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基于160 km/h电动车组的拉杆橡胶关节寿命提升研究
Research on fatigue life improvement of axle box bushing on 160 km/h power concentrated EMUs
- 机车电传动 2023年第1期 页码：60-65
- 作者机构：
1.株洲时代瑞唯减振装备有限公司，湖南 株洲 412007
2.株洲时代新材料科技股份有限公司，湖南 株洲;412007
- 作者简介：
王峰宇（1992—），男，主要从事机车零部件产品设计开发；E-mail: wangfy3@csrzic.com
- 基金信息：
DOI：10.13890/j.issn.1000-128X.2023.01.008
中图分类号： U266.2纸质出版日期：2023-01-10，
收稿日期：2022-01-28，
修回日期：2022-11-16，
- 稿件说明：
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王峰宇, 程海涛, 赵斌, 等. 基于160 km/h电动车组的拉杆橡胶关节寿命提升研究[J]. 机车电传动, 2023(1): 60-65.
WANG Fengyu, CHENG Haitao, ZHAO Bin, et al. Research on fatigue life improvement of axle box bushing on 160 km/h power concentrated EMUs[J]. Electric Drive for Locomotives, 2023(1): 60-65.
王峰宇, 程海涛, 赵斌, 等. 基于160 km/h电动车组的拉杆橡胶关节寿命提升研究[J]. 机车电传动, 2023(1): 60-65. DOI： 10.13890/j.issn.1000-128X.2023.01.008.
WANG Fengyu, CHENG Haitao, ZHAO Bin, et al. Research on fatigue life improvement of axle box bushing on 160 km/h power concentrated EMUs[J]. Electric Drive for Locomotives, 2023(1): 60-65. DOI： 10.13890/j.issn.1000-128X.2023.01.008.
摘要
从速度为160 km/h的动力集中电动车组转向架的轴箱拉杆橡胶关节应用失效案例出发，通过优化产品结构来解决该轴箱拉杆橡胶关节的使用寿命问题。通过运行工况的边界条件和既有结构的失效原因进行分析，基于分析结果设定合理的预压量，并结合贴近式橡胶型面和易流式金属弧面设计，以及采用合适的橡胶层厚度等多方面进行结构优化。通过对比两种结构的有限元疲劳仿真分析结果，优化结构的橡胶应变降低了9.64%，疲劳损伤值降低了60%，橡胶关节的使用寿命将显著提升。最后通过疲劳试验验证，进一步佐证了优化结构后的橡胶关节疲劳性能的提升。试验结果显示：疲劳次数提升了3倍。经过初步评估，结构优化后的橡胶关节的疲劳寿命将由2~5年提升至8年，使得机车的运行可靠性得到改善，降低非必要的维修次数。优化设计的橡胶关节目前已在线运行近4年，各项性能表现良好。本优化设计可为其他径向变形较大的橡胶关节优化提供参考：径向预压量应与橡胶关节疲劳变形相当，避免橡胶受拉伸应力；针对径向位移较大的橡胶关节类产品，贴近式橡胶型面可以均衡橡胶表面应变，可有效缓解橡胶受载后出现褶皱现象，提升橡胶关节的疲劳寿命。
Abstract
The current study is aimed to extend the service life of axle box bushing mounted on the bogie of 160 km/h power concentrated EMUs by structural optimization
based on the failure cases of such a train component. Firstly
an analysis was made on the boundary conditions of operating cases and failure reasons of the original structure. Then
according to the analysis results
structural improvements were made in many aspects like a rational pre-compression
close-contact rubber profile
streamline cambered surface of steel parts
and suitable thickness of the rubber layer. By the contrast of finite element analysis (FEA) results between the optimized structure and original one
rubber strain decreased by 9.64% and fatigue damage value decreased by 60% for the former
contributing to an obvious improvement in the service life of bushings. Finally
the effectiveness of the optimized structure to improve fatigue performance was proved in the fatigue test
showing a tripled fatigue performance. Through the preliminary evaluation
the fatigue life of bushings in the optimized structure could be extended from 2-5 years to about 8 years
which could improve the operating reliability of the EMUs and reduce unnecessary maintenance. The optimized product has been applied in on-track operation for about 4 years
turning out satisfactory in all performance indexes. The optimization design presented provides a reference for other bushings with a large radial deformation. Specially
the radial pre-compression should be equivalent to fatigue deformation to avoid tensile load on the bushings; aiming at the bushings with a large radial displacement
the close-contact rubber profile could balance rubber surface strain and effectively relieve folds arising from loading on them
thus improve their fatigue life.
关键词
轴箱拉杆橡胶关节结构优化有限元仿真分析疲劳试验寿命提升
Keywords
axle box bushingstructural optimizationfinite element analysisfatigue testlife improvement
references
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