Effect of axle box rotary arm node performance on wheel-rail coupling vibration for high-speed EMUs
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摘要: 为分析钢轨波磨、车轮多边形等轮轨短波不平顺条件下轴箱转臂节点性能对轮轨耦合振动的影响，分别从仿真计算、现场试验和台架试验3个方面进行综合分析，通过建立车辆-轨道刚柔耦合系统动力学仿真模型，分析了钢轨波磨和车轮多边形对轮轨耦合振动的影响，并在武广高铁进行了钢轨波磨条件下新、旧轴箱转臂节点对轴箱振动响应的影响试验，在滚动试验台上进行了高阶车轮多边形条件下新、旧轴箱转臂节点对转向架振动响应的影响试验；对已服役运用120万公里的A、B型轴箱转臂节点进行了1 000万次疲劳耐久性试验，论证了服役轴箱转臂节点疲劳可靠性的安全裕量。研究结果表明：在钢轨波长为120 mm，车轮多边形为20阶，钢轨波磨和车轮多边形波深均为0.04 mm的条件下，当轴箱转臂节点径向刚度由40 MN·m-1增加到200 MN·m-1时，钢轨振动加速度、轴箱振动加速度和轮轨垂向力基本不变，在钢轨波磨和车轮多边形等短波激励下，轴箱转臂节点刚度变化不会对轮轨耦合振动产生明显影响；随着疲劳试验次数的增加，轴箱转臂节点径向和轴向刚度均逐渐下降，退役轴箱转臂节点在经历1 000万次疲劳耐久性试验后外观状态基本无改变，芯轴与橡胶粘接部分出现轻微开胶和裂纹，开胶和裂纹深度不大于5 mm，橡胶本体均无裂纹，各项性能满足《机车车辆用橡胶弹性元件通用技术条件》(TB/T 2843—2015)中的规定。Abstract: To analyze the effect of axle box rotary arm node performance on the wheel-rail coupling vibration under wheel-rail short-wave irregularities such as rail corrugation and wheel polygon, the comprehensive research was conducted from three aspects, such as simulation calculation, field test, and bench test. A dynamics simulation model of a vehicle-track rigid-flexible coupling system was established to analyze the effects of rail corrugation and wheel polygon on the wheel-rail coupling vibration. The effects of new and old axle box rotary arm nodes on the axle box vibration responses under the rail corrugation and the bogie vibration responses under the high-order polygon were tested using a rolling test bench along the Wuhan-Guangzhou High-Speed Railway Line. 10 million fatigue durability tests were conducted on the type A and B axle box rotary arm nodes that have been in service for 1.2 million km, to demonstrate the fatigue reliability safety margins of the nodes. Research results show that the vibration accelerations of rails and axle box as well as the wheel-rail vertical force effectively remain unchanged with an increase in the radial stiffness of the axle box rotary arm node from 40 MN·m-1 to 200 MN·m-1, when the rail wavelength is 120 mm, the wheel polygon is of the 20th order, and the wave depths of rail corrugation and wheel polygon are both 0.04 mm. The change in the axle box rotary arm node stiffness will not significantly influence the wheel-rail coupling vibration responses under short-wave excitations such as rail corrugation and wheel polygon. With an increase in the number of fatigue test, the radial and axial stiffnesses of axle box rotary arm nodes decrease gradually. After 10 million fatigue durability tests, the appearances of the decommissioned axle box rotary arm nodes remain basically unchanged. Although the core shaft and rubber adhesive parts show slight tackle and cracking, the tackle and cracking depths are not more than 5 mm. The rubber body itself shows no cracks. In general, the performance still meets the General Technical Requirements for Rolling Stock Rubber to Metal Parts (TB/T 2843—2015). 3 tabs, 14 figs, 30 refs.
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Key words:
- high-speed EMUs /
- axle box rotary arm node /
- rail corrugation /
- wheel polygon /
- fatigue durability
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图 1 车辆-轨道刚柔耦合系统动力学模型
Figure 1. Dynamics model of vehicle-track rigid-flexible coupling system
图 2 钢轨波磨对轮轨耦合振动的影响
Figure 2. Effects of rail corrugation on wheel-rail coupling vibrations
图 3 车轮多边形对轮轨耦合振动的影响
Figure 3. Effects of wheel polygon on wheel-rail coupling vibrations
图 6 非波磨区段轴箱振动加速度
Figure 6. Vibration accelerations of axle boxes in non-rail corrugation section
图 7 钢轨波磨区段轴箱振动加速度
Figure 7. Vibration accelerations of axle boxes in rail corrugation section
图 11 转臂定位座垂向振动加速度
Figure 11. Vertical vibration accelerations of rotary arm positioning seats
图 13 A型轴箱转臂节点疲劳耐久性试验结果
Figure 13. Fatigue durability test results of type A axle box rotary arm node
图 14 B型轴箱转臂节点疲劳耐久性试验结果
Figure 14. Fatigue durability test results of type B axle box rotary arm node
表 1 轨道计算参数
Table 1. Track calculation parameters
参数名称 参数值 钢轨每延米质量/(kg·m-1) 60 轨枕间距/m 0.63 扣件垂向刚度/(MN·m-1) 23 扣件横向刚度/(MN·m-1) 23 扣件垂向阻尼/(kN·s·m-1) 75 扣件横向阻尼/(kN·s·m-1) 60 
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表 2 轴箱转臂节点更换方案
Table 2. Replacement schemes of axle box rotary arm nodes
轴位 更换前型号 更换前刚度/ (MN·m-1) 更换后型号 更换后刚度/ (MN·m-1) 更换前、后刚度变化率/% 1 MTC 102.6 A 119.4 16.4 94.6 124.2 31.3 2 MTC 100.8 B 111.9 11.0 116.9 113.6 -3.0
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表 3 轴箱转臂节点疲劳耐久性试验工况
Table 3. Fatigue durability test conditions of axle box rotary arm node
项目 径向 轴向 载荷/kN 27 22 频率/Hz 2 2
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