轨道车辆服役工况下一系悬挂系统中的金属螺旋弹簧疲劳断裂时有发生，影响列车运行安全性。针对某一系螺旋弹簧进行疲劳失效故障，本文考虑轮轨激励与弹簧结构动态特性耦合关系，建立准确提取弹簧载荷的模型，通过结构频域疲劳分析法计算弹簧动应力响应与疲劳寿命。首先考虑螺旋弹簧结构的动态特性，建立包含一系动刚度特性的车辆-轨道耦合精细化动力学模型，然后在轮轨激励下提取服役工况弹簧两端动载荷，最后采用结构频域疲劳分析法计算弹簧动应力响应与疲劳寿命，并与实测动应力结果进行对比验证。结果表明：螺旋弹簧自身动态特性体现在：多阶模态频率下弹簧中部的最大模态变形与簧条1~2圈间的最大模态应力；基于耦合动力学模型，计算得到内簧动应力响应与实测结果一致，在58Hz的动应力峰值是其它频率动应力峰值的3倍以上；由于内簧一阶固有频率与轮轨系统P2共振频率接近，弹簧内部共振引起簧条1.2圈内侧高应力，该处疲劳寿命最短的分析结果与现场断裂位置吻合，而外簧的最短疲劳寿命约为内簧的3.6倍。因此，同时考虑轮轨激励与螺旋弹簧自身动态特性，使得一系螺旋弹簧固有频率远离轮轨共振频率，对该结构抗疲劳设计具有重要意义。
Abstract
Fatigue failure of metal coil springs in the suspension system of railway vehicle during service can affect the safety of train operation. In response to a fatigue failure in a certain series of coil springs, an accurate model for extracting the spring load is established, taking into account the coupling relationship between wheel/rail excitation and spring structural dynamic characteristics. The structural frequency-domain fatigue analysis method is used to calculate the dynamic stress response and fatigue life of the spring. Firstly, the dynamic characteristics of the coil spring structure are considered, and a refined vehicle-track coupling dynamic model containing a series of dynamic and stiffness characteristics is established. Then, under wheel-rail excitation, the dynamic loads at both ends of the service-condition spring are extracted. Finally, the structural frequency-domain fatigue analysis method is used to calculate the dynamic stress response and fatigue life of the spring, which is compared and verified with the measured dynamic stress results. The results show that the dynamic characteristics of the coil spring itself are reflected in the maximum mode deformation at the middle of the spring and the maximum mode stress between the first and second coils under multi-mode frequency. Based on the coupling dynamic model, the calculated internal spring dynamic stress response is consistent with the measured results, and the dynamic stress peak value at 58Hz is more than three times that at other frequencies. Due to the close resonance frequency between the first-order natural frequency of the inner spring and the P2 resonance frequency of the wheel-rail system, internal resonance of the spring causes high stress on the inner side of the first two coils, and the analysis result of the shortest fatigue life at that location coincides with the actual fracture position. The shortest fatigue life of the outer spring is about 3.6 times that of the inner spring. Therefore, considering both the wheel-rail excitation and the dynamic characteristics of the coil spring itself, it is of great significance for the anti-fatigue design of the coil spring series to keep its natural frequency far away from the wheel-rail resonance frequency.
关键词
轨道车辆 /
螺旋弹簧 /
模态频率 /
动应力 /
振动疲劳
{{custom_keyword}} /
Key words
Railway vehicle /
coil spring /
modal frequency /
dynamic stress /
vibration fatigue
{{custom_keyword}} /
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] Bruni, S., Vinolas, J., Berg, M., Polach, O.,ETC. Modelling of suspension components in a rail vehicle dynamics context[J]. Vehicle System Dynamics. 2011, 49(7), 1021-1072.
[2] 谭琳. 25G 型客车轴箱弹簧折断原因分析及预防措施[J]. 机车车辆工艺, 2010 (6): 39-40.
TAN Lin. Fracture analysis of the journal box spring for 25G passenger coach and the precautions[J]. Locomotive and Rolling Stock Technology, 2010 (6): 39-40.
[3] 崔利通, 杨集友, 曾一鸣, 等. 城际轨道交通动车组一系钢弹簧断裂故障问题研究[J]. 城市轨道交通研究, 2021.
CUI Li-tong, YANG Ji-you, ZENG Yi-ming, et. al. Study on intercity rail transit EMU primary steel spring fracture problem [J], Urban Mass Transit, 2021， 24(2): 38-43.
[4] 袁浩智. 广州地铁三号线北延段列车一系钢弹簧断裂原因分析及处理[J]. 轨道交通装备与技术, 2015, 000(001):32-34.
YUAN Zhi-hao. Analysis and treatment of fracture causes of primary steel springs in north extension of Guangzhou metro line 3 [J]. Rail Transit Equipment and Technology, 2015, 000(001):32-34.
