206KP型转向架定位臂抗疲劳设计与工艺研究
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摘要
中国南车四方机车车辆股份有限公司从1985年开始与各有关高校和研究所联合研制设计准高速转向架,206KP型转向架在1994年底完成线路动力学试验后应用于提速列车,通过不断的优化和改进,该转向架成为提速客车的主型转向架之一。
无摇动台客车转向架具有结构简单、安全可靠、检修维护方便的特点,已被国外铁路发达国家在高速列车上广泛采用。206KP型转向架应用以来总体情况良好,但在转向架构架定位臂的疲劳强度方面仍存在一些问题,需进行进一步分析研究。
本文运用疲劳分析方法对206KP型转向架构架定位臂结构进行了以下研究:
首先,应用大型有限元软件ANSYS对206KP型转向架构架定位臂进行有限元分析,结合实际应用情况,找到了结构疲劳部位。
其次,根据定位臂结构特点,提出了改进方案并通过有限元程序进行了比较计算。
再次,对定位臂补强时的焊接变形及采取的防变形措施进行了研究。
最后,通过在线路对定位臂进行动应力测试,比较分析了改进前后定位臂的疲劳强度和寿命。
通过对206KP型转向架构架定位臂的结构进行改进和疲劳分析,将使该型转向架能更好的满足运用要求。
The CSR Sifang locomotive and Rolling Stock Co., LTD researched and developed the quasi—high speed bogie of passenger car, cooperated with some relative universities and institutes since 1985. 206KP type of bogie had been used for speed-up train after it finished the dynamic test in 1994. This bogie has been one of the main bogies of speed-up passenger car by continuing optimization and improvement.
Bolsterless bogie of passenger car has some characteristics: simplified structure, safety and reliability, convenience for examination and maintenance, so it has been used extensively on the high-speed train in foreign countries of developed railway. The 206KP bogie is well used as a whole, but there are still some problems on the fatigue strength of positioning arm and more analysis was needed.
In this paper, the fatigue analysis methods were used for improving 206KP bogie positioning arm:
Firstly, the positioning arm of 206KP bogie was analyzed by finite element software ANSYS, the fatigue parts of the structure were found combined the finite element analysis results with real application.
Secondly, two improvement schemes were put forward to solve the problem of the positioning arm, the finite element analysis was made on the original model and the improvement schemes.
Thirdly, a study for controlling welding distortion during filling the objections of the positioning arm.
Finally, the fatigue strength and life of the original and the improving positioning arm was carried out by dynamic stress testing on line.
The results of the researches on positioning arm both in improvement and fatigue analysis indicate that the 206KP bogie will have excellent performance for application.
无摇动台客车转向架具有结构简单、安全可靠、检修维护方便的特点,已被国外铁路发达国家在高速列车上广泛采用。206KP型转向架应用以来总体情况良好,但在转向架构架定位臂的疲劳强度方面仍存在一些问题,需进行进一步分析研究。
本文运用疲劳分析方法对206KP型转向架构架定位臂结构进行了以下研究:
首先,应用大型有限元软件ANSYS对206KP型转向架构架定位臂进行有限元分析,结合实际应用情况,找到了结构疲劳部位。
其次,根据定位臂结构特点,提出了改进方案并通过有限元程序进行了比较计算。
再次,对定位臂补强时的焊接变形及采取的防变形措施进行了研究。
最后,通过在线路对定位臂进行动应力测试,比较分析了改进前后定位臂的疲劳强度和寿命。
通过对206KP型转向架构架定位臂的结构进行改进和疲劳分析,将使该型转向架能更好的满足运用要求。
The CSR Sifang locomotive and Rolling Stock Co., LTD researched and developed the quasi—high speed bogie of passenger car, cooperated with some relative universities and institutes since 1985. 206KP type of bogie had been used for speed-up train after it finished the dynamic test in 1994. This bogie has been one of the main bogies of speed-up passenger car by continuing optimization and improvement.
Bolsterless bogie of passenger car has some characteristics: simplified structure, safety and reliability, convenience for examination and maintenance, so it has been used extensively on the high-speed train in foreign countries of developed railway. The 206KP bogie is well used as a whole, but there are still some problems on the fatigue strength of positioning arm and more analysis was needed.
