铁路车辆车轮辐板磁粉探伤工艺参数优化设计
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摘要
列车轮对为铁路车辆重要的行走部。在生产和装配过程中轮对往往形成残余应力,而在实际运行当中,轮对因受到复杂的机械和热载荷作用,易形成缺陷。同时车轮辐板上为操作方便设计的辐板孔容易造成应力集中,加速车轮的破坏。含有辐板孔的车轮已经多次引起安全事故。现在役的车轮中还有半数以上的车轮含有辐板孔,只能在十年以内逐步更换,因此辐板孔缺陷已严重威胁着当前铁路行车安全。
因此在车轮厂段修期间准确高效的发现辐板孔缺陷并及时进行修理成为铁路行车安全的重要课题。为此应制订相应的车轮磁粉探伤工艺规范。基于当前只存在车轴磁粉探伤工艺规范的情况,本文以检测的准确度、时间和成本为综合优化目标对车轴的磁粉探伤工艺进行参数设计。首先运用热力耦合有限元分析方法揭示了辐板上应力分布并确定了辐板周向区域为重点检测区域。然后以电磁场有限元分析为辅助手段进行试验设计,实地收集数据,并通过方差分析和多元回归方法考察了充磁电流、充磁时间、辐板孔位置和喷磁悬液时间四个主要工艺参数对检测的准确度的关系,再结合上述四个参数与时间和成本关系以多响应曲面方法求解出优化参数值,作为车轮磁粉探伤工艺规范的建议参数值,最后通过现场试验验证了参数设计的结果。
与常规的确定车轮磁粉探伤工艺参数方法不同,论文最终强调的思想是:参数设计不仅应该考虑到工艺准确性的要求,还应考虑工艺的时间和成本等其他因素,寻求综合最优,在保证工艺准确性的前提下提高工艺的时间和经济效率。在寻求合适的参数水平时应采用基于数理统计理论的参数设计方法,摒弃单纯依靠经验的方法。
The wheelset is an important moving part of the railway vehicles. During manufacturing and assembly process the wheelsets are subject to residual stresses. Apart from that, the wheelsets experience complex mechanical and thermal loads during service and flaws are likely to emerge. Moreover, the sprag holes in the wheel webs, which are manufactured for easy handling, intend to aggrandize stress concentration and lead the wheels to break. In fact the wheels with sprag holes have led to many accidents recently. Over half of the wheels in service contain sprag holes in China and cannot be totally replaced within 10 years. Thus the sprag hole caused flaws have become a severe threat to the railway safety.
Consequently it is a central issue to detect sprag hole caused flaws accurately and effectively and repair them in time. It is necessary to establish standards for magnetic inspection process (MIP) of wheels. Now there are only standards of MIP for shafts. Based on the existing standards, this thesis figures out the accuracy, cost and time as indicator for optimization and perform parameter design (PD) for MIP for wheels. At first we quantify the stress distribution in the wheel webs through mechanical-thermal coupled finite element analysis and determine the circumferential region near sprag hole as inspection focus. Then we perform design of experiment (DoE) with the aid of electromagnetic finite element analysis, administrate field surveys and set up the relationship between definition of the magnetic display and four key factors, namely the magnetizing current, magnetizing time, position of the sprag hole during inspection and spray time of magnetic suspension by using methods of variance analysis and multivariate regression. Taking into account the relationship between the four factors and inspection time and cost, we obtain the optimization solution through multi-response surface techniques. This solution could be the recommendation values for MIP standards for wheels. The field test confirms the result of parameter design finally.
The emphasis of the thesis is that, distinctive from other methods for determining MIP parameters for wheels, it is more reasonable to consider not only the demand for accuracy but also other factors like time and cost in order to search for overall optimization, i.e. improving the efficiency and economy while maintaining accuracy. Parameter design based on statistical methodology should be the tool to determine parameter values, instead of mere experience and sense.
