基于虚拟疲劳试验的铁路车辆焊接结构疲劳寿命预测
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摘要
随着我国铁路向着高速、重载的方向发展,铁路车辆的疲劳事故不断发生,关键部位疲劳断裂一旦发生,将产生非常严重的后果。车辆的疲劳问题治理是铁路安全运输的迫切需求。焊接是铁路车辆结构的重要联接方式,也是最容易发生疲劳破坏的薄弱环节,绝大多数的疲劳事故发生在焊接部位。由于目前还不能从理论上将影响疲劳的众多复杂因素归纳为统一的物理模型或数学模型来描述,所以国内外对疲劳问题的研究主要集中在实验环节上,对焊接结构的疲劳研究更是如此。然而,疲劳试验本身需要物理样机,且成本高、周期长,而且承受复杂随机载荷的铁路车辆的整车在试验台上进行疲劳试验,目前还办不到。因此,基于先进的数值仿真手段,科学地预测铁路车辆焊接结构的疲劳寿命,并快速地进行方案对比,对铁路车辆的结构可靠性设计及其运行中的安全评定具有重要的理论价值及工程意义。
本文在对国内外关于焊接结构疲劳及铁路车辆疲劳寿命预测研究现状综述的基础上,取铁路车辆车体及转向架焊接构架为研究载体,分别从理论方法上、数值仿真上、程序实现上,进行了一系列深入研究,归纳起来,本文的研究工作及研究成果主要有:
在研究了焊接结构疲劳寿命预测的基本理论和方法的基础上,针对没有物理样机之前预测疲劳寿命的困难。提出了基于虚拟疲劳试验的铁路车辆焊接结构疲劳寿命预测的技术路线;给出了用于虚拟疲劳试验的有限元模型的建模方法及疲劳寿命评估点的选取原则;对虚拟疲劳试验加载模式、虚拟动应力的换算及多载荷通道疲劳寿命预测方法等虚拟疲劳试验的关键技术提出了解决方法。
鉴于目前铁路车辆焊接结构的疲劳评价标准少,且美国AAR标准仅是针对铁路货车制定的。在进行虚拟疲劳试验中,引入了工程上广泛应用的国际焊接协会ⅡW标准和英国BS标准,从而丰富了焊接结构的疲劳特性参数,扩大了焊接结构的疲劳预测范围。通过对三种标准的系统研究,归纳了三种标准的焊接结构疲劳寿命评估方法的特点,并以客车转向架焊接构架为对象,应用ⅡW标准进行疲劳寿命预测。验证了本文提出的虚拟疲劳试验的工程应用可靠性。
结构疲劳寿命评估的反问题是指在给定产品寿命条件下来确定结构的设计细节。由于AAR标准中疲劳寿命评估计算流程中数据流动存在唯一性,所以从数学的角度反求结构应力是成立的。本文以AAR标准为基础,讨论了结构疲劳评估的反问题,推导了多载荷作用下的结构设计应力反求解析式,为车体的可靠性设计下的等寿命设计提供了理论基础。
为使更多的设计人员在产品方案设计阶段,就能对包括焊缝在内的每一个结构细节进行疲劳寿命预测,开发了铁路货车疲劳寿命预测系统。该系统以AAR标准为内核,以Visual Studio.NET集成开发环境为设计平台,并运用二次开发技术,将AAR标准嵌入到大型有限元分析软件Ⅰ-DEAS中。系统内置了AAR标准中用于疲劳计算的各种载荷谱和焊接接头数据库,并可以方便地实现数据库的扩充,能以人机交互方式实现提取Ⅰ-DEAS后处理中的应力结果,并自动计算待评估点的当量应力数值,能计算待评估点的疲劳损伤值及设计寿命汇总数据,自动生成疲劳计算报告等功能。
本文的创新点:
1.针对铁路车辆焊接结构的特点、提出了适合工程应用的虚拟疲劳寿命预测方法。
2.研究了铁路货车疲劳寿命评估的反问题,推导了基于AAR标准的多载荷作用下的结构设计应力反求解析式,并进行了工程实例验证。
3.从抗疲劳的角度提出了局部设计或补强的一个重要原则——刚度协调,从而改变了治理局部应力集中的传统补强模式。
4.以AAR标准为内核,以大型有限元分析软件Ⅰ—DEAS为平台,基于二次开发技术,开发了一个适合工程应用的铁路货车疲劳寿命预测系统。
本课题得到国家“863”高技术研究发展计划项目:《复杂产品协同设计、仿真、优化一体化平台研究开发及其应用》(项目编号:2006AA04Z160)以及中国北车集团科技研究开发计划项目《基于AAR标准的大秦线25吨轴重货车疲劳寿命预测研究》(项目编号:2004NZ009)的资助。
As China's railway develops towards the high-speed and the heavy load one, railway vehicles' accidents of fatigue are occurring, once fatigue fracture is apper in key positions, the consequences will be serious. Vehicle's fatigue governance is a pressing need to the safety of rail transport. Weld is main connection for rail vehicles structure, is also prone to fatigue failure of the danger zone. Currently, fatigue problem can not be described theoretically as a united physical and mathematical model because too many factors effect structure fatigue. So, fatigue research mainly focus on the test step both inland and abroad, and the more to the research on welding structure. Whole vehicle fatigue experimentation needs physical prototype, a high cost, a long cycle, and complex random load, so it is still impossible now. Therefore, scientific prediction of fatigue life of the rail vehicle's welded structure is important theoretical value and engineering significance to the structure reliability design and safety assessment of the rail vehicle.
Based on the summary of the domestic and foreign studies on the welded structure fatigue and the rail vehicle's fatigue life prediction, take rail vehicle body and its key component -Bogie welding structure for studying, from theoretical method, numerical simulation, the program, conducted a series of in-depth research. To sum up, the research work and achievements are as follows:
After detailed analysis of the basic theory and prediction methods of welded structure's fatigue life, and defeat the difficulty of fatigue life prediction without physical prototype, on basis of virtual fatigue test, rail vehicle's welding structure fatigue life prediction technology route is proposed; finite element modeling method and choice principle of fatigue life evaluational points are given; and the solutions to key technology, such as test loading mode, dynamic stress virtual conversion and multi-channel load fatigue life prediction methods and so on, are given.
As welding structure standard of rail vehicles' fatigue evaluation is rarely found, and the United States' AAR standard is only developed to use in railway wagon, so that in the virtual fatigue test, the widely used international Welding Association standard IIW and the British Standard BS are introduced. So as to enrich the fatigue characteristic parameter of welding structure, and to expand the scope of the prediction of welding structure. Through the systematic research of the three standards, the characteristics of welding structure's fatigue life evaluation method under the these standards are generalized, and engineering application reliability of virtual fatigue test is verified by means of welding structure fatigue life prediction of bogies under standard IIW.
The reverse problem of the structural fatigue life evaluation is to set down the design details of the structure under a given product fatigue life. There exists the uniqueness of the data flow in process of the fatigue life evaluation under the AAR tandard, so from mathematics view, reverse calculating structural stress is available. Theoretical expression of a converse problem considering multi-load spectrums is derived to predict fatigue life of wagon body based on American AAR standard. The result shows that the means can be used to not only efficiently calculate the body structure design stress under a specified fatigue life but also theoretically provide improved design scheme to achieve wagon equivalent life design.
In order to rapidly predict fatigue life for production structure including design details on welding line to wagon body-designers, fatigue life prediction software system is developed. Base on secondary development technolgy, it embedded in the large-scale finite element analysis software- I-DEAS. The system was developed with Visual Studio.NET and in which the stress detail of FEA result can be picked up in I-DEAS Post Processing by man-machine interact way. By using the system, the equivalent stress, fatigue damage data, the sum data of designal life and report file can be automatically calculated and generated respectively. The system contains load spectrum database of the AAR standard and the database can be conviently expanded.
In this paper, four innovations are given as follows:
1. A practical analysis method is presented to achieve fatigue life prediction of vehicle welded structure ahead of physics specimen.
