基于虚拟激励法的地铁车辆排障器疲劳失效研究及拓扑优化

doi:10.3969/j.issn.1004-132X.2025.04.021

摘要/Abstract

摘要： 排障器是地铁车辆重要的安全保障装置。通过线路试验及理论研究对排障器失效原因进行调查分析发现，排障器的一阶固有模态（95.7 Hz）与小半径曲线钢轨波磨的通过频率95 Hz接近，从而导致排障器共振，这是排障器过早发生疲劳失效的主要原因。根据失效原因对排障器进行拓扑优化设计，利用模态错频设计方法，将排障器一阶固有模态增加到160 Hz，解决了排障器的共振问题。提出一种基于虚拟激励法的子结构分析技术，建立随机振动模型，再现排障器真实服役工况下的振动环境，计算关键位置动应力，结果表明，仿真与实测最大动应力误差为1.8%。最后，优化激励加载处理方法，基于线路实测数据，验证排障器的疲劳寿命。分别采用Dirlik法及Zhao-Baker法计算优化后排障器的疲劳寿命，结果表明优化结构在焊缝及母材位置均满足30年360万km的设计寿命要求。

关键词: 排障器, 钢轨波磨, 动应力, 虚拟激励, 疲劳寿命

Abstract: The cowcatchers were an important safety guarantee device for metro vehicles. The causes of the cowcatcher failure were investigated by field test and theoretical research. The results indicate that the resonance of the cowcatcher contributes to the premature fatigue failure due to the first-order eigenmode frequency (95.7 Hz) which is close to the passing frequency(95 Hz) of the rail corrugation in small-radius curves. Topology optimization design of the cowcatchers was carried out according to the causes of failure based on the mistuning modal design method. The first-order eigenmode frequency was raised to 160 Hz, and the resonance problems of the cowcatchers were solved. A sub-structure analysis technique was proposed based on the virtual excitation method. A random vibration model was established to reproduce the vibration environment of the cowcatchers under real conditions. And the dynamic stresses at key positions was calculated and the results show that the maximum dynamic stress error between simulation and measurement as 1.8%. Finally, the excitation loading method was optimized, and the fatigue life of the cowcatchers was verified based on field test data. The fatigue life of the optimized cowcatchers was calculated by using the Dirlik and the Zhao-Baker method, and the results show that the optimized structure meets the design life requirements of 30 years and 3.6 million kilometers at both of the weld and base material locations.

Key words: cowcatcher, rail corrugation, dynamic stress, virtual excitation, fatigue life

中图分类号:

U270

刘阳1, 温泽峰1, 吴兴文2, 周亚波1, 陶功权1, 张振先3, 侯建文3, 易志4. 基于虚拟激励法的地铁车辆排障器疲劳失效研究及拓扑优化[J]. 中国机械工程, 2025, 36(04): 840-849.

LIU Yang1, WEN Zefeng1, WU Xingwen2, ZHOU Yabo1, TAO Gongquan1, ZHANG Zhenxian3, HOU Jianwen3, YI Zhi4. Fatigue Failure Study and Topology Optimization of Metro Vehicle Cowcatchers Based on Virtual Excitation Method[J]. China Mechanical Engineering, 2025, 36(04): 840-849.

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链接本文: https://www.cmemo.org.cn/CN/10.3969/j.issn.1004-132X.2025.04.021

https://www.cmemo.org.cn/CN/Y2025/V36/I04/840

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