因此在车轮厂段修期间准确高效的发现辐板孔缺陷并及时进行修理成为铁路行车安全的重要课题。为此应制订相应的车轮磁粉探伤工艺规范。基于当前只存在车轴磁粉探伤工艺规范的情况,本文以检测的准确度、时间和成本为综合优化目标对车轴的磁粉探伤工艺进行参数设计。首先运用热力耦合有限元分析方法揭示了辐板上应力分布并确定了辐板周向区域为重点检测区域。然后以电磁场有限元分析为辅助手段进行试验设计,实地收集数据,并通过方差分析和多元回归方法考察了充磁电流、充磁时间、辐板孔位置和喷磁悬液时间四个主要工艺参数对检测的准确度的关系,再结合上述四个参数与时间和成本关系以多响应曲面方法求解出优化参数值,作为车轮磁粉探伤工艺规范的建议参数值,最后通过现场试验验证了参数设计的结果。
与常规的确定车轮磁粉探伤工艺参数方法不同,论文最终强调的思想是:参数设计不仅应该考虑到工艺准确性的要求,还应考虑工艺的时间和成本等其他因素,寻求综合最优,在保证工艺准确性的前提下提高工艺的时间和经济效率。在寻求合适的参数水平时应采用基于数理统计理论的参数设计方法,摒弃单纯依靠经验的方法。
The wheelset is an important moving part of the railway vehicles. During manufacturing and assembly process the wheelsets are subject to residual stresses. Apart from that, the wheelsets experience complex mechanical and thermal loads during service and flaws are likely to emerge. Moreover, the sprag holes in the wheel webs, which are manufactured for easy handling, intend to aggrandize stress concentration and lead the wheels to break. In fact the wheels with sprag holes have led to many accidents recently. Over half of the wheels in service contain sprag holes in China and cannot be totally replaced within 10 years. Thus the sprag hole caused flaws have become a severe threat to the railway safety.
Consequently it is a central issue to detect sprag hole caused flaws accurately and effectively and repair them in time. It is necessary to establish standards for magnetic inspection process (MIP) of wheels. Now there are only standards of MIP for shafts. Based on the existing standards, this thesis figures out the accuracy, cost and time as indicator for optimization and perform parameter design (PD) for MIP for wheels. At first we quantify the stress distribution in the wheel webs through mechanical-thermal coupled finite element analysis and determine the circumferential region near sprag hole as inspection focus. Then we perform design of experiment (DoE) with the aid of electromagnetic finite element analysis, administrate field surveys and set up the relationship between definition of the magnetic display and four key factors, namely the magnetizing current, magnetizing time, position of the sprag hole during inspection and spray time of magnetic suspension by using methods of variance analysis and multivariate regression. Taking into account the relationship between the four factors and inspection time and cost, we obtain the optimization solution through multi-response surface techniques. This solution could be the recommendation values for MIP standards for wheels. The field test confirms the result of parameter design finally.
The emphasis of the thesis is that, distinctive from other methods for determining MIP parameters for wheels, it is more reasonable to consider not only the demand for accuracy but also other factors like time and cost in order to search for overall optimization, i.e. improving the efficiency and economy while maintaining accuracy. Parameter design based on statistical methodology should be the tool to determine parameter values, instead of mere experience and sense.
引文
[1]方明群主编.铁路机车车辆运用、检修、维护、保养与标准规范全书第二册.吉林电子出版社, 2003.
[2]郑红霞,谢基龙.φ840D货车车轮辐板孔疲劳裂纹扩展特性研究.铁道学报, 2006, 28(3): 27-31
[3]陈雷. 840D货车车轮辐板孔疲劳裂纹研究.北京交通大学学报, 2007, 31(1): 1-7
[4] Lawrence P G, George E N, Daniel H S, et al. Railroad car wheel. United States, 1979
[5] Downes G W. Magnetic particle inspection equipment for testing railway wheelsets. Insight NDT, 1994: 1
[6] Railway Group Standard Gm/rt. Certification processes for NDT operatives, equipment and facilities used for inspecting rail vehicles. 2005
[7] Stone D, Lonsdale C, Kalay S, et al. Effect of wheel impact loading on shattered rims. Proceeding of 13th International Wheelset Congress. Rome: 2001.1-14
[8] Mutton P J, Epp C J, D J, et al. Rolling Contact Fatigue in Railway Wheels Under High Axle Loads. Wear, 2001: 1-16
[9] Endsley L E. Method of treating cab wheels. United States, 1941
[10] Hodge J M, Wandrisco J M. Wrought railroad wheels made of alloy steels. United States, 1957
[11] ISO 1005-6. Railway rolling stock material-Part 6: Solid wheels for tractive and trailing stock-Technical delivery conditions. 1994
