Structural design and strength analysis method for inner journal high-speed railway axles

GUO Feng; WU Sheng-chuan; FENG Yang; LIU Jian-xin; LIANG Shu-lin; YIN Zhen-kun

doi:10.19818/j.cnki.1671-1637.2021.05.012

Volume 21 Issue 5

Nov. 2021

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GUO Feng, WU Sheng-chuan, FENG Yang, LIU Jian-xin, LIANG Shu-lin, YIN Zhen-kun. Structural design and strength analysis method for inner journal high-speed railway axles[J]. Journal of Traffic and Transportation Engineering, 2021, 21(5): 138-148. doi: 10.19818/j.cnki.1671-1637.2021.05.012

Citation:

GUO Feng, WU Sheng-chuan, FENG Yang, LIU Jian-xin, LIANG Shu-lin, YIN Zhen-kun. Structural design and strength analysis method for inner journal high-speed railway axles[J]. Journal of Traffic and Transportation Engineering, 2021, 21(5): 138-148. doi: 10.19818/j.cnki.1671-1637.2021.05.012

Citation:

GUO Feng, WU Sheng-chuan, FENG Yang, LIU Jian-xin, LIANG Shu-lin, YIN Zhen-kun. Structural design and strength analysis method for inner journal high-speed railway axles[J]. Journal of Traffic and Transportation Engineering, 2021, 21(5): 138-148. doi: 10.19818/j.cnki.1671-1637.2021.05.012

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Structural design and strength analysis method for inner journal high-speed railway axles

doi: 10.19818/j.cnki.1671-1637.2021.05.012

1.
State Key Laboratory of Traction Power, Southwest Jiaotong University, Chengdu 610031, Sichuan, China
2.
National Engineering Research Center of Railway Vehicles, CRRC Changchun Railway Vehicles Co., Ltd., Changchun 130062, Jilin, China

Funds:

National Natural Science Foundation of China 52072321

Project of Science and Technology Research and Development Plan of China Railway P2018J003

Open Project of State Key Laboratory of Traction Power 2019TPL-Q05

Open Project of State Key Laboratory of Traction Power 2021TPL-T04

Open Project of State Key Laboratory of Traction Power 2021TPL-T06

More Information

Author Bio:
GUO Feng(1988-), male, doctoral student, gfnz9@163.com

WU Sheng-chuan(1979-), male, professor, PhD, wusc@swjtu.edu.cn

LIU Jian-xin(1965-), male, professor, PhD, jxliu@swjtu.edu.cn
Received Date: 2021-03-29
Available Online: 2021-11-13
Publish Date: 2021-10-01

Abstract

Abstract

To achieve the lightweight design of high-speed trains, the unique inner supporting structures and load-bearing characteristics of inner journal high-speed railway axles were analyzed, and a theoretical model to study both the load-bearing status and structural strength was established for the inner journal high-speed railway axle. An analytical calculation method was proposed to calculate the design limit load and fatigue strength for the inner journal high-speed railway axle. Based on the presented methods, theoretical analysis, finite element method, and vehicle system dynamics, a structural design method was developed for inner journal high-speed railway axles. Further, an inner journal high-speed railway axle with a 17-t axle load was used as a case study to carry out the application research. The critical safety section and detailed dimension scheme of the axle were determined using the theoretical load-bearing analysis results of the inner journal high-speed railway axle. A finite element model for the inner journal high-speed railway axle was established, and the fatigue strength of the axle was evaluated and verified. A rigid-flexible coupled system dynamics simulation analysis model for the high-speed electric multiple unit (EMU) with inner journal axles was constructed. The dynamics properties of the vehicle and the dynamic loads of the axle were obtained and verified. Analysis results reveal that the weight of newly developed inner journal high-speed railway axle with a 17-t axle load is 273.6 kg, about 30% less than that of the traditional outer journal high-speed railway axle. The safety factor of fatigue strength for each section of inner journal high-speed railway axle is larger than 1.66. The critical safety sections are transferred to the bottom of relief groove between the journal and the wheel seat as well as to the arc-shaped transition zone between the journal and the axle body. The high-speed EMU with inner journal axles can stably pass through a curved route with a radius of 5.5 km at a speed of 350 km·h^-1, and its main dynamics property indices are excellent. The dynamic loads borne by the axles under the selected curve passing conditions fall within the design limit loads. Therefore, it is robust enough to carry out the structural design and strength analysis for the axles. Thus, the inner journal high-speed railway axle shows significant technical advantages in achieving the lightweight design of high-speed trains with excellent high-speed adaptability. It has immense development and application potential in the field of high-speed trains. 2 tabs, 10 figs, 32 refs.
- vehicle engineering,
- high-speed train,
- inner journal high-speed railway axle,
- vehicle dynamics,
- design limit load,
- lightweight design,
- fatigue strength

