基于复合材料应用和结构优化的车体轻量化关键技术

Key Technology of Lightweight Carbody Based on Composite Material Application and Structural Optimization

车体轻量化设计是实现高速动车组高水平轻量化的必然选择。通过对高速动车组车体质量占比、车体组成结构质量占比情况进行分析,明确了车体轻量化设计的必要性。对比6000系与7000系铝合金车体牵引梁的结构性能发现,7000系铝合金牵引梁在结构安全系数提升的情况下,牵引梁壁厚减少2.0~4.0 mm,质量减轻约7.5%。对比复合材料与传统金属材料的性能差异,系统介绍复合材料在高速动车组的应用情况、“积木式”试验验证及无损检测方法等,并阐述了复合材料面临的结构强度和适应性问题。以某型动车组车体为例进行结构优化设计,在满足车体结构静强度、疲劳强度、模态等性能要求的前提下,车体结构质量由10.35 t降至8.88 t,质量减轻约14.2%;并采用新技术实现车窗、座椅、电器柜、空调系统等车上设备设施的轻量化。

The lightweight design of carbody is necessary for high speed EMUs to achieve high-level lightweight.By analyzing the proportion of carbody mass and the proportion of carbody assembly structural mass of high speed EMUs,the necessity of carbody lightweight design is clarified;by comparing the structural performance of the draft sill of 6000 series and 7000 series aluminum alloy car bodies,it is found that the wall thickness of the draft sill of 7000 series aluminum alloy draft sill is reduced by 2.0~4.0 mm and the mass is reduced by about 7.5%when the structural safety factor is improved;by comparing the performance differences between composite materials and traditional metal materials,this paper systematically introduces the use of composite materials in high speed EMUs,“building block”test verification and NDT method,and expounds the structural strength and adaptability problems faced by composite materials.Taking the carbody of a certain type of EMU as an example,this paper studies for structural optimization design,and the results show that on the premise of meeting the requirements of static strength,fatigue strength and modal performance of the carbody structure,the mass of the carbody structure is reduced from 10.35 t to 8.88 t,and the mass is reduced by about 14.2%;new technologies are adopted to realize the lightweight of on-board equipment and facilities such as windows,seats,electrical cabinets and air conditioning systems.