铁路货车车体疲劳台架试验仿真模拟的关键技术研究

Key-technology Research of Fatigue-test Rig Simulation on Railway Freight Car Body

为解决全尺寸车体疲劳试验周期长、成本高等问题,基于刚柔耦合多体动力学理论,依托铁路货车全尺寸车体疲劳试验台架,开展了台架试验仿真模拟关键技术研究。首先建立由虚拟刚性试验台架与柔性车体组成的刚柔耦合多体动力学试验模型,然后通过侧滚、浮沉等典型工况完成虚拟试验系统的理论验证,最后,将试验的随机驱动载荷作为仿真输入,开展虚拟试验台架上的车体动态响应计算与试验对比。结果表明:车体枕梁加速度仿真与试验结果吻合较好,加速度的频谱形状一致;关键部位动应力仿真结果与试验测试结果波形一致,验证了虚拟试验方法的合理性。该虚拟试验台架模型的建立为提升铁路货车产品疲劳可靠性提供了有力依据。

In order to solve the problems of long-term and high cost of fatigue test on full-size car body,based on the rigid-flexible coupled multi-body dynamics theory and the full-size vehicle body fatigue test rig of railway wagon,the key technology of test rig simulation was carried out.Firstly,a rigid-flexible coupled multi-body dynamics model consisting of a virtual rigid test rig and a flexible car body were established.The theoretical verification of the virtual test system was completed by typical working conditions such as roll,float and sink.Finally,the random drive loads of the test was used as the simulation input,and the dynamic response calculation and test comparison of the vehicle body on the virtual test rig were carried out.The results show that the maximum error of the simulation and test of the occipital beam acceleration is 31%,and the spectrum distribution of the acceleration are the same.The simulation results of the dynamic stress of the key parts are closed to the test results,which verifies the rationality of virtual test method.The virtual test rig model provides a powerful basis for the development of virtual rig tests in the field of railway wagons.