剪切螺栓设计及在电力机车结构耐撞性上的运用  

Shear bolt design and its application in crashworthiness of electric loco-motive structure

作　　者：杨毅 朱涛[1] 张江田 黄明惠 肖守讷[1] 丁浩谞 YANG Yi;ZHU Tao;ZHANG Jiangtian;HUANG Minghui;XIAO Shoune;DING Haoxu(State Key Laboratory of Traction Power,Southwest Jiaotong University,Chengdu 610031,China;CRRC Datong Co.Ltd.,Datong 037038,China)

机构地区：[1]西南交通大学牵引动力国家重点实验室,四川成都610031 [2]中车大同电力机车有限公司,山西大同037038

出　　处：《中南大学学报（自然科学版）》2022年第5期1877-1888,共12页Journal of Central South University:Science and Technology

基　　金：国家自然科学基金资助项目(52172409);四川省杰出青年基金资助项目(2022JDJQ0025)。

摘　　要：为提高电力机车被动安全性,提出回退式车钩剪切螺栓设计方法,并对机车端部结构进行耐撞性设计,提高既有机车的耐撞性。首先,对剪切螺栓开展准静态与动态冲击试验,研究剪切螺栓失效的最大剪切力及失效形式;然后,基于试验数据对剪切螺栓用45号钢J-C本构模型参数进行优化,结合数值仿真讨论最大剪切力的参数依赖性;最后,基于数值仿真,验证回退式车钩的功能可行性,同时,基于多级能量吸收的原则,改进既有机车端部结构并对耐撞性指标进行分析。研究结果表明:剪切螺栓可有效应用于回退式车钩,以保证机车碰撞中车钩回退到恰当的位置;基于试验数据优化后的45号钢J-C本构模型能够准确模拟剪切螺栓剪切力及失效形式,剪切力最大相对误差为4.31%;剪切螺栓的最大剪切力与螺栓自身直径无关,与剪切螺栓凹槽横截面面积成正比;随着螺栓凹槽宽度增大,螺栓的最大剪切力减小,螺栓剪切段的塑性逐渐增强;剪切螺栓的回退式车钩在整车仿真中能够实现回退功能,使吸能装置有效发挥吸能作用;改进后的机车相较于既有机车的纵向最大平均加速度减少了2.49g,峰值界面力减少了472 kN,碰撞前后司机室纵向生存空间增加了12.54%。In order to improve the passive safety of electric locomotive,the design method of retractable coupler shear bolt was proposed,and the crashworthiness of locomotive end structure was designed to improve the crashworthiness of the existing locomotive.Firstly,the quasi-static and dynamic impact tests of shear bolts were carried out,and the maximum shear force and failure mode of shear bolts were studied.Then,based on the experimental data,the parameters of the J-C constitutive model of 45 steel for shear bolt were optimized,and the parameter dependence of the maximum shear force was discussed combined with numerical simulation.Finally,based on the numerical simulation,the functional feasibility of the fallback coupler was verified.At the same time,based on the principle of multi-level energy absorption,the end structure of the existing locomotive was improved,and the crashworthiness index was analyzed.The results show that the shear bolt can be effectively applied in the retraction coupler to ensure that the coupler retracts to the appropriate position in locomotive collision.Based on the test data,the optimized J-C constitutive model of 45 steel can accurately simulate the shear force and failure mode of shear bolt,and the maximum error is 4.31%.The maximum shear force of the shear bolt has nothing to do with the diameter of the bolt itself,and is directly proportional to the cross-sectional area of the shear bolt groove.With the increase of bolt groove width,the maximum shear force of bolt decreases,and the plasticity of bolt shear section increases gradually.The retraction coupler with shear bolt can realize the retraction function in the whole vehicle simulation,so that the energy absorption device can effectively play the role of energy absorption.Compared with the existing locomotive,the longitudinal maximum average acceleration of the improved locomotive is reduced by 2.49g,the peak interface force is reduced by 472 k N,and the longitudinal living space of the cab before and after collision is increased by 1

关 键 词：剪切螺栓 回退式车钩 本构模型 耐撞性 

分 类 号：O313.4[理学—一般力学与力学基础] U270.2[理学—力学]