Analysis of vibration fatigue failure of primary coil springs within railway vehicles

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Journal of Vibration and Shock ›› 2024, Vol. 43 ›› Issue (1) : 230-236.

SUN Wenjing1, WANG Jiahao1, THOMPSON David2, WANG Tengfei1, ZHOU Jinsong1

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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.

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Railway vehicle / coil spring / modal frequency / dynamic stress / vibration fatigue

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SUN Wenjing1, WANG Jiahao1, THOMPSON David2, WANG Tengfei1, ZHOU Jinsong1. Analysis of vibration fatigue failure of primary coil springs within railway vehicles[J]. Journal of Vibration and Shock, 2024, 43(1): 230-236

References

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