[12]陈虎,燕慧阳.浅谈国产车轮的发展方向及其相关问题.铁道物资科学管理, 1999(4): 23-24
[13]朱梅.制定车轮标准的一些问题与分析.铁道技术监督, 2004(8): 6-9
[14] Lynch M R, Mutton P J, Epp K J, et al. Improving Wheelset Performance under High Axle Loads. Proceeding of 13th International Wheelset Congress. Rome: 2001.1-12
[15] Kappes W, Kroening M, Rockstroh B, et al. Non-destructive testing of wheel-sets as a contribution to safety of rail traffic. 2000: 1-11
[16] Choi S, Park S, Stubbs N, et al. Nondestructive damage detection in structures using changes in compliance. International Journal of Solids and Structures, 2005, 42(15): 4494-4513
[17] Dymkin G Y, Shev A V. Technique of Ultrasonic Testing of Disks of Wagon Solid-Rolled Wheels by Surface Waves. Acoustic Methods, 2003, 39(7): 497-505
[18] Raj B, Mukhopadhyay C K, Jayakumar T, et al. Frontiers in NDE research nearing maturity for exploitation to ensure structural integrity of pressure retaining components. International Journal of Pressure Vessels and Piping, 2006(83): 322-335
[19] Righiniotis T D. A comparative study of fatigue inspection methods. Journal of constructional steel research, 2006(62): 352-358
[20] Shubochkin A E. Eddy-Current Testing of the Quality of Railway Wheels. Russian Journal of Nondestructive Testing, 2005, 41(3): 189-192
[21] Simsir M, Ankara A. Comparison of two non-destructive inspection techniques on the basis of sensitivity and reliability. Materials and design, 2007(28): 1433-1439
[22]邓嘉鸣. QMT/C-8000型铁路车辆车轮磁粉自动探伤机的研制.无损探伤, 2000, 27(6): 23-25
[23]赵俊.新型线圈磁化法在铁路整体车轮磁粉检测中的应用.无损探伤, 2003, 27(6): 23-25
[24] Myers R H, Carter W H. Response surface techniques for dual response systems. Technometrics, 1973, 15(2): 301-317
[25] Pignatiello J J. Strategies for robust multiresponse quality engineering. IIE Transactions. IIE Transactions, 1993, 25(3): 5-15
[26] Vining G G. A compromise approach to multi-response optimization. Journal of Quality Technology, 1998, 10(4): 309-313
[27] The American Society For Non-destructive Testing. American NDT Manual. 1994.
[28]陈革新.影响磁粉检测灵敏度的因素.安装, 2003(130(5)): 45-46
[29]中华人民共和国铁道部.铁道车辆轮轴探伤工艺规程.中国铁道出版社, 1995
[30]焦政.磁粉检测的可靠性.安徽化工, 2006, 142(4): 54-55
[31]蒋凤阳,周德锦.磁粉探伤方法及磁粉探伤设备选购.试验技术与试验机, 2003, 43(4): 29-34
[32]蔺大伟.轮对扩展辐板部位探伤技术的升级改造.铁道机车车辆工人, 1006(11): 15-19
[33] Wise S. Railway wheelsets-a critical review. Proceedings of the Institute of Mechanical Engineers, 1987, 201(D4): 257
[34] Edel K O, Schaper M. Fracture mechanics fatigue resistance analysis of the crack damaged tread of over braked solid railway wheels. Rail International, 1992: 35
[35] Michael C F, Sehitoglu H. Thermal mechanical damage in railroad wheels due to hot spotting. Wear, 1985(102): 31
[36] Ramanan L, Krishna K R, Sriraman R, et al. Thermo mechanical analysis of rail wheel. Proc. of 3rd International Conference on Modern Practice in Stress and Vibration Analysis. Ireland: 1997
[37] Lunden R. Contact region fatigue of railway wheels under combined mechanical rolling pressure and thermal brake loading. Wear, 1991(144): 57
[38] Fermer M. Optimization of railway freight car wheel by use of fractional factorial design method. Proceedings of the Institute of Mechanical Engineers, 1994(208): 97
[39] Moyar G J, Stone D H. An analysis of thermal contributions to railway wheel shelling. Wear, 1991(144): 117
[40] Report of railway engineering research at Chalmers University in Gothenburg. Proceedings of the Institute of Mechanical Engineers, 1992(206): 145
[41] Jergeus J. Wheel/Rail contact problem modelled with three dimensional finite elements in a supercomputer. Chalmers University of Technology, Report T125, 1991
[42] Ramanan L, Krishna K R, Sriraman R, et al. Thermo-mechanical finite element analysis of a rail wheel. International Journal of Mechanical Sciences, 1999, 41(4-5): 487-505
[43] Aar S-660-83. Procedure for the analytical evaluation of locomotive and freight car wheel designs.Manual of standards and recommended practices, Mechanical Division. 1983
[44] Kumugai N, Ishikawa H, Haga K, et al. Factors of wheel flats occurrence and preventive measures. Wear, 1991, 144(1-2): 277-288
[45]阎照文. ANSYS 10.0工程电磁分析技术与实例详解.北京:中国水利水电出版社, 2006.