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0. 引言

The inner neck axle is a new type of axle structure that has been successfully used in the field of urban rail transit vehicles in recent years, with significant lightweight effects. Liang Shulin and others^[18]This article summarizes the development history, basic structural models, advantages and disadvantages of internal journal axles, and believes that internal journal axles have advantages in reducing unsprung mass, improving vehicle operating quality, and enhancing line adaptability, and have broad application prospects in the field of urban rail vehicles; Deng Tiesong and others^[19]The influence of axle box arrangement on the curve passing performance of subway vehicles was compared, and it was found that subway vehicles with inner journal axles have better curve passing performance, especially when the wheels have non-uniform wear, their dynamic performance is better than traditional subway vehicles; Wu et al^[20]The influence of inner journal axle on the wheel rail contact state, creep force, and wear of urban rail vehicles was studied. It was found that compared with traditional outer journal axle, using inner journal axle can significantly improve the vehicle's ability to pass through curves, and is conducive to suppressing the rail corrugation phenomenon that occurs when the vehicle passes through small radius curve lines; Cai Minghao and others^[21]We studied the structural characteristics and application indicators of the inner neck axle of 100% low floor light rail vehicles. We constructed a multi-objective and multi parameter optimization model for the axle using Kriging difference method and Latin hypercube sampling test method, and carried out lightweight design for the axle; Wu et al^[22-23]The critical safety section of the inner journal axle of urban rail vehicles was analyzed, and the anti fatigue performance of the inner journal axle was evaluated using an advanced step fatigue assessment framework. The research on the inner journal axle mentioned above is mainly aimed at urban rail vehicles with normal speed and small axle load. The related research content mainly focuses on vehicle dynamic performance, axle fatigue reliability, and structural optimization. There are few reports on bearing characteristics and design methods, especially in the field of high-speed trains, where there is no relevant research and application. The high-speed adaptability of the inner journal axle urgently needs to be studied.

1. 铁道车轴结构与强度

1.1 典型车轴结构

Figure 1. Two powered wheelsets of high-speed railway

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1.2 主要承受载荷

Figure 2. Load-bearing status of inner journal high-speed railway axle

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$P_{1} =\left(0.625+0.087\ 5 \frac{h}{b}\right) m g$

(1)

$P_{2} =\left(0.625-0.087\ 5 \frac{h}{b}\right) m g$

(2)

$Y_{1} =0.35 m g$

(3)

$Y_{2} =0.175 m g$

(4)

$H =0.175 m g$

(5)

Within the longitudinal section of the axleO₁andO₂The torque balance equation can be used to solve the vertical reaction force at the contact position between the wheel and rail on both sidesQ₁andQ₂respectively

$\begin{aligned} Q_{1}=& \frac{1}{2 s}\left[\left(Y_{1}-Y_{2}\right) R+P_{1}(b+s)+P_{2}(s-b)+\right.\\ &\left.F_{1}\left(2 s-y_{1}\right)+F_{2}\left(2 s-y_{2}\right)+F_{3}\left(2 s-y_{3}\right)\right] \end{aligned}$

(6)

$\begin{aligned} Q_{2}=& \frac{1}{2 s}\left[\left(Y_{2}-Y_{1}\right) R+P_{1}(s-b)+P_{2}(b+s)+\right.\\ &\left.F_{1} y_{1}+F_{2} y_{2}+F_{3} y_{3}\right] \end{aligned}$

