复合材料在轨道交通车辆中的应用与展望

肖守讷; 江兰馨; 蒋维; 何子坤; 阳光武; 杨冰; 朱涛; 王明猛

doi:10.19818/j.cnki.1671-1637.2021.01.007

复合材料在轨道交通车辆中的应用与展望

doi: 10.19818/j.cnki.1671-1637.2021.01.007

西南交通大学牵引动力国家重点实验室，四川成都 610031

基金项目:

国家重点研发计划项目 2016YFB1200404

国家自然科学基金项目 51675446

牵引动力国家重点实验室自主课题 2020TPL_T07

详细信息

作者简介:
肖守讷(1964-), 男, 浙江上虞人, 西南交通大学研究员, 从事车辆结构强度及轻量化研究

中图分类号: U270.4
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出版历程
- 收稿日期: 2020-09-30
- 刊出日期: 2021-08-27

Application and prospect of composite materials in rail transit vehicles

State Key Laboratory of Traction Power, Southwest Jiaotong University, Chengdu 610031, Sichuan, China

Funds:

National Key Research and Development Program of China 2016YFB1200404

National Natural Science Foundation of China 51675446

Independent Subject of State Key Laboratory of Traction Power 2020TPL_T07

More Information

Author Bio:
XIAO Shou-ne(1964-), male, professor, snxiao@home.swjtu.edu.cn

摘要

摘要: 围绕玻璃纤维、碳纤维、铝基陶瓷等复合材料在轨道交通车辆中的应用展开了综述；介绍了针对上述复合材料开展的基础与应用研究历程及进展，分析了应用在大型复合材料构件的结构特点；针对头车/司机室、中间车车体、转向架、制动结构、其他结构，系统性地总结整理了复合材料种类、成型工艺、设计方法、优化方法等，全面阐述了复合材料在轨道交通车辆各个部件上的应用情况，并对目前应用存在的问题和未来应用发展方向进行了探讨。研究结果表明：复合材料的主要研究方法以理论研究为基础，在大型结构件中以有限元仿真研究为主，应用多尺度研究方法深入分析复合材料在微观、细观和宏观层面的性能；将复合材料应用到结构中时，在兼具刚度和轻量化的条件下，多采用三明治结构；复合材料之间、复合材料与金属材料的连接结构多采用胶接连接、螺栓连接、胶-螺混合连接等，其中混合连接结构强度大，稳定性高，在工程中应用最为广泛；复合材料已在轨道交通车辆中有一定的应用，纤维复合材料多用于头车/司机室、车体、转向架，而铝基陶瓷复合材料多用于制动结构；在未来应建立适用于轨道交通行业的复合材料相关标准与规范，研发新工艺，采用整体设计模式，扩大复合材料的使用范围，将更多高性能、低成本和轻质化的复合材料应用到轨道交通车辆中。
- 轨道交通车辆 /
- 复合材料 /
- 有限元仿真 /
- 结构特性 /
- 玻璃纤维复合材料 /
- 碳纤维复合材料
Abstract: The use of composite materials such as the glass fiber reinforced plastic, carbon fiber reinforced plastic, and aluminum matrix ceramic composite materials in rail transit vehicles was reviewed. The history and progress of basic and applied research on the aforementioned composite materials were described, and the structural characteristics of these materials when used in large composite components were analyzed. A systematic summary was provided on the types, forming processes, design methodologies, and optimization of composite materials used in the lead car/cab, the carbody of middle cars, bogie, brakes, and other structures, the application of composite materials in all the components of a rail transit vehicle was comprehensively described. Current problems and future trends of composite material usage in rail vehicles were also described. Analysis result shows that the studies regarding composite materials are primarily based on theoretical approaches, and finite element analysis is usually used in large structural components. Multi-scalar methods are used in detailed analyses to study how composite materials behave at the microscopic, mesoscopic, and macroscopic levels. When composite materials are applied to structures, the sandwich structure is mostly used in considering the stiffness and lightweight. As the connection structure between composite materials, composite materials and metal materials, the adhesive connection, bolt connection, adhesive-bolt mixed connection are mostly used. The mixed connection structure has higher strength and stability, which is most widely used in engineering. Composite materials have been used in rail transit vehicles, including the fiber reinforced composite materials used in lead car/cab, carbody, bogie, and the aluminum matrix ceramic composite materials used in brake structure. In the future, relevant standards and specifications applicable to rail transit industry should be established, new technologies should be developed, and overall design mode should be adopted. The using range of composite materials should be expanded, and higher performance, lower cost and lighter composite materials should be applied to rail transit vehicles. 2 tabs, 14 figs, 167 refs.
- rail transit vehicle /
- composite materials /
- finite element simulation /
- structural characteristic /
- GFRP /
- CFRP

