaul workshop of the railway system. As a general equipment of the railway system, the structure strength and stiffness directly impact the press-mounting quality of the rolling bearings. Furthermore, they impact the life-cycle of the rolling bearings. As the railway system develops quickly and the train speed is being enhanced, it appears to be really important to improve the press-mounting quality of the rolling bearing. Based on the special analysis object of press-mounting system, using the modern design theory and method, this thesis adopts the popular mechanical finite element analysis software to analyze the press-mounting machine and the process of the press-mounting.
On the basis of the finite element analysis of the press-mounting machine, to solve the modeling error of the previous modeling method, a new mixed-model method using the spring element and thin-layer solid element was introduced in this thesis. An experiment designed to test the interface static stiffness was carried out and the needed modeling datum was obtained. Compared to traditional modeling method, the new mixed-model method considers the stiffness of the interface and its influence to stress distribution. It is more accurate. Using the new modeling method, the finite element model of the press-mounting machine was revised and re-analyzed. And the simulation results are closed to the test results. The results accuracy raised 30% compared to the traditional method. At last some revise suggestions to the structure are given based on the simulation results.
The press-mounting quality of the rolling bearing has big influence to the rolling bearing fatigue life and safe operation of the freight train. Because it is impossible to measure the micro interference fitting contact stress after press-mounting, the Department of railway system just uses the press-force as the criteria of the press-mounting quality. But the interference fitting contact stress has big influence to the rolling bearing fatigue life. Considering the complexity
引文
1 宋威岩,刘 俭. 新型位移—压力曲线轴承压装机的原理. 哈尔滨铁道科技. 2000,4:24~25
2 齐宏志,聂欣然. 铁路货车滚动轴承压装机与轴承压装质量. 铁道车辆. 200139(8):33~37
3 许小强,赵洪伦. 过盈配合应力的接触非线性有限元分析. 机械设计与研究. 2000,(1):33~35
4 魏延刚,宋亚昕. 机车轮对压装过程弹塑性模拟 机械设计. 2004,21(9):46~48
5 S. Aleksander,S. Marek. Analysis of Wheel–rail Interaction Using FE Software. Wear. 2005,258:1217~1223
6 T. Tanel , O. Ulf. Wheel–rail Wear Simulation. Wear. 2004 , 257 :1145~1153
7 万贤妃. 谈新型列车轮对轴承压装机设计. 液压与气动. 2001,(10):6~7
8 马万兵. 铁路货车滚动轴承压装机监控系统的研究. 哈尔滨工业大学硕士学位论文. 2005,11:1~3
9 柳波,聂宝安. 新型铁道轮对轴承压装机设计研究. 液压与气动. 2001,1:20~21
10 K.K. Gupta,J.L. Meek. A Brief History of the Beginning of the Finite Element Method. International Journal for Numerical Method in Engineering. 1996,39(22):3761~3774
11 孙鹏举. 近距离捕获地面实验系统有限元分析. 哈尔滨工业大学硕士论文. 2005,7:10~15
12 T. Vidar. From Finite Differences to Finite Elements:A Short History of Numerical Analysis of Partial Differential Equations. Journal of Computational and Applied Mathematics. 2001,128:1~54
