铁路客车车体轻量化设计及仿真分析  

Lightweight Design and Simulation Analysis of Railway Passenger Car Body

作　　者：杨小荣 YANG Xiaorong(National Engineering Research Center of CRRC Qingdao Sifang Locomotive&Rolling Stock Co.,Ltd.,Qingdao 266111,China)

机构地区：[1]中车青岛四方机车车辆股份有限公司国家工程研究中心,山东青岛266111

出　　处：《智慧轨道交通》2022年第3期74-80,共7页SMART RAIL TRANSIT

摘　　要：研究了铁路客车车体轻量化设计,采用拓扑优化仿真分析了力流的传递路径,通过在力流传递路径上合理设置结构承载梁,从而对端部底架进行了有效地减重设计;同时由于采用先进的激光焊接技术应用在侧墙板与骨架中间的焊接,对侧墙板和骨架板厚都进行了减薄设计,从而减轻了侧墙重量,提升了侧墙美观度。仿真计算结果表明,整个车体在减重1.5 t后的结构可以满足标准要求,最大应力位置为安全系数最小值是1.00,工况为纵向拉伸载荷组合工况,位置在侧墙窗角处。底架纵梁与横梁连接处焊缝疲劳载荷最恶劣,数值为16.4 MPa,满足标准要求。同时对比了整车模态仿真与试验数据,找出了导致偏差的原因,为后续的车体仿真计算提供了指导。This article introduces the lightweight structure design of railway passenger vehicle body.Topology optimization simulation was used to analyze the transfer path of force flow,and the load-bearing beam was set reasonably on the transfer path of force flow to reduce the weight of the bottom frame effectively.At the same time,due to the use of advanced laser welding technology in the middle of the side wall panel and skeleton welding,the thickness of the side wall and skeleton plate are thinly designed,so as to reduce the weight of the side wall,while improving the side wall beauty.The simulation results show that the structure of the whole car body can meet the standard requirements after the weight loss of 1.5t,the maximum stress position is 1.00,the minimum safety factor is 1.00,the working condition is the combination of longitudinal tensile load,and the position is at the corner of the side wall window.The worst fatigue load of welding seam at the connection between bottom rail and beam is 16.4mpa,which meets the standard requirements.At the same time,the model simulation and test data of the whole vehicle are compared to find out the cause of the deviation,which provides guidance for the subsequent car body simulation calculation.

关 键 词：铁路客车 车体轻量化 车体强度 激光焊接 拓扑优化仿真 

分 类 号：U270.3[机械工程—车辆工程]