(7)

$M_{x}= \begin{cases}Y_{1} R-Q_{1} y & y \leqslant s-b \\ Y_{1} R-Q_{1} y+P_{1}(y+b-s) & s-b<y \leqslant y_{1} \\ Y_{1} R-Q_{1} y+P_{1}(y+b-s)+F_{1}\left(y-y_{1}\right) & y_{1}<y \leqslant y_{2} \\ Y_{1} R-Q_{1} y+P_{1}(y+b-s)+F_{1}\left(y-y_{1}\right)+F_{2}\left(y-y_{2}\right) & y_{2}<y \leqslant y_{3} \\ Y_{1} R-Q_{1} y+P_{1}(y+b-s)+F_{1}\left(y-y_{1}\right)+F_{2}\left(y-y_{2}\right)+F_{3}\left(y-y_{3}\right) & y_{3}<y \leqslant b+s \\ Y_{2} R-Q_{2}(2 s-y) & b+s<y \leqslant 2 s\end{cases}$

(8)

$M_{x}^{\prime}=F_{\mathrm{f}} \varGamma y_{\mathrm{f}}$

(9)

$M_{y}^{\prime}=0.3 P^{\prime} R$

(10)

$M_{z}^{\prime}=F_{\mathrm{f}} \varGamma \frac{R_{\mathrm{f}}}{R} y_{\mathrm{f}}$

(11)

$M_{\mathrm{R}}=\sqrt{\left(M_{x} \pm M_{x}^{\prime}\right)^{2}+M_{y}^{\prime 2}+M_{z}^{\prime 2}}$

(12)

1.3 强度分析方法

$\sigma_{\mathrm{i}}=\frac{32 K d^{\prime} M_{\mathrm{R}}}{{\rm{ \mathsf{ π} }}\left(d^{4}-d^{\prime 4}\right)} \leqslant \sigma_{\mathrm{a}, \mathrm{i}}$

(13)

$\sigma_{\mathrm{o}}=\frac{32 K d M_{\mathrm{R}}}{{\rm{ \mathsf{ π} }}\left(d^{4}-d^{\prime 4}\right)} \leqslant \sigma_{\mathrm{a}, \mathrm{o}}$

(14)

Figure 3. Fatigue stress concentration positions of high-speed railway axle

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$K_{1}=A B+1$

(15)

$K_{2}=A+1$

(16)

$\left\{\begin{array}{l} A=\frac{(4-Y)(Y-1)}{5(10 X)^{2.5 X-0.5 Y+1.5}} \\ B=\frac{-1.2 X^{2}+37 X}{Y^{6}}+1.74 \\ X=r / d \\ Y=D / d \end{array}\right.$

(17)

2. 内轴颈高铁车轴设计方法

The axle is the most important critical safety component of high-speed trains. Scholars at home and abroad have comprehensively and deeply studied the bearing characteristics and design methods of traditional outer journal axles, forming design standards such as TB/T 2395-2018, EN 13104-2013, JIS E 4501-1995, and UIC 515 3-1994. However, there are currently no reports on the design research of inner journal high-speed railway axles, which is not conducive to the development of axle box embedded high-speed trains using inner journal high-speed railway axles.

Figure 4. Design process of inner journal high-speed railway axle

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3. 标准轨距内轴颈高铁车轴

3.1 车轴结构方案设计

At 350 km · h^-1Taking the EA4T steel inner journal high-speed railway axle with a 17 ton axle load as an example, structural design and load-bearing performance analysis are carried out. Refer to the technical specifications and overall design parameters of CRH-380 series high-speed trains and CR400 AF/BF series Chinese standard high-speed trains^[24-25]The design parameters for high-speed railway axles with standard track gauge inner neck have been developed, with a wheelset inner side gauge of 1353mm. The wheels use integral wheels with a nominal rolling circle diameter of 920mm, and the tread is LM in accordance with TB/T 449-2016_BType wear tread, other main design parameters such asTable 1As shown.