[5] 王文静, 李广君, 唐薇, 等. 高速动车组轴箱弹簧疲劳失效机理研究[J]. 铁道学报, 2015, 37(6): 41-47.
WANG wen-jing, LI guang-jun, TANG wei, et al. Research on mechanism of fatigue crack of High-speed train axle box spring[J]. Journal of the China Railway Society, 2015, 37(6): 41-47.
[6] Wang K, Yang Y, Yang Y, et al. An experimental investigation of the mechanism and mitigation measures for the coil spring fracture of a locomotive[J]. Engineering Failure Analysis, 2022, 135: 106157.
[7] 曾成，陈忠明. 广州地铁某型车辆一系螺旋钢弹簧断裂问题分析[J]. 城市轨道交通研究, 2018 (9): 145-147.
ZENG Chen, CHEN Zhong-ming. Fracture problem analysis of series 1 suspension helical spring on a certain type vehicle in Guangzhou metro [J]. Urban Mass Transit, 2018 (9): 145-147.
[8] EN 13906-1. Cylindrical helical spring made from round wire and bar-calculation and design Part 1 (2013).
[9] 张英会,刘辉航，王德成. 弹簧手册[M]. 北京：机械工业出版社, 2008.
ZHANG Ying-hui, LIU Hui-hang, WANG De-cheng. Spring Manual [M]. Beijing: China Machine Press, 2008.
[10] 孙文静, 宫岛, 周劲松, 等. 一系螺旋弹簧动刚度对车辆-轨道耦合振动影响分析[J]. 振动与冲击, 2015, 34(5): 49-55.
SUN Wen-jing, GONG Dao, ZHOU Jin-song, et.al. Influence of dynamic stiffness of primary suspension on vehicle-track coupled vibration [J], Journal of Vibration and Shock, 2015,34(5):49-55.
[11] 何伟, 张合吉, 陈帅,等. 车轮多边形对地铁车辆一系钢弹簧疲劳寿命的影响研究[J]. 机械, 2020,47 (6):44-55.
HE Wei, ZHANG He-ji, CHEN Shuai, et al. Effects of wheel polygonization on the service life of the primary suspension coil spring of metro vehicles[J]. Machinery, 2020,47 (6):44-55.
[12] Ling L, Li W, Foo E, et al. Investigation into the vibration of metro bogies induced by rail corrugation[J]. Chin J Mech Eng. 2017;30(1):93–102.
[13] 严琰, 赵飞, 任永海. 高速铁路机车用弹簧失效分析[J]. 热加工工艺, 2012, 41(22): 232-234.
YAN Yan, ZHAO Fei, REN Yong-hai. Failure analysis on spring used in High-speed railway locomotive[J]. Hot Working Technology, 2012, 41(22): 232-234.
[14] 陈忠明. 广州地铁三号线北延段列车一系螺旋弹簧断裂原因分析[J]. 机电信息, 2012 (12): 106-107.
CHEN Zhong-ming. Analysis on the fracture causes of the primary coil springs in the north extension of Guangzhou metro Line 3 [J]. Electromechanical information, , 2012 (12): 106-107.
[15] Zhou C, Chi M, Wen Z, et al. An investigation of abnormal vibration–induced coil spring failure in metro vehicles[J]. Engineering Failure Analysis, 2020, 108: 104238.
[16] 周新建, 冯后东, 王向阳, 等. 基于多体动力学的快速地铁车辆一系钢圆弹簧振动特性分析[J]. 机械设计, 2021，38（2）：60-69.
ZHOU Xin-jian，FENG Hou-dong，WANG Xiang-yang，et al. Analysis on the vibration characteristics of primary steel circular springs for fast metro vehicles based on multi-body dynamics[J]. Journal of Machine Design, 2021，38（2）：60-69.
[17] Lee J, Thompson D J. Dynamic stiffness formulation, free vibration and wave motion of helical springs[J]. Journal of Sound and Vibration, 2001, 239(2): 297-320.
[18] Sun W, Zhou J, Thompson D, et al. Vertical random vibration analysis of vehicle–track coupled system using Green's function method [J]. Vehicle System Dynamics, 2014, 52(3): 362-389.
[19] 田国英, 高建敏, 赵春发. 铁路轨道不平顺谱研究进展[J]. 铁道工程学报, 2016, 33(9): 35-40.
TIAN Guo–ying, GAO Jian-min, ZHAO Chun–fa. Progress in the Research on the Railway Track Irregularity Power Spectral Density [J]. Journal of Railway Engineering Society, 2016, 33(9): 35-40.
[20] Sun W, Thompson D, Zhou J. The influence of vehicle–track dynamic coupling on the fatigue failure of coil springs within the primary suspension of metro vehicles[J]. Vehicle System Dynamics, 2020, 58(11): 1694-1710.
[21] Dirlik Turan. Application of computers in fatigue analysis [D]. University of Warwick, 1985.
{{custom_fnGroup.title_cn}}
脚注
{{custom_fn.content}}
PDF(2646 KB)