[46] Montgomery D C. Design And Analysis Of Experiments (6th Ed.). John Wiley & Sons Inc, 2005.
[47]王颉.试验设计与SPSS应用.北京:化学工业出版社, 2007.
[48]荣泰生. SPSS与研究方法.台北:五南图书出版公司, 2006.
[49] Tacq J. Multivariate Analysis Techniques in Social Science Research. London: SAGE, 1997.
[50] Belsley D A, Kuh E, Welsch R E, et al. Regression Diagnostics. New York: John Wiley&Sons, Inc., 1980.
[51] Jeong I J, Kim K J. Interactive Desirability Function Approach to Multi-Response Surface Optimization. International Journal of Reliability, Quality and Safety Engineering, 2003, 10(2): 205-217
[52] Magrab E B. An Engineer's Guide to MATLAB: with Applications from Mechanical, Aerospace, Electrical, and Civil Engineering. Upper Saddle River: Prentice Hall/Pearson, 2004.
[2]郑红霞,谢基龙.φ840D货车车轮辐板孔疲劳裂纹扩展特性研究.铁道学报, 2006, 28(3): 27-31
[3]陈雷. 840D货车车轮辐板孔疲劳裂纹研究.北京交通大学学报, 2007, 31(1): 1-7
[4] Lawrence P G, George E N, Daniel H S, et al. Railroad car wheel. United States, 1979
[5] Downes G W. Magnetic particle inspection equipment for testing railway wheelsets. Insight NDT, 1994: 1
[6] Railway Group Standard Gm/rt. Certification processes for NDT operatives, equipment and facilities used for inspecting rail vehicles. 2005
[7] Stone D, Lonsdale C, Kalay S, et al. Effect of wheel impact loading on shattered rims. Proceeding of 13th International Wheelset Congress. Rome: 2001.1-14
[8] Mutton P J, Epp C J, D J, et al. Rolling Contact Fatigue in Railway Wheels Under High Axle Loads. Wear, 2001: 1-16
[9] Endsley L E. Method of treating cab wheels. United States, 1941
[10] Hodge J M, Wandrisco J M. Wrought railroad wheels made of alloy steels. United States, 1957
[11] ISO 1005-6. Railway rolling stock material-Part 6: Solid wheels for tractive and trailing stock-Technical delivery conditions. 1994
[12]陈虎,燕慧阳.浅谈国产车轮的发展方向及其相关问题.铁道物资科学管理, 1999(4): 23-24
[13]朱梅.制定车轮标准的一些问题与分析.铁道技术监督, 2004(8): 6-9
[14] Lynch M R, Mutton P J, Epp K J, et al. Improving Wheelset Performance under High Axle Loads. Proceeding of 13th International Wheelset Congress. Rome: 2001.1-12
[15] Kappes W, Kroening M, Rockstroh B, et al. Non-destructive testing of wheel-sets as a contribution to safety of rail traffic. 2000: 1-11
[16] Choi S, Park S, Stubbs N, et al. Nondestructive damage detection in structures using changes in compliance. International Journal of Solids and Structures, 2005, 42(15): 4494-4513
[17] Dymkin G Y, Shev A V. Technique of Ultrasonic Testing of Disks of Wagon Solid-Rolled Wheels by Surface Waves. Acoustic Methods, 2003, 39(7): 497-505
[18] Raj B, Mukhopadhyay C K, Jayakumar T, et al. Frontiers in NDE research nearing maturity for exploitation to ensure structural integrity of pressure retaining components. International Journal of Pressure Vessels and Piping, 2006(83): 322-335
[19] Righiniotis T D. A comparative study of fatigue inspection methods. Journal of constructional steel research, 2006(62): 352-358
[20] Shubochkin A E. Eddy-Current Testing of the Quality of Railway Wheels. Russian Journal of Nondestructive Testing, 2005, 41(3): 189-192
[21] Simsir M, Ankara A. Comparison of two non-destructive inspection techniques on the basis of sensitivity and reliability. Materials and design, 2007(28): 1433-1439
[22]邓嘉鸣. QMT/C-8000型铁路车辆车轮磁粉自动探伤机的研制.无损探伤, 2000, 27(6): 23-25
[23]赵俊.新型线圈磁化法在铁路整体车轮磁粉检测中的应用.无损探伤, 2003, 27(6): 23-25
[24] Myers R H, Carter W H. Response surface techniques for dual response systems. Technometrics, 1973, 15(2): 301-317
[25] Pignatiello J J. Strategies for robust multiresponse quality engineering. IIE Transactions. IIE Transactions, 1993, 25(3): 5-15
[26] Vining G G. A compromise approach to multi-response optimization. Journal of Quality Technology, 1998, 10(4): 309-313
[27] The American Society For Non-destructive Testing. American NDT Manual. 1994.
