基于载荷谱提升转向架构架疲劳可靠性研究
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摘要
铁路客车转向架构架在服役过程中,首先在横侧梁连接区域发生疲劳裂纹。经多次局部补强,构架仍存在疲劳可靠性不足的状况。这一现象表明:真实运用载荷未能成为构架设计的输入条件,构架设计时所用抗疲劳设计规范中的载荷规定尚不能完全针对目前车辆的真实运用环境,有必要开展实际运用环境下的构架载荷研究,从而提升构架的疲劳可靠性,确保运用安全。构建高精度测力构架,建立构架载荷系与疲劳控制部位的损伤传递关系;将测力构架换装到实际运用车辆,在裂纹发生比例高的线路多次往返跟踪测试,获得构架载荷系-时间历程与构架疲劳控制部位的动应力;建立用于提升构架疲劳可靠性的载荷谱;通过系统施加补强结构和持续优化补强结构细部形式分析载荷谱作用下的构架疲劳控制区域应力,完成构架优化改进。线路验证测试结果表明,构架疲劳可靠性得到系统性提升。
During the service life of the speed increased passenger car bogies,the connecting part of the cross and side beams would generate fatigue cracks first.Despite repeated local reinforcements,insufficient reliability of bogie frame still remains.This demonstrates that the actual operation loads are not the input condition of bogie design,and the load standards of bogie frame specified by the anti-fatigue design specifications cannot fully cover the actual operation environment of the current vehicles.Therefore,it is necessary to study the bogie loads under the actual operation environment to improve the fatigue reliability of bogie frame to ensure operation safety.In this paper,a high-precision test frame was calibrated to establish the fatigue damage transfer relationship between the frame load systems and the fatigue control parts.The test frame was installed in an operating train,and multiple round-trip tracking tests were conducted on the track lines where cracks occurred frequently to obtain the load-time history and dynamic stress of the fatigue control parts of the frame.After that the load spectrum was established to improve the reliability of bogie frame.Besides,the stress of the frame fatigue control parts extracted from the load spectrum was also decreased by the application and continuously optimization of reinforcing structure to complete the bogie frame structure optimization.At last,the results of the track test show that the reliability of the bogie frame is improved systematically.
During the service life of the speed increased passenger car bogies,the connecting part of the cross and side beams would generate fatigue cracks first.Despite repeated local reinforcements,insufficient reliability of bogie frame still remains.This demonstrates that the actual operation loads are not the input condition of bogie design,and the load standards of bogie frame specified by the anti-fatigue design specifications cannot fully cover the actual operation environment of the current vehicles.Therefore,it is necessary to study the bogie loads under the actual operation environment to improve the fatigue reliability of bogie frame to ensure operation safety.In this paper,a high-precision test frame was calibrated to establish the fatigue damage transfer relationship between the frame load systems and the fatigue control parts.The test frame was installed in an operating train,and multiple round-trip tracking tests were conducted on the track lines where cracks occurred frequently to obtain the load-time history and dynamic stress of the fatigue control parts of the frame.After that the load spectrum was established to improve the reliability of bogie frame.Besides,the stress of the frame fatigue control parts extracted from the load spectrum was also decreased by the application and continuously optimization of reinforcing structure to complete the bogie frame structure optimization.At last,the results of the track test show that the reliability of the bogie frame is improved systematically.
引文
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[3]European Committee for Standardization.EN 13749:2005Railway Applications-Methods of Specifying Structral Requirements of Bogie Frames[S].London:British Standards Institution,2005.
[4]YU L,CHAN T H T.Moving Force Identification Based on the Frequency-time Domain Method[J].Journal of Sound and Vibration,2003,261:329-349.
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[6]北美铁路协会.AAR机务标准手册[S].华盛顿:北美铁路协会,2007.
[7]任尊松,孙守光,李强.高速动车组轴箱弹簧动态载荷特性[J].中国机械工程学报,2010,46(10):109-115.REN Zunsong,SUN Shouguang,LI Qiang.Axle Spring Load Test and Dynamic Characteristics Analysis of High Speed EMU[J].Chinese Journal of Mechanical Engineering,2010,46(10):109-115.
[8]王文静,王燕,孙守光,等.高速列车转向架载荷谱长期跟踪试验研究[J].西南交通大学学报,2015,50(1):84-89.WANG Wenjing,WANG Yan,SUN Shouguang,et al.Long-term Load Spectrum Test of High-speed Train Bogie[J].Journal of Southwest Jiaotong University,2015,50(1):84-89.
[9]邹骅.城际动车组转向架构架载荷谱研究[D].北京:北京交通大学,2016.
[10]李凡松,邬平波,曾京.车下设备承载结构疲劳试验载荷谱编制方法[J].机械工程学报,2016,52(24):99-106.LI Fansong,WU Pingbo,ZENG Jing.Compilation Method of Fatigue Test Load Spectrum for Underfloor Equipment Bearing Structure[J].Chinese Journal of Mechanical Engineering,2016,52(24):99-106.
[11]赵方伟.铁路货车车体载荷谱测试及疲劳强度评价研究[D].北京:北京交通大学,2015.
[12]任尊松.轮轨多点接触及车辆-道岔系统动态相互作用[M].北京:科学出版社,2014.
[13]严隽耄.车辆工程[M].北京:中国铁道出版社,2007.
[14]郭杏林.结构随机载荷识别的理论和实验研究[D].大连:大连理工大学,2003.
