动车组制动系统箱体类部件轻量化设计方法

Lightweight Design Method for Box Components of EMU Braking System

针对材料替代轻量化设计中如何确定新结构板材厚度的问题,在推导箱体类部件的板材厚度与固有频率关系的基础上,提出以轻量化设计后铝合金箱体的刚度与原碳钢箱体的刚度相当为目标,通过获取箱体固有频率确定铝合金箱体各部分板材厚度的轻量化设计方法。以某型动车组制动控制箱体为例,提出铝合金制动控制箱体的设计方案,并进行仿真和试验验证。结果表明:使用铝合金箱体时制动控制装置前3阶固有频率分别为66,69和71Hz,与使用碳钢箱体时相当;与碳钢箱体比,铝合金箱体的重量减轻了59%,静强度安全系数从3.5提高到4.2,疲劳强度安全系数从8.3降到1.6,但仍满足标准EN12663-1—2010规定的要求;采用轻量化设计的铝合金箱体满足疲劳强度的要求,实现了轻量化的目标。

In view of the problem that how to determine the plate thickness of new structures in the light weight design of material substitution,the relationship between the plate thickness of box components and the natural frequency was derived.On this basis,a lightweight design method was proposed for determining the plate thickness of each part of aluminum alloy box by acquiring the natural frequency of the box with the objective that the stiffness of aluminum alloy box was equivalent to that of the original carbon steel box after lightweight design.Taking the braking control box of certain EMU for example,the design scheme for the braking control box of aluminum alloy was presented and verified by simulation and test.Results indicated that the first three-order natural frequencies of braking control module with aluminum alloy box were 66,69 and 71 Hz,which were equivalent to those of the braking control module using original carbon steel box.Compared with the original carbon steel box,the weight of aluminum alloy box was nearly reduced by 59%,the safety factor of static strength was increased from 3.5 to 4.2,and the safety factor of fatigue strength was decreased from 8.3 to 1.6,but still satisfied the requirement of standard EN12663-1—2010.The lightweight aluminum alloy box was designed to satisfy the requirement of fatigue strength and achieve the goal of lightweight.