In this paper, the fatigue analysis methods were used for improving 206KP bogie positioning arm:
Firstly, the positioning arm of 206KP bogie was analyzed by finite element software ANSYS, the fatigue parts of the structure were found combined the finite element analysis results with real application.
Secondly, two improvement schemes were put forward to solve the problem of the positioning arm, the finite element analysis was made on the original model and the improvement schemes.
Thirdly, a study for controlling welding distortion during filling the objections of the positioning arm.
Finally, the fatigue strength and life of the original and the improving positioning arm was carried out by dynamic stress testing on line.
The results of the researches on positioning arm both in improvement and fatigue analysis indicate that the 206KP bogie will have excellent performance for application.
引文
[1]VDVl52,符合BOStrab的用于公共交通的轨道车辆结构要求[S].
[2]EN 12663,适用于铁路的铁道车辆车体结构要求[S].
[3]JIS E 7105,铁道车辆强度试验方法[S].
[4]GB7928,地铁车辆通用技术条件[S].
[5]UIC515-4,客车转向架构架的机械强度试验程序[S].
[6]TB/T1335-1996,铁道车辆强度设计及试验鉴定规范[S].
[7]苗德政.206W型转向架研制简介[J].铁道车辆,1990,(4):1-5
[8]王松文,张洪.206WP,206KP型准高速客车转向架研制[J],铁道车辆,1995,(12):137-142
[9]张洪,准高速客车转向架轮缘磨耗原因及改进措施[J],铁道车辆,2000,(5):8-10
[10]张瑞亭,王斌杰,206KP型转向架定位臂结构优化设计分析[J],2005,(12):12-15
[11]缪炳荣,机车车辆结构疲劳寿命预测方法的研究[J],内燃机车,2005,(11):1-5
[12]刘鸿文.材料力学[M].高等教育出版社,北京:1987
[13]龚曙光.ANSYS基础应用及范例解析[M].机械工业出版社,北京:2004
[14]张志国,谢基龙.转向架结构静强度及疲劳强度评估报告[M].北方交通大学出版社,北京:2003.01
[15]Dowming S D,Socie D F.Simple rainflow counting algorithms [J].Int.J.Fatigue,1982,4(1):32-40
[16]Glinka,G.and Kam,J.C.P.,Rainflow counting algorithm for very long stress history[J].Int.J.Fatigue,1987,9(3):pp223-228.
[17]徐灏.疲劳强度设计[M].机械工业出版社,北京:1981
[18]程育仁,缪龙秀,侯炳麟.疲劳强度[M].中国铁道出版社,北京:1990
[19]缪龙秀,孙守光.提速客车转向架焊接构架应力谱的试验研究[J].铁 道车辆,1998,(4)
[20]Dahle T.,Larsson B.,Spectrum Fatigue Data in Comparison to Design Curves in the Long Life Regime[J].International Symposium of Fatigue Design,Helsinki,1992
[21]American Association of State Highway and Transportation Official (AASHTO).Interim specifications,Standard Specifications for Highway Bridges[M].Washington D.C.,USA:1998
[22]李强,刘志明,提速客车转向架动应力分布拟合的研究[J].铁道学报,2001,(23)
[23]张瑞亭,崔洪举,提速客车车轴疲劳载荷谱的实验研究[J].铁道车辆,2006,(6)
[24]王成国.新型高速客车构架的疲劳寿命数值仿真分析[J].中国铁道科学,2001,(3):11-15
[25]刘德刚,李强.提速客车转向架主要部件寿命预测方法探讨[J].铁道机车车辆,2002增刊:21-24
[26]李梁,提高结构疲劳牲能的工艺探讨[J].煤矿机械,2004,(1):51-53
[27]严隽髦.车辆工程[M].中国铁道出版社,北京:1999
[28]田中真一[日].转向架构架疲劳设计[J].日本机械学会志,1984,(9):82-86
[29]崛川武等[日].转向架构架的疲劳寿命设计与可靠性评价[J].机械设计(日),1984,(5):71-76
[30]文中,蔡启舟.箱形梁焊接结构安全可靠性分析方法[J].起重运输机械,2004,(9):22-25
[31]沈海军,郭万林.结构疲劳寿命、可靠性可视化技术与虚拟疲劳设计[J].机械设计,2003,(3):20-23
[32]王国强.实用工程数值模拟技术及其在ANSYS上的实践[M].西北工业大学出版社,西安:1999
[2]EN 12663,适用于铁路的铁道车辆车体结构要求[S].
