踏面清扫装置轻量化缸体设计及研制

Design and development of light cylinder block for tread cleaning device

踏面清扫装置具有优异的车轮踏面修形功能,已广泛运用在国内地铁线路。传统的踏面清扫装置缸体采用球铁材质,重量占整机的47%,缸体减重意义极大。为此,文章开展了缸体的轻量化材质设计,基于7系铝合金进行了材料的选型设计,并通过优化材料成分进一步提升了材料性能。然后,对锻造和热处理工艺进行了4种形式的工艺验证,结果表明,材料的抗拉强度和屈服强度相比球铁大幅提升。同时,为验证材质变化对整机性能的可能影响,对踏面清扫装置整机模态、振动疲劳强度进行了仿真验证,并结合踏面清扫装置型式试验要求,开展了振动传递测试、振动耐久、强度及低温等型式试验。结果表明,研制的轻量化缸体力学和试验性能满足要求,重量降幅高达60%,为轨道交通车辆踏面清扫装置的轻量化技术发展提供了全新的解决方案。

With an excellent wheel tread modification function,the tread cleaning devices are widely used in our domestic metro lines.The cylinder block of conventional tread cleaner is made of nodular cast iron which accounts for 47%of the weight of the whole device,so the weight reduction of the cylinder block is of great significance.For this reason,the paper presents the design of materials for the light weight cylinder block,selection and design of materials based on Series 7 aluminum alloy and the optimization of material composition to further improve the material properties.Four kinds of techniques for the forging and heat treatment processes are then verified,and the results show that the tensile strength and yield strength of the material is dramatically improved over the nodular cast iron.In the meantime,simulation and verification of the whole device mode,vibration fatigue and vibration strength of the tread cleaning device is carried out to verify the influence of the change of materials on the performance of the whole system,and also type tests of vibration transmission,vibration endurance,strength and low temperature are implemented in consideration of the requirements on the type test of the cleaning device.Test results demonstrate that the mechanical properties and experimental test of the newly developed light cylinder block meet the requirements with a weight reduction as much as 60%,which provide a new solution to the lightweight technology for the tread cleaning device of rail transit vehicles.