Virtual Experiments to Predict Bolster Fatigue Lifetime Based on FEM Model Validated by Static Tests
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摘要: 为了研究地铁车辆枕梁服役安全性问题，考虑到大量疲劳实验耗时长且成本高，利用虚拟实验方法对枕梁结构疲劳寿命进行评估，根据EN12663-1标准设计枕梁静力实验，获得枕梁表面特征点的应力值和位移值；然后对枕梁进行有限元建模并仿真，对比静力实验结果，调整后获得与枕梁实际结构相符的有限元模型；最后利用Monte Carlo方法，进行地铁车辆枕梁在恒幅载荷与变幅载荷作用下的虚拟疲劳实验. 研究结果表明：在标准规定的恒幅载荷作用下，该地铁车辆枕梁寿命大于1 000万次载荷循环的可靠度约为0.73；在变幅载荷作用下，寿命大于1 000万次载荷作用的可靠度约为0.81；因此，该地铁车辆枕梁完全满足设计与使用要求.Abstract: To study the service safety of a metro train bolster, a virtual experiment method was used to evaluate fatigue lifetime, avoiding time-consuming and expensive fatigue tests. A static test of the bolster was designed based on the EN12663-1 standard, and the stresses and displacements on its surface were measured. An FEM model of the bolster was then established and analysed for comparison with the static test results; an FEM model that is consistent with the actual structure was thus determined. Finally, virtual experiments of the bolster under constant amplitude loads and variable amplitude loads were conducted using a Monte Carlo method. It is concluded that the fatigue reliability of this bolster with 107 loads cycles is 0.73 under constant amplitude loads and 0.81 under variable amplitude loads. This metro train bolster therefore meets the design and service requirements.
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Key words:
- static test /
- finite element method /
- virtual experiments /
- reliability /
- lifetime prediction
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图 8 实测位移与计算位移对比
Figure 8. Comparison of measured displacements and calculated displacements
图 11 恒幅载荷虚拟实验流程
Figure 11. Processes of the virtual experiment under constant amplitude loads
图 13 变幅载荷虚拟实验流程
Figure 13. Processes of the virtual experiment under variable amplitude loads
图 14 恒幅载荷下虚拟实验结果
Figure 14. Results of the virtual experiment under constant amplitude loads
图 15 恒幅载荷下寿命概率密度曲线
Figure 15. Lifetime probability density curve under constant amplitude loads
图 16 变幅载荷下虚拟实验结果
Figure 16. Results of the virtual experiment under variable amplitude loads
图 17 变幅载荷下寿命概率密度曲线
Figure 17. Lifetime probability density curve under variable amplitude loads
表 1 应力测点测量数据
Table 1. Results of the stress measurement sites
测点 应力值 测点 应力值 测点 应力值 1 3.381 7 – 0.552 13 0.759 2 3.243 8 – 5.175 14 2.691 3 – 0.897 9 – 4.209 15 2.208 4 2.277 10 – 7.452 16 3.657 5 2.208 11 4.761 17 0.759 6 8.556 12 – 0.138 18 – 5.589 
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表 2 位移测点测量数据
Table 2. Results of the displacement measurement sites
测点 位移值/mm 1 1.752 2 2.513 3 1.832
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表 3 应力计算结果
Table 3. Stress calculation results
测点 应力值 测点 应力值 测点 应力值 1 3.580 7 –1.300 13 1.004 2 3.151 8 –5.590 14 2.924 3 –0.971 9 –10.814 15 2.191 4 2.536 10 –13.253 16 7.210 5 2.240 11 4.7454 17 1.148 6 8.220 12 0.184 18 –1.717
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