Calculation methods of stress factor in welding seam quality grade evaluation of EMUs aluminum alloy car body
-
摘要: 建立了某型动车组铝合金焊接车体的有限元分析模型，对焊缝部位进行简化建模，焊缝与实际存在的差异在等效结构应力计算中进行修正；基于标准BS EN 12663—1:2010分析了车体承受的载荷，采用Box-Behnken正交矩阵设计确定了车体的9个疲劳载荷工况；对车体有限元模型施加多轴载荷，分析了车体侧墙上的4条长焊缝部位的应力分布，确定了6个应力因数计算的关注点；采用名义应力法和等效结构应力法计算车体侧墙焊缝的应力因数，对比分析了2种应力分析方法。分析结果表明：2种应力分析方法在循环次数为1.0×107的许用应力范围不同，名义应力为16.40 MPa，等效结构应力为26.61 MPa；6个关注点的名义应力范围均小于其等效结构应力范围，得到的车体焊缝6个关注点的名义应力和等效结构应力的应力因数分别为0.33、0.25、0.50、0.49、0.76、0.62和0.23、0.24、0.39、0.45、0.61、0.48；针对同一焊缝的关注点，名义应力法计算的应力因数大于采用等效结构应力法计算的应力因数；名义应力法存在很大的分散性，导致应力因数偏大，而等效结构应力法物理意义更明确，计算的应力因数更为合理。Abstract: The finite element analysis model of the aluminum alloy welded car body for a type of electric multiple units (EMUs) was established. The welding seam was simplified modeling, and the difference between the welding seam and the actual existence was corrected in the calculation of the equivalent structural stress. The loads on the car body were analyzed based on BS EN 12663-1:2010. Nine fatigue load cases of car body were determined by the Box-Behnken orthogonal matrix design. A multi-axial load was applied to the finite element model of car body, and the stress distribution of the four long welding seams on the car body side wall were analyzed. Six concerned points for stress factor calculations were identified. The stress factors of welding seams on the car body side wall were calculated by using the nominal stress method and the equivalent structural stress method. Two stress analysis methods were compared and analyzed. Analysis results show that the allowable stress ranges of the two stress analysis methods are different at 1.0×107 cycles, with a nominal stress of 16.40 MPa and an equivalent structural stress of 26.61 MPa. The nominal stress ranges of the six concerned points are all smaller than the equivalent structural stress ranges, and the obtained stress factors of the nominal stress and equivalent structural stress are 0.33, 0.25, 0.50, 0.49, 0.76, 0.62 and 0.23, 0.24, 0.39, 0.45, 0.61, 0.48, respectively. For the concerned points of the same welding seam, the stress factors obtained by the nominal stress method are greater than the values obtained by the equivalent structural stress method. The nominal stress method has a large dispersion, which leads to a large stress factor. The structural stress method has a clearer physical meaning, and the calculated stress factor is more reasonable. 2 tabs, 8 figs, 30 refs.
-
Key words:
- EMUs /
- aluminum alloy welded car body /
- welding seam quality grade /
- stress factor /
- nominal stress /
- structural stress /
- fatigue load
-
图 3 基于名义应力法的应力因数计算流程
Figure 3. Stress factor calculation process based on nominal stress method
图 4 基于等效结构应力法的应力因数计算流程
Figure 4. Stress factor calculation process based on equivalent structural stress method
图 6 名义应力范围和结构应力范围转化方法
Figure 6. Transformation method for nominal stress range and structural stress range
表 1 组合疲劳载荷工况
Table 1. Combined fatigue load conditions
工况编号 横向加速度 纵向加速度 垂向加速度 1 0.15g 0 0.85g 2 0 0.15g 0.85g 3 0 -0.15g 0.85g 4 0.15g 0.15g 1.00g 5 0 0 1.00g 6 -0.15g 0.15g 1.00g 7 0.15g 0 1.15g 8 0 -0.15g 1.15g 9 0 0.15g 1.15g 
下载: 导出CSV
表 2 焊缝质量的标准等级
Table 2. Standard grades of welding seam quality
应力因数 应力状态 安全需求 焊缝质量等级 S≥ 0.90 高 高 CP A 高 中 CP B 高 低 CP C2 0.75≤S < 0.90 中 高 CP B 中 中 CP C2 中 低 CP C3 S < 0.75 低 高 CP C1 低 中 CP C3 低 低 CP D
下载: 导出CSV
-
