Evolutionary structure topology optimization method of rail wheel web plate considering UIC strength criterion
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摘要: 为了提高轨道车轮的结构性能, 利用渐进结构拓扑优化方法(ESO)建立了轨道车轮的结构优化模型; 以双S型轨道车轮为设计蓝本, 分析了轨道车轮的辐板设计域, 提出了轨道车轮在多工况作用下的渐进结构拓扑优化方法; 介绍了利用渐进结构拓扑优化方法实现结构应力均匀化的优化思路; 根据《整体车轮技术检验》(UIC 510-5:2003)标准, 分别考虑了轨道车轮在直线工况、曲线工况和道岔通过工况, 不仅获得这3种典型工况共同作用下的拓扑优化结构, 而且还获得了3种典型工况依次作用下的6种拓扑结构; 对比了优化前后车轮辐板的应力, 并利用有限元工具验证了优化后车轮的辐板应力特性, 证明渐进结构拓扑优化方法的正确性和有效性。研究结果表明: 利用渐进结构拓扑优化方法对轨道车轮的拓扑优化是适用的; 在车轮质量不增加的前提下, 优化后车轮辐板的厚度增加且不等厚, 有效地减小应力集中, 降低结构应力; 对比原双S型车轮, 优化后6种车轮模型的结构性能均有所提升, 分别提高了16.6%、20.7%、22.5%、21.3%、20.1%和19.5%, 其中, 方案3的优化车轮在3种工况下辐板处的最大结构应力分别降低了4.0%、14.5%和6.7%。研究有助于轨道车轮结构强度的提高, 并对多工况耦合作用下轨道车轮结构优化具有重要的参考价值。Abstract: To improve the structural performance of rail wheels, a structural optimization model of rail wheels was established by using the evolutionary structure topology optimization method. The double S-shaped rail wheel was used as the design blueprint, the design field of rail wheel web plate was analyzed, and the evolutionary structure topology optimization method of the rail wheel web plate was put forward under multi-working conditions. The optimization idea using the evolutionary structure topology optimization method to achieve the structural stress homogenization was introduced. According to the standard Overall Wheel Technical Inspection(UIC 510-5: 2003), considering the rail wheels in linear working condition, curved working condition and passing working condition of ballast, respectively, not only was the topology optimization structure obtained under the joint action of 3 typical working conditions, but also six topology structures were obtained under the action of 3 typical working conditions in turn. The stress conditions of wheel web plate before and after optimization were compared, and the web plate stress features of the optimized wheels were verified by using the finite element tool. The correctness and effectiveness of evolutionary structural topology optimization method were proved. Research result shows that the evolutionary structure topology optimization method is suitable for the topology optimization of rail wheels. Under the premise that the wheel weight does not increase, the thickness of wheel web plate increases and is unequal, the stress concentration reduces effectively, and the structural stress reduces. Compared with the original double S-shaped wheels, the structural performances of the optimized six wheel models improve by 16.6%, 20.7%, 22.5%, 21.3%, 20.1%, and 19.5%, respectively. The maximum structural stresses of the optimized wheel web plates of scheme 3 reduce by 4.0%, 14.5%, and 6.7% under 3 working conditions, respectively. The research contributes to the improvement of structural strength of the rail wheels, and has important reference value for the optimization of rail wheel structure under the multi-working coupling condition.
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Key words:
- vehicle engineering /
- rail wheel /
- ESO /
- topology optimization /
- multi-working conditions /
- structural stress
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图 2 车轮载荷作用力方向和位置(单位: mm)
Figure 2. Wheel load force directions and positions (unit: mm)
图 4 取交集的ESO多工况优化方法流程
Figure 4. Flow of ESO multi-working condition optimization method for intersection
图 5 取交集的ESO多工况优化过程
Figure 5. ESO multi-working condition optimization process for intersection
图 6 三种工况下车轮初始设计模型的单元应力分布
Figure 6. Element stress distributions of wheel initial design model under three working conditions
图 7 依次循环ESO多工况优化流程
Figure 7. ESO multi-working condition optimization flow with sequential cycles
图 9 六种优化结果在工况2下的单元应力分布
Figure 9. Element stress distributions of six kinds of optimization results under working condition 2
图 12 优化前后车轮辐板形状对比
Figure 12. Comparison of wheel web plate shapes before and after optimization
图 14 工况2下车轮优化前后结构应力分布
Figure 14. Structural stress distributions before and after wheel optimization under working condition 2
表 1 轨道车轮参数及材料属性
Table 1. Rail wheel parameters and material properties
类别 名称 数值 车轮参数 轴质量/t 16 车轮质量/kg 288 车轮直径/mm 840 材料属性 泊松比 0.3 弹性模量/MPa 2.0×105 密度/(kg·m-3) 7 800 强度极限/MPa 900 屈服极限/MPa 580 许用应力/MPa 352 疲劳极限/MPa 315 
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表 2 车轮载荷工况
Table 2. Wheel load conditions
工况 Fyi Fzi 1 0 1.25pg/2 2 -0.7pg/2 1.25pg/2 3 0.42pg/2 1.25pg/2
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表 3 ESO多工况的依次循环优化方案
Table 3. ESO sequential cycles optimization schemes under multi-working conditions
优化方案 工况顺序 1 工况1、工况2、工况3 2 工况1、工况3、工况2 3 工况2、工况1、工况3 4 工况2、工况3、工况1 5 工况3、工况1、工况2 6 工况3、工况2、工况1
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表 4 优化结果对比
Table 4. Comparison of optimization results
指标 单元应力/MPa 性能指标 效果/% 工况1 工况2 工况3 模型A 61.37 257.62 187.54 2.02 19.5 优化方案 1 61.37 263.76 179.47 1.97 16.6 2 61.37 256.12 183.79 2.04 20.7 3 61.37 251.75 184.07 2.07 22.5 4 61.37 253.90 184.67 2.05 21.3 5 61.37 256.78 185.29 2.03 20.1 6 61.37 257.25 174.89 2.02 19.5 原始 77.17 307.60 204.94 1.69
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表 5 最大结构应力对比
Table 5. Comparison of maximum structural stresses
类型 工况1 工况2 工况3 双S型车轮 50 124 90 优化模型 A 38 197 132 B 48 106 84
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