[28]陈革新.影响磁粉检测灵敏度的因素.安装, 2003(130(5)): 45-46
[29]中华人民共和国铁道部.铁道车辆轮轴探伤工艺规程.中国铁道出版社, 1995
[30]焦政.磁粉检测的可靠性.安徽化工, 2006, 142(4): 54-55
[31]蒋凤阳,周德锦.磁粉探伤方法及磁粉探伤设备选购.试验技术与试验机, 2003, 43(4): 29-34
[32]蔺大伟.轮对扩展辐板部位探伤技术的升级改造.铁道机车车辆工人, 1006(11): 15-19
[33] Wise S. Railway wheelsets-a critical review. Proceedings of the Institute of Mechanical Engineers, 1987, 201(D4): 257
[34] Edel K O, Schaper M. Fracture mechanics fatigue resistance analysis of the crack damaged tread of over braked solid railway wheels. Rail International, 1992: 35
[35] Michael C F, Sehitoglu H. Thermal mechanical damage in railroad wheels due to hot spotting. Wear, 1985(102): 31
[36] Ramanan L, Krishna K R, Sriraman R, et al. Thermo mechanical analysis of rail wheel. Proc. of 3rd International Conference on Modern Practice in Stress and Vibration Analysis. Ireland: 1997
[37] Lunden R. Contact region fatigue of railway wheels under combined mechanical rolling pressure and thermal brake loading. Wear, 1991(144): 57
[38] Fermer M. Optimization of railway freight car wheel by use of fractional factorial design method. Proceedings of the Institute of Mechanical Engineers, 1994(208): 97
[39] Moyar G J, Stone D H. An analysis of thermal contributions to railway wheel shelling. Wear, 1991(144): 117
[40] Report of railway engineering research at Chalmers University in Gothenburg. Proceedings of the Institute of Mechanical Engineers, 1992(206): 145
[41] Jergeus J. Wheel/Rail contact problem modelled with three dimensional finite elements in a supercomputer. Chalmers University of Technology, Report T125, 1991
[42] Ramanan L, Krishna K R, Sriraman R, et al. Thermo-mechanical finite element analysis of a rail wheel. International Journal of Mechanical Sciences, 1999, 41(4-5): 487-505
[43] Aar S-660-83. Procedure for the analytical evaluation of locomotive and freight car wheel designs.Manual of standards and recommended practices, Mechanical Division. 1983
[44] Kumugai N, Ishikawa H, Haga K, et al. Factors of wheel flats occurrence and preventive measures. Wear, 1991, 144(1-2): 277-288
[45]阎照文. ANSYS 10.0工程电磁分析技术与实例详解.北京:中国水利水电出版社, 2006.
[46] Montgomery D C. Design And Analysis Of Experiments (6th Ed.). John Wiley & Sons Inc, 2005.
[47]王颉.试验设计与SPSS应用.北京:化学工业出版社, 2007.
[48]荣泰生. SPSS与研究方法.台北:五南图书出版公司, 2006.
[49] Tacq J. Multivariate Analysis Techniques in Social Science Research. London: SAGE, 1997.
[50] Belsley D A, Kuh E, Welsch R E, et al. Regression Diagnostics. New York: John Wiley&Sons, Inc., 1980.
[51] Jeong I J, Kim K J. Interactive Desirability Function Approach to Multi-Response Surface Optimization. International Journal of Reliability, Quality and Safety Engineering, 2003, 10(2): 205-217
[52] Magrab E B. An Engineer's Guide to MATLAB: with Applications from Mechanical, Aerospace, Electrical, and Civil Engineering. Upper Saddle River: Prentice Hall/Pearson, 2004.