基于DVS 1608的轨道车辆空气弹簧焊接上盖疲劳评估方法研究  

Research on the Fatigue Assessment Method of Rail Vehicle Air Spring Welded Top Plate Based on DVS 1608

作　　者：林佳志 宋红光 韩跃 吴霜 赵国艳 徐聪 谭江江 LIN Jiazhi;SONG Hongguang;HAN Yue;WU Shuang;ZHAO Guoyan;XU Cong;TAN Jiangjiang(CRRC Qingdao Sifang Rolling Stock Research Institute Co.,Ltd.,Qingdao 266031 Shandong,China;CRRC Tangshan Co.,Ltd.,Tangshan 063035 Hebei,China;Wuhan Metro Operation Co.,Ltd.,Wuhan 430070 Hubei,China)

机构地区：[1]中车青岛四方车辆研究所有限公司,山东青岛266031 [2]中车唐山机车车辆有限公司,河北唐山063035 [3]武汉地铁运营有限公司,武汉430070

出　　处：《铁道机车车辆》2023年第2期8-17,共10页Railway Locomotive & Car

摘　　要：空气弹簧作为轨道交通车辆的二系悬挂,其安全可靠性对车辆的动力学特性和乘坐舒适性有着重要的影响,文中给出了一种对空气弹簧焊接上盖进行疲劳评估的计算方法。首先,采用疲劳耐久极限法确定空气弹簧疲劳载荷工况,空载45 kN,横向位移±110 mm;建立轴对称模型,进行旋转得到三维模型,再施加边界条件和垂向载荷,进行横向位移加载;其次,得到焊接上盖的应力结果,根据计算出的母材最大应力92.0 MPa和焊接区域最大应力32.6 MPa,判断满足静态强度要求;进而,完成上盖焊缝横向位移时的应变测量,验证仿真计算结果与试验结果一致;最后,选取最严苛部分(或提取全部)节点应力数据,根据DVS 1608定义的方法进行疲劳估算,计算出各节点应力利用率,依次进行焊接疲劳强度可靠性评估。计算得出焊缝外侧过渡区应力利用率最大1.09,大于允许值1,由于文中对焊缝过渡区域进行打磨处理,疲劳强度值可以提高30%,判定焊缝满足1000万次疲劳强度要求。As a secondary suspension of rail vehicles,the safety and reliability of air spring has an important influence on the vehicle dynamics and passenger riding comfort.In this paper,a calculation method for fatigue assessment of air spring welded top plate is presented.First,the fatigue load condition of air spring was determined by the fatigue endurance limit method,with tare load of 45 kN and transverse displacement of±110 mm.Then,an axisymmetric model was established to obtain a three-dimensional model by rotation,and boundary conditions and vertical loads were applied to carry out transverse displacement loading.Moreover,the stress results of welded top plate were obtained.According to calculated maximum stress of base material of 92.0 MPa and maximum stress of welding area of 32.6 MPa,it was judged that the static strength requirements were met.Then,the strain measurement of the top plate weld is completed to verify that the simulation results are consistent with the test results.Finally,select the most severe part(or extract all)of node stress data,according to the method defined by DVS 1608 to perform fatigue estimation,calculate the stress utilization rate of each node,and conduct reliability assessment of welding fatigue strength.It was calculated that maximum stress utilization rate of transition zone outside weld was 1.09,which was greater than the allowable value 1.However,due to grinding treatment of the transition zone of weld in this paper,the fatigue strength value could be increased by 30%,and it was determined that the weld could meet the requirement of fatigue strength for 10 million times.

关 键 词：DVS 1608 空气弹簧 焊接上盖 疲劳 有限元 利用率 

分 类 号：U270.1[机械工程—车辆工程]