[3]JIS E 7105,铁道车辆强度试验方法[S].
[4]GB7928,地铁车辆通用技术条件[S].
[5]UIC515-4,客车转向架构架的机械强度试验程序[S].
[6]TB/T1335-1996,铁道车辆强度设计及试验鉴定规范[S].
[7]苗德政.206W型转向架研制简介[J].铁道车辆,1990,(4):1-5
[8]王松文,张洪.206WP,206KP型准高速客车转向架研制[J],铁道车辆,1995,(12):137-142
[9]张洪,准高速客车转向架轮缘磨耗原因及改进措施[J],铁道车辆,2000,(5):8-10
[10]张瑞亭,王斌杰,206KP型转向架定位臂结构优化设计分析[J],2005,(12):12-15
[11]缪炳荣,机车车辆结构疲劳寿命预测方法的研究[J],内燃机车,2005,(11):1-5
[12]刘鸿文.材料力学[M].高等教育出版社,北京:1987
[13]龚曙光.ANSYS基础应用及范例解析[M].机械工业出版社,北京:2004
[14]张志国,谢基龙.转向架结构静强度及疲劳强度评估报告[M].北方交通大学出版社,北京:2003.01
[15]Dowming S D,Socie D F.Simple rainflow counting algorithms [J].Int.J.Fatigue,1982,4(1):32-40
[16]Glinka,G.and Kam,J.C.P.,Rainflow counting algorithm for very long stress history[J].Int.J.Fatigue,1987,9(3):pp223-228.
[17]徐灏.疲劳强度设计[M].机械工业出版社,北京:1981
[18]程育仁,缪龙秀,侯炳麟.疲劳强度[M].中国铁道出版社,北京:1990
[19]缪龙秀,孙守光.提速客车转向架焊接构架应力谱的试验研究[J].铁 道车辆,1998,(4)
[20]Dahle T.,Larsson B.,Spectrum Fatigue Data in Comparison to Design Curves in the Long Life Regime[J].International Symposium of Fatigue Design,Helsinki,1992
[21]American Association of State Highway and Transportation Official (AASHTO).Interim specifications,Standard Specifications for Highway Bridges[M].Washington D.C.,USA:1998
[22]李强,刘志明,提速客车转向架动应力分布拟合的研究[J].铁道学报,2001,(23)
[23]张瑞亭,崔洪举,提速客车车轴疲劳载荷谱的实验研究[J].铁道车辆,2006,(6)
[24]王成国.新型高速客车构架的疲劳寿命数值仿真分析[J].中国铁道科学,2001,(3):11-15
[25]刘德刚,李强.提速客车转向架主要部件寿命预测方法探讨[J].铁道机车车辆,2002增刊:21-24
[26]李梁,提高结构疲劳牲能的工艺探讨[J].煤矿机械,2004,(1):51-53
[27]严隽髦.车辆工程[M].中国铁道出版社,北京:1999
[28]田中真一[日].转向架构架疲劳设计[J].日本机械学会志,1984,(9):82-86
[29]崛川武等[日].转向架构架的疲劳寿命设计与可靠性评价[J].机械设计(日),1984,(5):71-76
[30]文中,蔡启舟.箱形梁焊接结构安全可靠性分析方法[J].起重运输机械,2004,(9):22-25
[31]沈海军,郭万林.结构疲劳寿命、可靠性可视化技术与虚拟疲劳设计[J].机械设计,2003,(3):20-23
[32]王国强.实用工程数值模拟技术及其在ANSYS上的实践[M].西北工业大学出版社,西安:1999