Life Prediction of Gearbox Body by Modified Quasi-static Superposition Method
-
摘要: 针对某型内燃机车齿轮箱箱体出现裂纹的情况，建立齿轮箱箱体有限元模型，提出了一种根据实测动应力修正准静态叠加法的应力时间历程计算方法，对单位加速度激励下的响应进行修正。分别用准静态叠加法和基于实测动应力修正的准静态叠加法计算绝对值最大主应力时程，使用雨流计数法对应力时程进行循环计数，根据Miner累积损伤理论对齿轮箱箱体寿命进行预测，后者预测结果与实际结果较为接近。两种方法计算结果差异较大，初步推测所测齿轮箱体发生共振，并通过对比加速度谱的频谱分析结果与齿轮箱箱体模态分析结果进行了验证。该研究为齿轮箱箱体结构设计和优化时疲劳寿命的预测提供了参考。Abstract: In order to trace the cause of gearbox body cracks of a diesel locomotive, a finite element model for the gearbox was established. A modified quasi-static superposition method according to the real dynamic stress was proposed to correct the response produced by unit acceleration and obtain the stress-time history. The maximum absolute principal-stress-time history was respectively acquired by the quasi-static superposition method and modified quasi-static superposition method. Then, the rain flow counting method was used to count the cycle of stress-time history. Finally, the fatigue life of the gearbox body was predicted with Miner's cumulative damage theory. The result of the latter method is in a good agreement with the experimental. The significant difference between the result via two methods is preliminarily believed to be caused by the resonance of gearbox body. It is proved by comparison between the acceleration spectrum analysis and the gearbox body modal analysis. This investigation provides references for predicting the fatigue life of gearbox body in structural design and optimization.
-
Key words:
- gearbox body /
- fatigue life /
- modified quasi-static superposition method /
- resonance
-
表 2 各位置实测及虚拟测试动应力最大值对比
测点位置 测点编号 实际测试最大动应力/MPa 虚拟测试最大动应力/MPa 比值
(实际虚拟)齿轮箱上箱体
车轮侧立板
合口拐角处1-0° 67.98 78.17 0.870 1-45° 51.70 65.93 0.784 1-90° 12.36 14.81 0.835 齿轮箱上箱体
电机侧立板
合口拐角处2-0° 53.32 62.08 0.859 2-45° 23.46 29.36 0.799 2-90° 13.44 15.37 0.874 挡油板与齿轮箱
下箱体焊缝附近3 87.02 100.74 0.864 抱轴箱安装座
上部焊缝附近4 69.83 79.01 0.884 
下载: 导出CSV
表 3 危险位置损伤及疲劳寿命值
km 位置 损伤D 疲劳寿命L 齿轮箱上箱体车轮侧
立板合口拐角处4.142×10-4 4.684×105 齿轮箱上箱体电机侧
立板合口拐角处1.123×10-3 1.727×105 挡油板与齿轮箱下箱体焊缝 1.085×10-3 1.788×105 抱轴箱安装座上部焊缝 8.434×10-4 2.300×105 抱轴箱安装座下部焊缝 4.558×10-5 4.256×106
下载: 导出CSV
表 4 齿轮箱箱体模态计算结果
阶数 固有频率/Hz 模态形式 1 57.57 轮对侧侧板一阶局部振动 2 71.12 两侧侧板一阶局部振动 3 86.63 轮对侧侧板二阶局部振动+
电机侧侧板一阶局部振动4 100.22 两侧侧板二阶局部振动 5 109.81 轮对侧侧板二阶局部振动 6 117.06 两侧侧板二阶局部振动 7 125.01 轮对侧侧板三阶局部振动+
电机侧侧板一阶局部振动8 134.49 轮对侧侧板二阶局部振动 9 157.52 电机侧侧板三阶局部振动 10 163.81 轮对侧侧板四阶局部振动
下载: 导出CSV
-
[1] Heege A, Betran J, Radovcic Y. Fatigue load computation of wind turbine gearboxes by coupled finite element, multi-body system and aerodynamic analysis[J]. Wind Energy, 2007, 10(5):395-413 doi: 10.1002/(ISSN)1099-1824 [2] 杨广雪, 李广全, 刘志明, 等.轮轨激励下高速列车齿轮箱箱体振动特性分析研究[J].铁道学报, 2017, 39(11):46-52 doi: 10.3969/j.issn.1001-8360.2017.11.007Yang G X, Li G Q, Liu Z M, et al. Vibration characteristics analysis of gearbox housing system of high-speed train subjected to wheel-rail excitation[J]. Journal of the China Railway Society, 2017, 39(11):46-52(in Chinese) doi: 10.3969/j.issn.1001-8360.2017.11.007 [3] 张彦吉, 董桉吉.试论高速动车组齿轮箱疲劳裂纹产生机理[J].中国战略新兴产业, 2017(28):142 http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=QKC20172017092100074917Zhang Y J, Dong A J. Discussion on mechanism of fatigue crack in gearbox of high-speed EMU[J]. China Strategic Emerging Industries, 2017(28):142(in Chinese) http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=QKC20172017092100074917 [4] 李广全, 刘志明, 王文静, 等.高速动车组齿轮箱疲劳裂纹机理分析研究[J].