13 刘兵山,黄聪. Patran 从入门到精通. 中国水利水电出版社. 2003,3:13~15
14 刘俭. 铁路货车滚动轴承压装机的设计与实现. 哈尔滨工业大学硕士学位论文. 2002,7:5~10
15 MSC.Software Corporation. Linear Static Analysis User’s Guide.MSC.Software Corporation. 2003:148~168
16 李春胜,黄德松. 金属材料手册. 化学出版社. 2005,11:112~115
17 秦绪柏,陈南等. 耦合结点子模型法在螺栓联接结构分析中的应用. 精密制造与自动化. 2003,1:30~32
18 陈新,孙庆鸿等. 基于接触单元的磨床螺栓连接面有限元建模与模型修正. 中国机械工程. 2001,12(5):524~527
19 陈生华. 数控高速铣齿机床结构有限元分析及优化研究. 南京工业大学硕士学位论文. 2005,6:33~42
20 L. P. Chris. Parameter Identification and Investigation of a Bolted Joint Model. 46th AIAA/ASME/ASCE/AHS/ASC Structures , Structural Dynamics and Materials Conference,2005,Austin,TX,United States:7007~7025
21 L. Gaul,J Lenz. Nonlinear Dynamics of Structures Assembled by Bolted Joints. Acta Mechanica. 1997,(125):169-181
22 H. Ahmadian , M. Ebrahimi. , J.E. Mottershead. , M.I. Friswell. Identification of Bolted-joint Interface Models. Proceedings of the 2002 International Conference on Noise and Vibration Engineering, ISMA. 2002:1741-1747
23 H. Ahmadian , H. Jalali. Identification of Nonlinear Interface Models. Proceedings of the 2004 International Conference on Noise and Vibration Engineering, ISMA. 2004:1221-1227
24 T.Y. Chen , L.F. Liu. A Simple Interface Modeling of Bolted Joints. Proceedings of the Tenth International Congress on Sound and Vibration. 2003:557-564
25 S. Yang.,C.J. Hartwigsenb,D.M. McFarlanda,A.F. Vakakisb,L.A. Bergmana. Simulation of Dynamics of Beam Structures with Bolted Joints Using Adjusted Iwan Beam Elements. Journal of Sound and Vibration. 2004,273:249–276
26 Y.X. Song,C. J. Hartwigsen,B.A. Lawrence.,V. F. Alexander. Dynamical Response Analysis of Joint Structures by 2-D/3-D Adjusted Iwan Beam Elements. Proceedings of the 44th AIAA/ASME/ASCE/AHS Structures, Structural Dynamics and Materials Conference. 2003,4:1~10
27 唐宏宾. 机电测试技术在模型试验中的应用. 长沙理工大学硕士学位论文. 2004,4:7~15
28 杨俊杰. 相似理论与结构模型试验. 武汉理工大学出版社. 2005:23~46
29 魏铁华. 模化与系列化设计. 水利电力机械. 1998,4:47~53
30 潘辉. 货车滚动轴承压装过程仿真. 组合机床与自动化技术. 2003,(7):4~6
31 孔庆文. 浅析货车轴承压装的质量控制. 铁道技术监督. 2000,4:27~29
32 铁道部车辆局. 铁路货车轮对和滚动轴承组装及检修规则.中国铁道出版社发行. 1998:52～56
33 B. Jesper,A. Soren. Simulation of Wear in Gears with Flank Interference:A Mixed FE and Analytical Approach. Wear. 2003,254:1216~1232
34 J. Haslingera,R. K. Cerab, Z. Dostal. An Algorithm for the Numerical Realization of 3D Contact Problems with Coulomb Friction. Journal of Computational and Applied Mathematics. 2004,164:387~408
35 U. Sellgren,S. Bjorklund,S. Andersson. A Finite Element-based Model of Normal Contact between Rough Surfaces. Wear. 2003,254:1180~1188
36 S. Satyanarayana , S.N. Melkote. Finite Element Modeling of Fixture Workpiece Contacts : Single Contact Modeling and Experimental Verification. International Journal of Machine Tools & Manufacture. 2004,44:903~913
37 O.S. Bursia,J.P. Jaspart. Basic Issues in the Finite element Simulation of Extended End Plate Connections. Computers and Structures. 1998,69:361~382
38 陈火红. Marc 有限元实例分析教程. 机械工业出版社. 2002,2:255~263
