Adhesive structure life prediction of EMU information window considering influence of temperature and load
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摘要: 针对动车信息窗粘接结构, 考虑环境和载荷对粘接结构寿命的影响, 提出了一种加速老化与自然老化相结合的寿命预测方法; 对粘接结构影响因素进行分析, 建立了加速老化的温度-动态载荷耦合循环谱, 制作了铝合金对接接头, 分别进行0、10、20、30循环周期的加速老化试验, 定期测试接头的剩余强度和失效形式, 获得粘接剂剩余强度随载荷循环次数的变化规律; 提取自然老化下不同行驶里程的实车胶条, 进行剩余强度测试, 获得了粘接剂剩余强度随行驶里程的变化规律; 采用多项式函数分别拟合载荷循环次数、行驶里程与粘接剂剩余强度衰减率的函数关系式, 建立了载荷循环次数与行驶里程之间的函数关系式。研究结果表明: 相比粘接接头初始强度, 温度循环10、20、30周期后粘接接头的剩余强度下降幅度依次为11.6%、15.9%、20.7%, 而温度-动态载荷耦合循环后强度分别下降了14.1%、18.9%、24.8%, 说明动态载荷加剧了接头强度的衰减, 并且均呈现先快后慢的下降趋势; 温度-动态载荷耦合试验作用后, 接头断面的失效形式和机理变化明显, 初始时接头胶层发生老化失效, 而后随着载荷循环次数的增加, 接头主要失效机理由老化失效转变为疲劳失效; 加速老化与自然老化下粘接剂失效强度的衰减率变化趋势基本一致, 建立的载荷循环次数与行驶里程的函数关系式能够较准确地预测粘接结构的寿命, 预测得到动车最大安全里程为8.34×106 km。Abstract: Aiming at the adhesive structure of EMU information window, considering the influence of environment and load on the life of adhesive structure, a life prediction method combining the accelerated aging and natural aging was proposed. The influence factors of adhesive structure were analyzed, and the temperature-dynamic load coupling cycle spectrum of accelerated aging was established. The aluminum alloy butt joints were made and the accelerated aging tests with 0, 10, 20 and 30 cycles were carried out, respectively. The residual strength and failure mode of joint were tested regularly, and the change rules of adhesive residual strength under the load cycles were obtained. The real vehicle adhesive strips with different driving mileages under natural aging were extracted, and the residual strength test was performed to obtain the change rule of adhesive residual strength with driving mileage. The polynomial function was used to fit the function relations of load cycles and driving mileage with the residual strength attenuation rate of adhesive. The functional relation between the load cycle and driving mileage was established. Analysis result shows that compared with the initial strength of adhesive joint, the residual strength of adhesive joint decreases by 11.6%, 15.9%, and 20.7% after 10, 20, and 30 temperature cycles, respectively, while the strength of adhesive joint decreases by 14.1%, 18.9% and 24.8% after the coupling cycle of temperature and dynamic load, respectively, which shows that the dynamic load intensifies the decline of joint strength, and presents the decline trend fast first and then slow. After the coupling test of temperature and dynamic load, the failure mode and mechanism of joint section change obviously. Initially, the joint adhesive layer suffers aging failure, and then with the increase of load cycles, the main failure mechanism of joint changes from aging failure to fatigue failure. It is found that the attenuation rate changing trends of adhesive failure strength under accelerated aging and natural aging are basically the same. The functional relationship between load cycle and driving mileage can accurately predict the life of adhesive structure, and the maximum safe mileage of high-speed train is 8.34×106 km.
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图 15 自然老化后胶层剩余强度曲线
Figure 15. Residual strength curves of adhesive layer after natural aging
图 16 加速老化后胶层剩余强度曲线
Figure 16. Residual strength curves of adhesive layer after accelerated aging
图 17 加速老化和自然老化衰减率曲线
Figure 17. Attenuation rate curves under accelerated aging and natural aging
表 1 材料属性参数
Table 1. Material property parameters
参数 6005A Sikaflex-265 钢化玻璃 密度/(kg·m-3) 2 700 1 500 2 500 泊松比 0.30 0.45 0.20 弹性模量/MPa 7.0×104 5.2 7.2×104 
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