机械工程学报, 2017, 53(2):99-105 http://d.old.wanfangdata.com.cn/Periodical/jxgcxb201702013Li G Q, Liu Z M, Wang W J, et al. Fatigue crack mechanism study on high-speed EMU gearbox[J]. Journal of Mechanical Engineering, 2017, 53(2):99-105(in Chinese) http://d.old.wanfangdata.com.cn/Periodical/jxgcxb201702013 [5] 潘红明.基于三区间法的高速动车组齿轮箱体疲劳寿命研究[D].成都: 西南交通大学, 2016 http://cdmd.cnki.com.cn/Article/CDMD-10613-1016177492.htmPan H M. Study on gearbox fatigue life analysis by steinberg method[D]. Chengdu: Southwest Jiaotong University, 2016(in Chinese) http://cdmd.cnki.com.cn/Article/CDMD-10613-1016177492.htm [6] 袁文东.标准动车组齿轮箱箱体强度分析与寿命预测[D].北京: 北京交通大学, 2016 http://cdmd.cnki.com.cn/Article/CDMD-10004-1016074226.htmYuan W D. Analysis on the strength and fatigue-life prediction of standard high-speed EMU gear box housing[D]. Beijing: Beijing Jiaotong University, 2016(in Chinese) http://cdmd.cnki.com.cn/Article/CDMD-10004-1016074226.htm [7] Le Moyne S, Tébec J L, Kraemer J C. Source effect of ribs in sound radiation of stiffened plates, experimental and calculation investigation[J]. Acta Acustica United with Acustica, 2000, 86(3):457-464 http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=f6997ac7d02ce7fd4621dadfa0cadbc5 [8] Le Moyne S, Tébec J L. Ribs effects in acoustic radiation of a gearbox-their modeling in a boundary element method[J]. Applied Acoustics, 2002, 63(2):223-233 doi: 10.1016/S0003-682X(01)00026-3 [9] Breton S P, Moe G. Status, plans and technologies for offshore wind turbines in Europe and North America[J]. Renewable Energy, 2009, 34(3):646-654 doi: 10.1016/j.renene.2008.05.040 [10] 陈忠伟, 卢宁, 杨建伟.城市轨道列车齿轮箱模态及振动响应分析[J].机械传动, 2016, 40(12):111-116 http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=QKC20162017010700037361Chen Z W, Lu N, Yang J W. Analysis of modal and vibration response of gearbox of urban rail train[J]. Journal of Mechanical Transmission, 2016, 40(12):111-116(in Chinese) http://www.wanfangdata.com.cn/details/detail.do?_type=perio&id=QKC20162017010700037361 [11] 常程城.高速列车齿轮箱线路试验及振动传递关系研究[D].北京: 北京交通大学, 2015 http://cdmd.cnki.com.cn/Article/CDMD-10004-1015558227.htmChang C C. Research on transmission of vibration of high speed train gear box and gear box line test[D]. Beijing: Beijing Jiaotong University, 2015(in Chinese) http://cdmd.cnki.com.cn/Article/CDMD-10004-1015558227.htm [12] 阳光武, 肖守讷, 金鼎昌.基于虚拟样机技术的地铁车辆构架疲劳寿命仿真[J].机车电传动, 2004(3):39-41 doi: 10.3969/j.issn.1000-128X.2004.03.013Yang G W, Xiao S N, Jin D C. Fatigue life simulation of metro vehicle bogie frame based on virtual prototype technology[J]. Electric Drive for Locomotives, 2004(3):39-41(in Chinese) doi: 10.3969/j.issn.1000-128X.2004.03.013 [13] 李凡松, 邬平波, 曾京, 等.构架三种常用疲劳强度校核方法对比研究[J].机械工程学报, 2014, 50(14):170-176 http://d.old.wanfangdata.com.cn/Periodical/jxgcxb201414024Li F S, Wu P B, Zeng J, et al. Study on the differences between the three common fatigue strength analysis methods for bogie frame[J]. Journal of Mechanical Engineering, 2014, 50(14):170-176(in Chinese) http://d.old.wanfangdata.com.cn/Periodical/jxgcxb201414024 [14] Baek S H, Cho S S, Joo W S. Fatigue life prediction based on the rainflow cycle counting method for the end beam of a freight car bogie[J]. International Journal of Automotive Technology, 2008, 9(1):95-101 doi: 10.1007/s12239-008-0012-y [15] Choi J H. Shape design sensitivity analysis and optimization of general plane arch structures[J]. Finite Elements in Analysis and Design, 2002, 39(2):119-136 doi: 10.1016/S0168-874X(02)00073-2 -
点击查看大图
图(11) / 表(4)
计量
- 文章访问数: 453
- HTML全文浏览量: 123
- PDF下载量: 20
- 被引次数: 0
