Dynamic stress calculation and fatigue whole life prediction of bogie frame for high-speed train
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摘要: 建立了车辆结构的刚柔耦合动力学模型, 对比了刚性构架和柔性构架的振动响应, 计算了构架的载荷谱; 分析了应力谱转化方法, 利用有限元方法与多项式拟合方法计算了构架的动应力谱; 基于动应力谱与相关标准, 运用线性累积损伤理论与疲劳裂纹扩展寿命Paris方程计算了构架的疲劳全寿命。计算结果表明: 相比于多刚体车辆系统动力学模型, 采用考虑构架柔性的车辆系统动力学模型计算的构架振动加速度响应在构架固有频率36.94~95.53Hz范围内的幅值较大, 因此, 构架的模态对振动响应的贡献显著; 将载荷谱转化为应力谱的多项式拟合方法与瞬态分析方法相比较, 应力误差最大值为1.16MPa, 相对最大误差为3%, 满足工程分析5%的计算精度要求; 基于疲劳损伤理论计算的可靠度为95%的构架疲劳寿命为1.82×106 km; 构架危险关注点裂纹由1mm扩展到2mm的寿命为1.76×106 km, 满足中国高速列车车辆检修标准中制定的五级检修周期为1.2×106 km的要求。可见, 构架模态参与下的动态应力谱计算方法与构架的疲劳全寿命预测方法可靠, 有益于构架的动态设计与维修周期的制定。Abstract: The rigid-flexible dynamics model of vehicle structure was established, the vibration responses of rigid and flexible bogie frames were compared, and the load spectrums of bogie frames were calculated.The transformation method of stress spectrum was analyzed, and the dynamic stress spectrums were computed by using the finite element method and the polynomial fitting method.On the basis of computed dynamic stress spectrums and related standard, the full fatigue life of bogie frame was calculated by using the linearly cumulative damage theory and the fatigue crack growth life's Paris equation.Computation result shows that when the natural frequency of bogie frame is 36.94-95.53 Hz, the amplitude of vibration acceleration response for bogie frame is greater with the vehicle system dynamics model considering flexible bogie frame than the multi-rigid-body vehicle system dynamics model, so the vibration modes of bogie frame have significant contribution on the vibration responses.When the load spectrums are convertedto the stress spectrums by using the polynomial fitting method and the transient analysis method, the maximum error of stress is 1.16 MPa, and the relative maximum error of stress is less than3% that meets the engineering analysis's calculation accuracy requirement of 5%.When the degree of reliability is 95%, the fatigue life of bogie frame is 1.82×106 km based on the fatigue damage cumulative theory.When the crack at the dangerous concern of bogie frame grows from 1mm to 2mm, the propagation life is 1.76×106 km that meets the fifth level maintenance period requirement of 1.2×106 km in China high-speed train maintenance standard.Obviously, the calculation method of dynamic stress spectrum based on the dynamic modes of bogie frame and the prediction method of fatigue full life for bogie frame are reliable, which is meaningful for the dynamic design and the maintenance cycle making of bogie frame.
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Key words:
- bogie frame /
- dynamic stress /
- mode /
- fatigue damage /
- crack growth life /
- S-N curve
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图 10 刚性和柔性构架垂向时域加速度对比
Figure 10. Comparison of vertical accelerations of rigid and flexible bogie frames in time domain
图 11 刚性和柔性构架垂向频域加速度对比
Figure 11. Comparison of vertical accelerations of rigid and flexible bogie frames in frequency domain
图 12 刚性和柔性构架横向时域加速度对比
Figure 12. Comparison of lateral accelerations of rigid and flexible bogie frames in time domain
图 13 刚性和柔性构架横向频域加速度对比
Figure 13. Comparison of lateral accelerations of rigid and flexible bogie frames in frequency domain
图 14 刚性和柔性构架空簧位置的载荷时间历程
Figure 14. Load-time histories of rigid and flexible bogie frames on air spring
图 15 构架有限元模型的边界条件
Figure 15. Boundary condition of finite element model for bogie frame
图 16 动应力的瞬态计算结果与拟合结果对比
Figure 16. Comparison of transient calculation and fitting results for dynamic stress
图 17 节点73043上表面应力差值块谱
Figure 17. Stress range spectrum blocks on upper surface of node 73043
图 18 节点73043下表面应力差值块谱
Figure 18. Stress range spectrum blocks on lower surface of node 73043
图 20 节点73043上表面雨流计数结果
Figure 20. Rainflow counting result on upper surface of node 73043
图 21 节点73043下表面雨流计数结果
Figure 21. Rainflow counting result on lower surface of node 73043
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