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Shape Optimization and Fatigue Strength Research of Wheel

Author: XuChuanLai
Tutor: MiCaiYing
School: Southwest Jiaotong University
Course: Vehicle Engineering
Keywords: Wheel Shape Optimization Flexible Body Wheel-Rail Contact Force Random Fatigue Life
CLC: U270.33
Type: Master's thesis
Year: 2009
Downloads: 326
Quote: 6
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Abstract


Excitation frequency of wheel-rail system is increased, the service environment of the lightweight wheelsets is deteriorated, and the structure fatigue reliability issues become more and more prominent with the continuous increase of train speed. The random fatigue life prediction of the wheel is achieved by using combination method of the flexible multi-body dynamic analysis, finite element analysis and fatigue life analysis in virtual computer environment. The random load spectrum is given by dynamics simulation. The structure will have a certain degree of elastic deformation when it is accelerating, decelerating motion or under the influence of load. Therefore, the random load spectrum is given in considering of flexibility of wheelset and brake discs. The influence of wheel-rail contact force is also analyzed.Optimal design method is one important direction of technical innovation and innovative design. This method has important guiding significance and practical value for improving the design level and quality of product, reducing production costs and material consumption, improving product performance and life, and shortening design cycles. The lightweight wheel is designed by optimal design method. Thereby, the dynamic performance of vehicle is improved, the comfort level is increased, the railway maintenance costs, train running resistance, work load of bearing structure and vibration impact energy are reduced.The parametric optimal design modeling of CRC CW400 trailer bogie wheel is accomplished based on APDL language of ANSYS software. The constraint conditions are fatigue analysis load and load conditions specified in UIC510-5 and EN13979-1. The objective function is wheel quality. The geometric shape of the wheel structure is optimized. The parametric optimal design and structural strength optimization of the wheel are analyzed together. The theoretical basis is provided for other aspects of parametric optimization of the wheel.The optimized wheel web thickness is reduced. The wheel quality reduces 22.89kg. The structural strength of the optimized wheel meets the requirements of UIC510-5 and EN13979-1. The maximum radial stress of optimal wheel is increased, and the minimum radial stress is reduced compared with the original wheel. The axial stress has no significant change. The change of the radial stress is largest with the load of curve passing condition, the maximum radial stress increases 41.1MPa and the minimum radial stress reduces 69.0MPa. The stress level and material utilization of optimal wheel web is increased. The optimal wheel gives full play to the mechanical properties of the material of the wheel. The optimal design method is conducive to reducing the quality of the wheel structure.The natural frequency related to wheel web of optimal wheel wheelset is significantly reduced compared with the original wheelset. The natural frequency of 1st anti-symmetric bending mode,2nd symmetric bending mode,1st symmetric umbrella mode and 1st anti-symmetric umbrella mode decrease 30.6Hz,45.7Hz, 64.8Hz and 87.2Hz respectively.The flexible wheelsets and brake discs are modeled by using ANSYS finite element software and SIMPACK dynamic software. The random load spectrum is given by the dynamic analysis of flexible multi-body trailer dynamic model. The fatigue life is predicted with FE-Safe software. The flexible of wheelset has small influence of wheel-rail contact vertical and lateral force with Germany’s low interference orbit spectrum as wheel-rail input conditions. The wheel web has minimum life of 14 million kilometers. The minimum safety factors are 1.383 and 1.000 when the wheel run 2 and 14 million kilometers respectively, and the wheel meets the application requirements. The lateral forces acting on the wheel have bigger influence of the wheel stress state and fatigue life than the vertical forces.

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CLC: > Transportation > Rail transport > Vehicle Engineering > General issues > Body construction and equipment > Traveling part
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