城市轨道交通车辆转向架一系钢弹簧疲劳断裂应力研究
舒友薛世海刘志远周殿买王宇张文康赵洪帝
Stress Analysis of Fatigue Fracture in Primary Steel Springs for Urban Rail Transit Vehicle Bogies
SHU YouXUE ShihaiLIU ZhiyuanZHOU DianmaiWANG YuZHANG WenkangZHAO Hongdi
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作者信息:中车长春轨道客车股份有限公司国家轨道客车工程研究中心，130062，长春
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Affiliation:National Engineering Research Center of Railway Vehicles, CRRC Changchun Railway Vehicles Co., Ltd., 130062, Changchun, China
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关键词:
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Key words:
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DOI:10.16037/j.1007-869x.2025.02.014
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中图分类号/CLCN:U270.33
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栏目/Col:研究报告
摘要:
［目的］城市轨道交通车辆转向架大多采用转臂定位结构。该结构下的一系钢弹簧常发生断裂问题，断裂区域多发生在与支撑圈接触的第一工作圈。导致钢弹簧断裂的影响因素较多，需要对此进行深入分析。［方法］结合车辆实际运用情况，优化了钢弹簧应力的计算方法，以具体项目设计参数为输入，评估了钢弹簧在考虑横向载荷后的应力水平情况，并计算其应力占比。选取某项目转向架一系钢弹簧组进行台架试验研究，描述了台架试验的设备及工装，一系内外螺旋钢弹簧贴片布置，以及试验加载及数据分析等情况。分析了B组内圈弹簧的应力测试结果，并以某测点在转臂侧的受力情况为例，分析了车辆采用转臂定位结构时钢弹簧的运用工况，重点分析了转臂转动对钢弹簧不同位置处所受应力的影响。最后从改善弹簧疲劳应力及接触线控制2个方面，对弹簧疲劳断裂的应对措施提出了建议。［结果及结论］此类弹簧疲劳断裂并非由于设计裕量不足引起，而是在制造过程中存在夹砂、聚粉及人工修磨不当等问题，导致接触线不连续，钢弹簧发生了应力集中。
Abstracts:
［Objective］ Bogies of urban rail transit vehicles often adopt a swing-arm positioning structure, within which the primary steel springs are prone to fracture, and typical fractures occur at the first working coil in contact with the support ring. Various factors contribute to the fatigue fracture of steel springs, necessitating an in-depth analysis. ［Method］ Considering actual vehicle operating conditions, the stress calculation method for steel springs is optimized. Using specific project design parameters as inputs, the stress levels of the steel springs under lateral load conditions are evaluated, and the proportion of stress contributions is calculated. A bench test is conducted on the primary steel spring set of a selected project bogie, and the setup and tooling of the bench test, including the arrangement of the inner and outer strain gauges on primary helical steel springs, test loading procedures, and data analysis methods, are expounded. Stress test results for the inner coil of Spring Group B are analyzed. Using a measurement point on the swing-arm side as an example, the operating conditions of steel springs when vehicle adopts a swing-arm positioning structure is analyzed, with emphasis on the impact of swing-arm rotation on stress at different steel spring positions. Finally, countermeasures against spring fatigue fractures are proposed by improving spring fatigue stress and controlling catenary wire continuity. ［Result & Conclusion］ The fatigue fractures of such springs are not caused by insufficient design margins, but rather by manufacturing defects, such as sand inclusions, powder aggregation, and improper manual grinding, that result in discontinuities in catenary wires, leading to stress concentration in the steel springs.
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