[1] 康兴东, 任玉鑫, 高超, 等. 铁路客车车体结构材料的演变与展望[J]. 铁道机车车辆, 2019, 39(2): 119-124. https://www.cnki.com.cn/Article/CJFDTOTAL-TDJC201902028.htmKANG Xing-dong, REN Yu-xin, GAO Chao, et al. Evolution and prospect of railway passenger car carbody structure materials[J]. Railway Locomotive and Car, 2019, 39(2): 119-124. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-TDJC201902028.htm [2] 王剑, 孙畅, 马纪军. 基于BS EN 15085标准的焊缝质量评估方法[J]. 计算机辅助工程, 2018, 27(3): 11-14, 53. https://www.cnki.com.cn/Article/CJFDTOTAL-JSFZ201803003.htmWANG Jian, SUN Chang, MA Ji-jun. Evaluation method of weld quality based on BS EN 15085 standard[J]. Computer Aided Engineering, 2018, 27(3): 11-14, 53. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-JSFZ201803003.htm [3] PAMNANI R, VASUDEVAN M, JAYAKUMAR T, et al. Numerical simulation and experimental validation of arc welding of DMR-249A steel[J]. Defence Technology, 2016, 12(4): 305-315. doi: 10.1016/j.dt.2016.01.012 [4] LI D, YANG X, CUI L, et al. Fatigue property of stationary shoulder friction stir welded additive and non-additive T joints[J]. Science and Technology of Welding and Joining, 2015, 20(8): 650-654. doi: 10.1179/1362171815Y.0000000045 [5] BRTDER T, STÖRZEL K, BAUMGARTNER J, et al. Evaluation of nominal and local stress based approaches for the fatigue assessment of seam welds[J]. International Journal of Fatigue, 2012, 34(1): 86-102. doi: 10.1016/j.ijfatigue.2011.06.002 [6] FRICKE W, REMES H, FELTZ O, et al. Fatigue strength of laser-welded thin-plate ship structures based on nominal and structural hot-spot stress approach[J]. Ships and Offshore Structures, 2015, 10(1): 39-44. doi: 10.1080/17445302.2013.850208 [7] DONG P. A structural stress definition and numerical implementation for fatigue analysis of welded joints[J]. International Journal of Fatigue, 2001, 23(10): 865-876. doi: 10.1016/S0142-1123(01)00055-X [8] BRUDER T, ST RZEL K, BAUMGARTNER J, et al. Evaluation of nominal and local stress based approaches for the fatigue assessment of seam welds[J]. International Journal of Fatigue, 2012, 34(1): 86-102. doi: 10.1016/j.ijfatigue.2011.06.002 [9] 秦叔经. 压力容器中焊接接头的疲劳分析方法[J]. 化工设备与管道, 2019, 56(6): 1-10. https://www.cnki.com.cn/Article/CJFDTOTAL-HGSB201906001.htmQIN Shu-jing. Fatigue analysis methods for welds in pressure vessel[J]. Process Equipment and Piping, 2019, 56(6): 1-10. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-HGSB201906001.htm [10] 卢耀辉, 张德文, 赵智堂, 等. 焊接残余应力对动车组铝合金车体疲劳强度的影响[J]. 交通运输工程学报, 2019, 19(4): 94-103. https://www.cnki.com.cn/Article/CJFDTOTAL-JYGC201904011.htmLU Yao-hui, ZHANG De-wen, ZHAO Zhi-tang, et al. Influence of welding residual stress on fatigue strength for EMU aluminum alloy carbody[J]. Journal of Traffic and Transportation Engineering, 2019, 19(4): 94-103. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-JYGC201904011.htm [11] DONG P S, HONG J K. The master S-N curve approach to fatigue of piping and vessel welds[J]. Welding in the World. 2004, 48(1/2): 28-36. [12] 李向伟. 基于主S-N曲线法的焊接结构疲劳寿命预测系统开发和关键技术[J]. 计算机辅助工程, 2014, 23(4): 46-52. https://www.cnki.com.cn/Article/CJFDTOTAL-JSFZ201404012.htmLI Xiang-wei. Development and key technologies of welded structure fatigue life prediction system based on master S-N curve method[J]. Computer Aided Engineering, 2014, 23(4): 46-52. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-JSFZ201404012.htm [13] 兆文忠, 李季涛, 李晓峰, 等. 高速动车组角焊缝应力集中的识别方法[J]. 中国铁道科学, 2018, 39(1): 82-87. https://www.cnki.com.cn/Article/CJFDTOTAL-ZGTK201801013.htmZHAO Wen-zhong, LI Ji-tao, LI Xiao-feng, et al. Identification method for stress concentration on fillet weld of high-speed EMU[J]. China Railway Science, 2018, 39(1): 82-87. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-ZGTK201801013.htm [14] 谢素明, 莫浩, 牛春亮, 等. 基于结构应力法的焊接构架应力状态研究[J]. 大连交通大学学报, 2019, 40(1): 36-39. https://www.cnki.com.cn/Article/CJFDTOTAL-DLTD201901008.htmXIE Su-ming, MO Hao, NIU Chun-liang, et al. Research on stress state of welded frame based on structural stress method[J]. Journal of Dalian Jiaotong University, 2019, 40(1): 36-39. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-DLTD201901008.htm [15] WEI Guo-qian, OCHBILEG O, YUE Xu-dong, et al. Combine S-N curve and fracture mechanics for fatigue life analysis of welded structures[J]. China Welding, 2019, 28(4): 39- 45. [16] JUN Yun-yu, JUNG Y S, LE D Y, et al. Fatigue crack evaluation on the underframe of EMU carbody[J]. Procedia Engineering, 2010, 2(1): 893-900. doi: 10.1016/j.proeng.2010.03.096 [17] LU Yao-hui, DANG Lin-yuan, ZHANG Xing, et al. Analysis of the dynamic response and fatigue reliability of a full-scale carbody of a high-speed train[J]. Journal of Rail and Rapid Transit, 2018, 232(7): 2006-2023. doi: 10.1177/0954409718757295 [18] KIM J S. Fatigue assessment of tilting bogie frame for Korean tilting train: analysis and static tests[J]. Engineering Failure Analysis, 2005, 13(8): 1326-1337. [19] 阳光武, 赵科, 肖守讷, 等. 