39 M. H. Maria,B. Bharat. Contact Analysis of Three-dimensional Rough Surfaces under Frictionless and Frictional Contact. Wear. 1996,200:265~280
40 R. Boman,J.P. Ponthot. Finite Element Simulation of Lubricated Contact in Rolling Using the Arbitrary Lagrangian–Eulerian Formulation. Computer Methods in Applied Mechanical and Engineering. 2004,193:4323~4353
41 J. Haslingera,R.K. Cerab,Z. Dostoalc. An Algorithm for the Numerical Realization of 3D Contact Problems with Coulomb Friction. Journal of Computational and Applied Mathematics. 2004,165:387~408
42 B. Boroomand,J. Parvizian,A.R. Pishevar. Contact Modeling in ForgingSimulation. Journal of Material Processing Technology. 2002 , 126 :583~573
43 机械工程材料性能数据手册编委会. 机械工程材料性能数据手册. 机械工业出版社. 1995,4:63~92
44 肖友刚,马捷声,陈欠根. 托轮轴的应力分析及疲劳寿命预测. 中国水泥. 2005,3:59~61
45 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
46 E.V. Torskaya,I.G. Goryacheva. The Effect of Interface Imperfection and External Loading on the Axisymmetric Contact with a Coated Solid. Wear. 2003,254:538~545
47 唐建湘,郝宗潮,李克明. 铁路货车滚动轴承压装压力检测标准的研究. 铁道技术监督. 1999,2:8~11
2 齐宏志,聂欣然. 铁路货车滚动轴承压装机与轴承压装质量. 铁道车辆. 200139(8):33~37
3 许小强,赵洪伦. 过盈配合应力的接触非线性有限元分析. 机械设计与研究. 2000,(1):33~35
4 魏延刚,宋亚昕. 机车轮对压装过程弹塑性模拟 机械设计. 2004,21(9):46~48
5 S. Aleksander,S. Marek. Analysis of Wheel–rail Interaction Using FE Software. Wear. 2005,258:1217~1223
6 T. Tanel , O. Ulf. Wheel–rail Wear Simulation. Wear. 2004 , 257 :1145~1153
7 万贤妃. 谈新型列车轮对轴承压装机设计. 液压与气动. 2001,(10):6~7
8 马万兵. 铁路货车滚动轴承压装机监控系统的研究. 哈尔滨工业大学硕士学位论文. 2005,11:1~3
9 柳波,聂宝安. 新型铁道轮对轴承压装机设计研究. 液压与气动. 2001,1:20~21
10 K.K. Gupta,J.L. Meek. A Brief History of the Beginning of the Finite Element Method. International Journal for Numerical Method in Engineering. 1996,39(22):3761~3774
11 孙鹏举. 近距离捕获地面实验系统有限元分析. 哈尔滨工业大学硕士论文. 2005,7:10~15
12 T. Vidar. From Finite Differences to Finite Elements:A Short History of Numerical Analysis of Partial Differential Equations. Journal of Computational and Applied Mathematics. 2001,128:1~54
13 刘兵山,黄聪. Patran 从入门到精通. 中国水利水电出版社. 2003,3:13~15
14 刘俭. 铁路货车滚动轴承压装机的设计与实现. 哈尔滨工业大学硕士学位论文. 2002,7:5~10
15 MSC.Software Corporation. Linear Static Analysis User’s Guide.MSC.Software Corporation. 2003:148~168
16 李春胜,黄德松. 金属材料手册. 化学出版社. 2005,11:112~115
17 秦绪柏,陈南等. 耦合结点子模型法在螺栓联接结构分析中的应用. 精密制造与自动化. 2003,1:30~32
18 陈新,孙庆鸿等. 基于接触单元的磨床螺栓连接面有限元建模与模型修正. 中国机械工程. 2001,12(5):524~527
19 陈生华. 数控高速铣齿机床结构有限元分析及优化研究. 南京工业大学硕士学位论文. 2005,6:33~42
20 L. P. Chris. Parameter Identification and Investigation of a Bolted Joint Model. 46th AIAA/ASME/ASCE/AHS/ASC Structures , Structural Dynamics and Materials Conference,2005,Austin,TX,United States:7007~7025
21 L. Gaul,J Lenz. Nonlinear Dynamics of Structures Assembled by Bolted Joints. Acta Mechanica. 1997,(125):169-181
22 H. Ahmadian , M. Ebrahimi. , J.E. Mottershead. , M.I. Friswell. Identification of Bolted-joint Interface Models. Proceedings of the 2002 International Conference on Noise and Vibration Engineering, ISMA. 2002:1741-1747