2. Theoretical expression of a converse problem considering multi-load spectrums is derived to predict fatigue life of wagon body based on American AAR standard. The theoretical expression is applied to an exported wagon.
3. From the point of fatigue resistance, an important local design or reinforcement principle -stiffness coordination is proposed. Thereby traditional reinforcement model of the governance of local stress concentration has been changed.
4. Base on AAR standard and secondary development technolgy, a fatigue life prediction software system embedded in the large-scale finite element analysis software- I-DEAS is developed for wagon body.
本文在对国内外关于焊接结构疲劳及铁路车辆疲劳寿命预测研究现状综述的基础上,取铁路车辆车体及转向架焊接构架为研究载体,分别从理论方法上、数值仿真上、程序实现上,进行了一系列深入研究,归纳起来,本文的研究工作及研究成果主要有:
在研究了焊接结构疲劳寿命预测的基本理论和方法的基础上,针对没有物理样机之前预测疲劳寿命的困难。提出了基于虚拟疲劳试验的铁路车辆焊接结构疲劳寿命预测的技术路线;给出了用于虚拟疲劳试验的有限元模型的建模方法及疲劳寿命评估点的选取原则;对虚拟疲劳试验加载模式、虚拟动应力的换算及多载荷通道疲劳寿命预测方法等虚拟疲劳试验的关键技术提出了解决方法。
鉴于目前铁路车辆焊接结构的疲劳评价标准少,且美国AAR标准仅是针对铁路货车制定的。在进行虚拟疲劳试验中,引入了工程上广泛应用的国际焊接协会ⅡW标准和英国BS标准,从而丰富了焊接结构的疲劳特性参数,扩大了焊接结构的疲劳预测范围。通过对三种标准的系统研究,归纳了三种标准的焊接结构疲劳寿命评估方法的特点,并以客车转向架焊接构架为对象,应用ⅡW标准进行疲劳寿命预测。验证了本文提出的虚拟疲劳试验的工程应用可靠性。
结构疲劳寿命评估的反问题是指在给定产品寿命条件下来确定结构的设计细节。由于AAR标准中疲劳寿命评估计算流程中数据流动存在唯一性,所以从数学的角度反求结构应力是成立的。本文以AAR标准为基础,讨论了结构疲劳评估的反问题,推导了多载荷作用下的结构设计应力反求解析式,为车体的可靠性设计下的等寿命设计提供了理论基础。
为使更多的设计人员在产品方案设计阶段,就能对包括焊缝在内的每一个结构细节进行疲劳寿命预测,开发了铁路货车疲劳寿命预测系统。该系统以AAR标准为内核,以Visual Studio.NET集成开发环境为设计平台,并运用二次开发技术,将AAR标准嵌入到大型有限元分析软件Ⅰ-DEAS中。系统内置了AAR标准中用于疲劳计算的各种载荷谱和焊接接头数据库,并可以方便地实现数据库的扩充,能以人机交互方式实现提取Ⅰ-DEAS后处理中的应力结果,并自动计算待评估点的当量应力数值,能计算待评估点的疲劳损伤值及设计寿命汇总数据,自动生成疲劳计算报告等功能。
本文的创新点:
1.针对铁路车辆焊接结构的特点、提出了适合工程应用的虚拟疲劳寿命预测方法。
2.研究了铁路货车疲劳寿命评估的反问题,推导了基于AAR标准的多载荷作用下的结构设计应力反求解析式,并进行了工程实例验证。
3.从抗疲劳的角度提出了局部设计或补强的一个重要原则——刚度协调,从而改变了治理局部应力集中的传统补强模式。
4.以AAR标准为内核,以大型有限元分析软件Ⅰ—DEAS为平台,基于二次开发技术,开发了一个适合工程应用的铁路货车疲劳寿命预测系统。
本课题得到国家“863”高技术研究发展计划项目:《复杂产品协同设计、仿真、优化一体化平台研究开发及其应用》(项目编号:2006AA04Z160)以及中国北车集团科技研究开发计划项目《基于AAR标准的大秦线25吨轴重货车疲劳寿命预测研究》(项目编号:2004NZ009)的资助。
As China's railway develops towards the high-speed and the heavy load one, railway vehicles' accidents of fatigue are occurring, once fatigue fracture is apper in key positions, the consequences will be serious. Vehicle's fatigue governance is a pressing need to the safety of rail transport. Weld is main connection for rail vehicles structure, is also prone to fatigue failure of the danger zone. Currently, fatigue problem can not be described theoretically as a united physical and mathematical model because too many factors effect structure fatigue. So, fatigue research mainly focus on the test step both inland and abroad, and the more to the research on welding structure. Whole vehicle fatigue experimentation needs physical prototype, a high cost, a long cycle, and complex random load, so it is still impossible now. Therefore, scientific prediction of fatigue life of the rail vehicle's welded structure is important theoretical value and engineering significance to the structure reliability design and safety assessment of the rail vehicle.