基于拉弯比的焊缝名义应力的提取[J]. 工程设计学报, 2011, 18(6): 423-427. https://www.cnki.com.cn/Article/CJFDTOTAL-GCSJ201106008.htmYANG Guang-wu, ZHAO Ke, XIAO Shou-ne, et al. Nominal stress extraction of weld based on ratio of tension and bending[J]. Journal of Engineering Design, 2011, 18(6): 423-427. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-GCSJ201106008.htm [20] LILLEMÄE I, REMES H, LⅡNALAMPI S, et al. Influence of weld quality on the fatigue strength of thin normal and high strength steel butt joints[J]. Welding in the World, 2016, 60(4): 731-740. [21] 卢耀辉, 冯振, 陈天利, 等. 铁道车辆转向架构架多轴疲劳强度有限元分析方法[J]. 北京交通大学学报, 2014, 38(4): 26-31, 39. https://www.cnki.com.cn/Article/CJFDTOTAL-BFJT201404006.htmLU Yao-hui, FENG Zhen, CHEN Tian-li, et al. Finite element analysis of multi-axial fatigue strength for railway vehicle bogie frame[J]. Journal of Beijing Jiaotong University, 2014, 38(4): 26-31, 39. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-BFJT201404006.htm [22] MEI J, DONG P S. An equivalent stress parameter for multi-axial fatigue evaluation of welded components including non-proportional loading effects[J]. International Journal of Fatigue, 2017, 101: 297-311. [23] LU Yao-hui, BI Wei, ZHANG Xing, et al. Calculation method of dynamic loads spectrum and effects on fatigue damage of a full-scale carbody for high-speed trains[J]. Vehicle System Dynamics, 2020, 58(7): 1037-1056. [24] DONG P. Arobust structural stress method for fatigue analysis of offshore/marine structures[J]. Journal of Offshore Mechanics and Arctic Engineering, 2005, 127(1): 68-74. [25] KYUBA H, DONG P S. Equilibrium-equivalent structural stress approach to fatigue analysis of a rectangular hollow section joint[J]. International Journal of Fatigue, 2004, 27(1): 85-94. [26] LU Yao-hui, ZHENG He-yan, LU Chuan, et al. Analysis methods of the dynamic structural stress in a full-scale welded carbody for high-speed trains[J]. Advances in Mechanical Engineering, 2018, 10(10): 1-16. [27] 周张义, 李芾. 基于表面外推的热点应力法平板焊趾疲劳分析研究[J]. 铁道学报, 2009, 31(5): 90-96. https://www.cnki.com.cn/Article/CJFDTOTAL-TDXB200905016.htmZHOU Zhang-yi, LI Fu. Study on fatigue analysis of welded toes of plate structures using hot spot stress method based on surface extrapolation[J]. Journal of the China Railway Society, 2009, 31(5): 90-96. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-TDXB200905016.htm [28] 卢耀辉, 冯振, 曾京, 等. 高速列车车体动应力分析方法及寿命预测研究[J]. 铁道学报, 2016, 38(9): 31-37. https://www.cnki.com.cn/Article/CJFDTOTAL-TDXB201609005.htmLU Yao-hui, FENG Zhen, ZENG Jing, et al. Research on dynamic stress analysis methods and prediction of fatigue life for carbody of high speed train[J]. Journal of the China Railway Society, 2016, 38(9): 31-37. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-TDXB201609005.htm [29] 马思群, 谷理想, 袁永文, 等. 焊接缺陷对动车组铝合金车体疲劳寿命影响研究[J]. 铁道学报, 2014, 36(2): 42-48. https://www.cnki.com.cn/Article/CJFDTOTAL-TDXB201402008.htmMA Si-qun, GU Li-xiang, YUAN Yong-wen, et al. Research on influence of welding defects on fatigue life of EMU aluminum-alloy car body[J]. Journal of the China Railway Society, 2014, 36(2): 42-48. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-TDXB201402008.htm [30] 周韶泽, 王超远, 李向伟, 等. 焊接接头质量等级评定方法与系统开发[J]. 机械研究与应用, 2020, 33(2): 164-167. https://www.cnki.com.cn/Article/CJFDTOTAL-JXYJ202002052.htmZHOU Shao-ze, WANG Chao-yuan, LI Xiang-wei, et al. Research and development of welded joint quality grade assessment system[J]. Mechanical Research and Application, 2020, 33(2): 164-167. (in Chinese) https://www.cnki.com.cn/Article/CJFDTOTAL-JXYJ202002052.htm -
点击查看大图
图(8) / 表(2)
计量
- 文章访问数: 740
- HTML全文浏览量: 280
- PDF下载量: 45
- 被引次数: 0