23 H. Ahmadian , H. Jalali. Identification of Nonlinear Interface Models. Proceedings of the 2004 International Conference on Noise and Vibration Engineering, ISMA. 2004:1221-1227
24 T.Y. Chen , L.F. Liu. A Simple Interface Modeling of Bolted Joints. Proceedings of the Tenth International Congress on Sound and Vibration. 2003:557-564
25 S. Yang.,C.J. Hartwigsenb,D.M. McFarlanda,A.F. Vakakisb,L.A. Bergmana. Simulation of Dynamics of Beam Structures with Bolted Joints Using Adjusted Iwan Beam Elements. Journal of Sound and Vibration. 2004,273:249–276
26 Y.X. Song,C. J. Hartwigsen,B.A. Lawrence.,V. F. Alexander. Dynamical Response Analysis of Joint Structures by 2-D/3-D Adjusted Iwan Beam Elements. Proceedings of the 44th AIAA/ASME/ASCE/AHS Structures, Structural Dynamics and Materials Conference. 2003,4:1~10
27 唐宏宾. 机电测试技术在模型试验中的应用. 长沙理工大学硕士学位论文. 2004,4:7~15
28 杨俊杰. 相似理论与结构模型试验. 武汉理工大学出版社. 2005:23~46
29 魏铁华. 模化与系列化设计. 水利电力机械. 1998,4:47~53
30 潘辉. 货车滚动轴承压装过程仿真. 组合机床与自动化技术. 2003,(7):4~6
31 孔庆文. 浅析货车轴承压装的质量控制. 铁道技术监督. 2000,4:27~29
32 铁道部车辆局. 铁路货车轮对和滚动轴承组装及检修规则.中国铁道出版社发行. 1998:52～56
33 B. Jesper,A. Soren. Simulation of Wear in Gears with Flank Interference:A Mixed FE and Analytical Approach. Wear. 2003,254:1216~1232
34 J. Haslingera,R. K. Cerab, Z. Dostal. An Algorithm for the Numerical Realization of 3D Contact Problems with Coulomb Friction. Journal of Computational and Applied Mathematics. 2004,164:387~408
35 U. Sellgren,S. Bjorklund,S. Andersson. A Finite Element-based Model of Normal Contact between Rough Surfaces. Wear. 2003,254:1180~1188
36 S. Satyanarayana , S.N. Melkote. Finite Element Modeling of Fixture Workpiece Contacts : Single Contact Modeling and Experimental Verification. International Journal of Machine Tools & Manufacture. 2004,44:903~913
37 O.S. Bursia,J.P. Jaspart. Basic Issues in the Finite element Simulation of Extended End Plate Connections. Computers and Structures. 1998,69:361~382
38 陈火红. Marc 有限元实例分析教程. 机械工业出版社. 2002,2:255~263
39 M. H. Maria,B. Bharat. Contact Analysis of Three-dimensional Rough Surfaces under Frictionless and Frictional Contact. Wear. 1996,200:265~280
40 R. Boman,J.P. Ponthot. Finite Element Simulation of Lubricated Contact in Rolling Using the Arbitrary Lagrangian–Eulerian Formulation. Computer Methods in Applied Mechanical and Engineering. 2004,193:4323~4353
41 J. Haslingera,R.K. Cerab,Z. Dostoalc. An Algorithm for the Numerical Realization of 3D Contact Problems with Coulomb Friction. Journal of Computational and Applied Mathematics. 2004,165:387~408
42 B. Boroomand,J. Parvizian,A.R. Pishevar. Contact Modeling in ForgingSimulation. Journal of Material Processing Technology. 2002 , 126 :583~573
43 机械工程材料性能数据手册编委会. 机械工程材料性能数据手册. 机械工业出版社. 1995,4:63~92
44 肖友刚,马捷声,陈欠根. 托轮轴的应力分析及疲劳寿命预测. 中国水泥. 2005,3:59~61
45 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
46 E.V. Torskaya,I.G. Goryacheva. The Effect of Interface Imperfection and External Loading on the Axisymmetric Contact with a Coated Solid. Wear. 2003,254:538~545
47 唐建湘,郝宗潮,李克明. 铁路货车滚动轴承压装压力检测标准的研究. 铁道技术监督. 1999,2:8~11