Based on the summary of the domestic and foreign studies on the welded structure fatigue and the rail vehicle's fatigue life prediction, take rail vehicle body and its key component -Bogie welding structure for studying, from theoretical method, numerical simulation, the program, conducted a series of in-depth research. To sum up, the research work and achievements are as follows:
After detailed analysis of the basic theory and prediction methods of welded structure's fatigue life, and defeat the difficulty of fatigue life prediction without physical prototype, on basis of virtual fatigue test, rail vehicle's welding structure fatigue life prediction technology route is proposed; finite element modeling method and choice principle of fatigue life evaluational points are given; and the solutions to key technology, such as test loading mode, dynamic stress virtual conversion and multi-channel load fatigue life prediction methods and so on, are given.
As welding structure standard of rail vehicles' fatigue evaluation is rarely found, and the United States' AAR standard is only developed to use in railway wagon, so that in the virtual fatigue test, the widely used international Welding Association standard IIW and the British Standard BS are introduced. So as to enrich the fatigue characteristic parameter of welding structure, and to expand the scope of the prediction of welding structure. Through the systematic research of the three standards, the characteristics of welding structure's fatigue life evaluation method under the these standards are generalized, and engineering application reliability of virtual fatigue test is verified by means of welding structure fatigue life prediction of bogies under standard IIW.
The reverse problem of the structural fatigue life evaluation is to set down the design details of the structure under a given product fatigue life. There exists the uniqueness of the data flow in process of the fatigue life evaluation under the AAR tandard, so from mathematics view, reverse calculating structural stress is available. Theoretical expression of a converse problem considering multi-load spectrums is derived to predict fatigue life of wagon body based on American AAR standard. The result shows that the means can be used to not only efficiently calculate the body structure design stress under a specified fatigue life but also theoretically provide improved design scheme to achieve wagon equivalent life design.
In order to rapidly predict fatigue life for production structure including design details on welding line to wagon body-designers, fatigue life prediction software system is developed. Base on secondary development technolgy, it embedded in the large-scale finite element analysis software- I-DEAS. The system was developed with Visual Studio.NET and in which the stress detail of FEA result can be picked up in I-DEAS Post Processing by man-machine interact way. By using the system, the equivalent stress, fatigue damage data, the sum data of designal life and report file can be automatically calculated and generated respectively. The system contains load spectrum database of the AAR standard and the database can be conviently expanded.
In this paper, four innovations are given as follows:
1. A practical analysis method is presented to achieve fatigue life prediction of vehicle welded structure ahead of physics specimen.
2. Theoretical expression of a converse problem considering multi-load spectrums is derived to predict fatigue life of wagon body based on American AAR standard. The theoretical expression is applied to an exported wagon.
3. From the point of fatigue resistance, an important local design or reinforcement principle -stiffness coordination is proposed. Thereby traditional reinforcement model of the governance of local stress concentration has been changed.
4. Base on AAR standard and secondary development technolgy, a fatigue life prediction software system embedded in the large-scale finite element analysis software- I-DEAS is developed for wagon body.
引文
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