[15]文祥荣,缪龙秀.由实测应变响应识别结构动态载荷[J].铁道学报,2000,22(6):36-39.WEN Xiangrong,MIAO Longxiu.Identif Ication of Structural Dynamic Load from Measured Strain Response[J].Journal of the China Railway Society,2000,22(6):36-39.
[16]叶红岩.高速转向架构架随机加载理论与试验研究[D].成都:西南交通大学,2011.
[17]刘克格,阎楚良,张书明.飞机主起落架载荷谱实测的台架标定[J].吉林大学学报(工学版),2006,36(6):1025-1028.LIU Kege,YAN Chuliang,ZHANG Shuming.Bench Calibration of Load Spectrum Measurement for Fighter Airplanemain Undercarriage[J].Journal of Jilin University(Engineering and Technology Edition),2006,36(6):1025-1028.
[18]刘克格,阎楚良.飞机起落架载荷谱实测与编制方法[J].航空学报,2011,32(5):841-848.LIU Kege,YAN Chuliang.Load Measurement and Compilation of Landing Gear of Airplane[J].Acta Aeronautica et Astronautica Sinica,2011,32(5):841-848.
[19]WANG P,WANG H X,WANG W.Finding Semantics in Time Series[C]//Proceedings of the ACM SIGMOD International Conference on Management of Data.New York:ACM,2011:385-396.
[20]Yasuko Matsubara,Yasushi Sakurai,Christos Faloutsos.AutoPlait:Automatic Mining of Co-evolving Time Sequences[C]//Proceedings of the ACM SIGMOD International Conference on Management of Data.New York:ACM,2014:193-204.
[2]Welding Standards Policy Committee to Technical Committee.BS 7608:1993 Code of Practice for Fatigue Design and Assessment of Steel Structures[S].London:British Standards Institution,1993.
[3]European Committee for Standardization.EN 13749:2005Railway Applications-Methods of Specifying Structral Requirements of Bogie Frames[S].London:British Standards Institution,2005.
[4]YU L,CHAN T H T.Moving Force Identification Based on the Frequency-time Domain Method[J].Journal of Sound and Vibration,2003,261:329-349.
[5]LAW S S,BU J Q,ZHU X Q,et al.Vehicle Axle Loads I-dentification Using Finite Element Method[J].Engineering Structures,2004,26:1143-1153.
[6]北美铁路协会.AAR机务标准手册[S].华盛顿:北美铁路协会,2007.
[7]任尊松,孙守光,李强.高速动车组轴箱弹簧动态载荷特性[J].中国机械工程学报,2010,46(10):109-115.REN Zunsong,SUN Shouguang,LI Qiang.Axle Spring Load Test and Dynamic Characteristics Analysis of High Speed EMU[J].Chinese Journal of Mechanical Engineering,2010,46(10):109-115.
[8]王文静,王燕,孙守光,等.高速列车转向架载荷谱长期跟踪试验研究[J].西南交通大学学报,2015,50(1):84-89.WANG Wenjing,WANG Yan,SUN Shouguang,et al.Long-term Load Spectrum Test of High-speed Train Bogie[J].Journal of Southwest Jiaotong University,2015,50(1):84-89.
[9]邹骅.城际动车组转向架构架载荷谱研究[D].北京:北京交通大学,2016.
[10]李凡松,邬平波,曾京.车下设备承载结构疲劳试验载荷谱编制方法[J].机械工程学报,2016,52(24):99-106.LI Fansong,WU Pingbo,ZENG Jing.Compilation Method of Fatigue Test Load Spectrum for Underfloor Equipment Bearing Structure[J].Chinese Journal of Mechanical Engineering,2016,52(24):99-106.
[11]赵方伟.铁路货车车体载荷谱测试及疲劳强度评价研究[D].北京:北京交通大学,2015.
[12]任尊松.轮轨多点接触及车辆-道岔系统动态相互作用[M].北京:科学出版社,2014.
[13]严隽耄.车辆工程[M].北京:中国铁道出版社,2007.
[14]郭杏林.结构随机载荷识别的理论和实验研究[D].大连:大连理工大学,2003.
[15]文祥荣,缪龙秀.由实测应变响应识别结构动态载荷[J].铁道学报,2000,22(6):36-39.WEN Xiangrong,MIAO Longxiu.Identif Ication of Structural Dynamic Load from Measured Strain Response[J].Journal of the China Railway Society,2000,22(6):36-39.
[16]叶红岩.高速转向架构架随机加载理论与试验研究[D].成都:西南交通大学,2011.
[17]刘克格,阎楚良,张书明.飞机主起落架载荷谱实测的台架标定[J].吉林大学学报(工学版),2006,36(6):1025-1028.LIU Kege,YAN Chuliang,ZHANG Shuming.Bench Calibration of Load Spectrum Measurement for Fighter Airplanemain Undercarriage[J].Journal of Jilin University(Engineering and Technology Edition),2006,36(6):1025-1028.
[18]刘克格,阎楚良.飞机起落架载荷谱实测与编制方法[J].航空学报,2011,32(5):841-848.LIU Kege,YAN Chuliang.Load Measurement and Compilation of Landing Gear of Airplane[J].Acta Aeronautica et Astronautica Sinica,2011,32(5):841-848.
[19]WANG P,WANG H X,WANG W.Finding Semantics in Time Series[C]//Proceedings of the ACM SIGMOD International Conference on Management of Data.New York:ACM,2011:385-396.
[20]Yasuko Matsubara,Yasushi Sakurai,Christos Faloutsos.AutoPlait:Automatic Mining of Co-evolving Time Sequences[C]//Proceedings of the ACM SIGMOD International Conference on Management of Data.New York:ACM,2014:193-204.
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