Table 1. Main design parameters of inner journal high-speed railway axle

参数符号	参数值
m/t	15.156
2b/mm	1 100
2s/mm	1 500
h/mm	1 200
R/mm	460
R_f/mm	350
F_f/kN	52
y_f/mm	73.5
Γ	0.3
P′/kN	88
F₁/kN	±2.35
F₂/kN	±0.80
F₃/kN	±2.35
y₁/mm	952.5
y₂/mm	1 040.0
y₃/mm	1 127.5

| Show Table

DownLoad: CSV

Figure 5. Bending moments of two high-speed railway axles

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Figure 6. Maximum resultant moment and critical safety positions of inner journal high-speed railway axle

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Taking into account the effects of interference fit and micro motion wear, the fatigue limit of a hollow axle needs to be considered separately in four areas: the inner hole, journal, shaft body, and other installation positions except for the journal. Therefore, according to EN 13104-2013, the safety factor of EA4T alloy steel hollow power axles should be less than 1.66, and the fatigue limits of each area of the axle are as follows:Table 2As shown.

Table 2. Fatigue limits of EA4T hollow axle MPa

区域	疲劳极限	许用应力
内孔	96	58
轴颈	113	68
除轴颈外其他安装位置	132	80
轴身	240	145

| Show Table

DownLoad: CSV

On this basis, after theoretical analysis and iterative design, the detailed dimensions and design schemes of the axle unloading groove, transition fillet, and overhang were determined. The main dimensions of the axle are as follows:Figure 6As shown. The weight of the inner neck high-speed railway axle designed in this article is 273.6 kg, which can reduce the weight by about 30% compared to the traditional outer neck high-speed railway axle with coaxial weight (weight of 400-450 kg).

3.2 车轴疲劳强度与验证

This article uses the Hertz contact formula to calculate the contact area between the wheel and rail. Apply constraints at the wheel contact spot position and apply to the load sidex、yandzDirectional displacement constraint, applied only on the unloading sidezRegarding displacement constraints, the two types of calculation boundary conditions for the axle are as followsFigure 7As shown. The equivalent stress of the axle under various operating conditions was calculated through finite element simulation, and the equivalent force of the axle under the far and near end loading conditions of the gearbox is shown inFigure 7.

Figure 7. Equivalent stresses of inner journal high-speed railway axle

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Figure 8. Comparison of calculated stresses and simulated stresses for inner journal high-speed railway axle

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3.3 车轴动荷载与验证

Figure 9. Wheel-rail vertical force-time histories for powered wheelsets under two selected curve passing conditions

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Figure 10. Wheel-axle lateral force-time histories for powered wheelsets under two selected curve passing conditions

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The analysis results indicate that using the reference empirical values of the traditional outer journal axle design ultimate load given in EN 13104-2013 to design the inner journal high-speed rail axle is sufficiently conservative, and may even be too conservative; By comprehensively adopting research methods such as simulation analysis, bench testing, and online loading testing, it is recommended to moderately reduce the design limit load of the inner journal high-speed rail axle and further achieve lightweight design, taking into account the most unfavorable conditions such as line conditions, vehicle limit conditions, vehicle suspension parameters, and wheel rail contact states.

4. 结语

(3) The weight of a 17 ton axle with an inner neck high-speed railway axle is about 30% lower than that of a traditional outer neck high-speed railway axle with the same axle weight, showing significant advantages in structural lightweighting.

(4) The high-speed train with an axle box embedded with an inner journal high-speed rail axle can reach a speed of 350 km · h^-1The speed of the vehicle is stable as it passes through a curved line with a radius of 5.5 km. The lateral and vertical stability indicators are 2.473 and 1.879, respectively. The wheel load reduction rate is 0.172, the derailment coefficient is 0.13, and the overturning coefficient is 0.155, all of which are below the safety limit. The vehicle has good adaptability to high speeds.

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Structural design and strength analysis method for inner journal high-speed railway axles

doi: 10.19818/j.cnki.1671-1637.2021.05.012