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图 1 微元体坐标系

Figure 1. Micro-unit coordinate system

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图 2 复合材料车体固有频率分析的有限元模型

Figure 2. Finite element model for natural frequency analysis of composite material carbody

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图 3 多尺度模型

Figure 3. Multiscale model

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图 4 复合材料多尺度分析方法

Figure 4. Multiscale analysis method of composite materials

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图 5 内聚力单元与接触单元计算结果对比

Figure 5. Calculation results comparison between cohesive element and contact element

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图 6 三明治结构和钎焊铝蜂窝板

Figure 6. Sandwich structure and brazing aluminum honeycomb plate

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图 7 胶-螺塔接结构与有限元模型

Figure 7. Adhesive-bolt tower connection structure and finite element model

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图 8 CRH挡风板和编织夹芯板结构

Figure 8. CRH wind deflector and structure of woven textiles and wich panel

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图 9 英国雷丁大学GFRP转向架

Figure 9. GFRP bogie of University of Reading in UK

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图 10 日本efWING转向架走行安全性试验结果

Figure 10. Running safety test results of Japanese efWING bogie

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图 11 青岛四方CFRP转向架

Figure 11. CFRP bogie of Qingdao Sifang

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图 12 瞬态温度场计算值

Figure 12. Transient temperature field calculated values

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图 13 高速列车全碳纤维复合材料设备舱

Figure 13. Full CFRP equipment cabin for high-speed train

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图 14 摆式列车混合复合材料车体

Figure 14. Hybrid composite material carbody of tilting train

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表 1 复合材料与金属材料的力学性能对比

Table 1. Mechanical properties comparison of composite materials and metal materials

材料类型	密度/(g·cm^-3)	抗拉强度/GPa	比强度/10⁷ mm	抗拉模量/GPa	比模量/10⁷ mm	线膨胀系数/10^-4 K^-1
高强碳纤维/环氧	1.6	1.80	11.30	128	8.00	58.3
芳纶/环氧	1.4	1.50	10.70	80	5.70	63.4
硼纤维/环氧	2.1	1.60	7.60	220	10.50	70.6
碳化硅纤维/环氧	2.0	1.50	7.50	130	6.50	66.0
石墨纤维/铝	2.2	0.80	3.60	231	10.50	64.1
玻璃钢	2.0	1.50	7.50	40	2.50
钢	7.8	1.40	1.80	210	2.70	96.5
铝合金	2.8	0.50	1.70	77	2.80	132.1
钛合金	4.5	1.00	2.20	110	2.40	86.8
尼龙6	1.2	0.07	0.06	3	0.02	187.2

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表 2 不同制动盘材料性能与价格

Table 2. Performances and prices of different brake disc materials

材料	拉伸强度/MPa	延伸率/%	密度/(kg·m^-3)	导热系数/[W·(m·K)^-1]	线膨胀系数/(10^-6·℃^-1)	价格
蠕墨铸铁	500	≥1.5	7.2	42	12.5	较低
锻钢	≥800	13.0~20.0	7.9	45	12.0	一般
铝基复合材料	≥250	1.0	2.8	135	18.4	较高
C/C复合材料	100	0.2	1.7	126	0.0	昂贵

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