100%低地板轻轨车的碳纤维及铝合金材料混合车体减重方案
刘鸿宇刘宇张庆刚
Weight Reduction Scheme of Carbon Fiber/Aluminum Alloy Hybrid Carbody for 100% Lowfloor Light Rail Vehicle
LIU HongyuLIU YuZHANG Qinggang
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作者信息:中车唐山机车车辆有限公司， 064099， 唐山
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Affiliation:CRRC Tangshan Co., Ltd., 064099, Tangshan, China
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关键词:
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Key words:
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DOI:10.16037/j.1007-869x.2023.08.050
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中图分类号/CLCN:U270.4
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栏目/Col:应用技术
摘要:
目的：车体结构减重已面临瓶颈，需通过合理选择车体材料来实现减重，故提出了一种应用于100%低地板轻轨车的碳纤维和铝合金材料混合车体减重方案。方法：以某100%低地板轻轨车全焊接铝合金车体为对比对象，分析其车体结构和车体各部位所用材料，并对铝合金车体进行静强度仿真分析。结合各大部件应力水平，按材料减重和安全可靠的思路，提出碳纤维和铝合金材料混合车体方案。其中，确定应力水平较高的车体底架仍采用铝合金型材，其余侧墙、车顶及端墙等部件采用碳纤维+PVC(聚氯乙烯)泡沫复合材料，碳纤维牌号选取T300，碳纤维大部件间采用铆接结构连接。根据EN 126631：2010，对碳纤维和铝合金材料混合车体结构进行静强度仿真分析，并运用TsaiWu强度准则计算面内应力强度因子，对碳纤维和铝合金材料混合车体进行评价。总结了碳纤维材料的优点及在车体应用的注意事项。结果及结论：碳纤维和铝合金材料混合车体质量比全焊接铝合金车体质量减少15%以上。仿真计算结果表明，碳纤维和铝合金材料混合车体的强度满足要求。说明采用碳纤维和铝合金材料混合车体兼顾了轻量化设计要求和强度要求。
Abstracts:
Objective: Carbody structure weight reduction is faced with bottlenecks. It is needed to achieve weight reduction through reasonable selection of carbody materials. In this regard, a weight reduction scheme for 100% lowfloor light rail vehicle of CFAA (carbon fiber and aluminum alloy) material hybrid carbody is proposed. Method: A fully welded aluminum alloy carbody for 100% lowfloor light rail vehicle is taken as a comparison object. The structure and the materials used for each component of the carbody are analyzed, and static strength simulation analysis is conducted on aluminum alloy carbody. Based on the stress level of each major component, a CFAA material hybrid carbody scheme is proposed according to the principles of material weight reduction and safetyreliability. In the scheme, the vehicle underframe with higher stress level still uses aluminum alloy profiles, while other components such as side walls, roof and end walls use carbon fiber + PVC (polyvinyl chloride) foam composite materials. The grade of selected carbon fiber is T300, and rivet joints are used to connect large carbon fiber components. According to EN 126631: 2010, static strength simulation analysis is carried out on the CFAA hybrid carbody structure, and the inplane stress strength factor is calculated using the TsaiWu strength criterion to evaluate the hybrid carbody. The advantages of carbon fiber material and precautions on carbody application are summarized. Result & Conclusion: The weight of CFAA material hybrid carbody is reduced by more than 15% compared to the fully welded aluminum alloy carbody. The simulation results show that the strength of CFAA hybrid carbody meets the requirements. It is demonstrated that the use of CFAA material hybrid carbody meets the requirements for both lightweight design and strength.
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