CN113806858B - Motor train unit body design method based on structural topology optimization - Google Patents

Motor train unit body design method based on structural topology optimization Download PDF

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CN113806858B
CN113806858B CN202110949936.9A CN202110949936A CN113806858B CN 113806858 B CN113806858 B CN 113806858B CN 202110949936 A CN202110949936 A CN 202110949936A CN 113806858 B CN113806858 B CN 113806858B
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于庆斌
邵晴
何玲利
刘春艳
张金
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CRRC Changchun Railway Vehicles Co Ltd
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Abstract

The invention provides a motor train unit body design method based on structural topology optimization, which breaks through the traditional sensitivity analysis and proxy model-based structural design method of the existing motor train unit body, implements the structural topology optimization idea into the structural design of the motor train unit body, and invents a brand-new motor train unit body design method based on structural topology optimization by researching the aspects of comprehensive optimization design of the size, shape and topology of the motor train unit body and the like, and reduces the weight of the motor train unit body to the greatest extent on the premise of ensuring that the performance indexes such as the strength, the mode and the fatigue of the motor train unit body are unchanged.

Description

Motor train unit body design method based on structural topology optimization
Technical Field
The invention relates to the field of railway passenger car bodies, in particular to a body related method based on structural topology optimization.
Background
At present, the structural design optimization of the railway vehicle body is mainly based on methods such as sensitivity analysis, agent models and the like, the shape and the size of the structure are optimized, a designer refers to related design rule requirements according to the actual structural characteristics of the vehicle body, and on the basis of reasonably optimizing the structural design of the vehicle body, the profile section, the edge beam of the underframe and other vehicle body structural details are correspondingly adjusted and optimized, but the conventional size and shape optimization design has the limitations of high dependence on design prototypes, small design variable scale, limited performance optimization space and the like, so that a new structural design method is urgently needed to break through the design limit of the size and shape optimization, further improve the lightweight design level of the vehicle body structure of the railway vehicle, and optimize the integral use performance of the railway vehicle.
In recent years, the topology optimization technology can obtain high-performance structural design without depending on experience of engineering personnel and designers, is gradually expanded to a plurality of other fields including fluid, acoustics, electromagnetism, optics and the like, and the light-weight technology based on the topology optimization method has become a main development trend of the high-speed train in the future, and although the optimization research of the railway vehicle body structure at home and abroad is relatively wide, the topology optimization technology still mainly focuses on a size/parameter optimization algorithm, and the research of the vehicle body structure design method based on the topology optimization is not enough.
Disclosure of Invention
The invention aims to research a brand-new vehicle body structure design method, which comprises comprehensive optimization of various design variables such as vehicle body size, shape, topology and the like, and provides a comprehensive optimization design method for the structure size, shape and topology by means of ideas of simulation design and reconstruction regeneration, wherein the three design variables of the vehicle body structure such as the size, shape and topology are integrally considered, the optimal combination of the structure size, shape and topology is found, and the structural topology optimization is performed on the aluminum vehicle body structure on the premise of ensuring that the performance indexes such as vehicle body strength, mode and fatigue are unchanged, so that the vehicle body quality is reduced to the greatest extent.
In order to achieve the above purpose, the invention provides a motor train unit body design method based on structural topology optimization, which comprises the following steps:
step 1: based on the existing motor train unit body structure characteristics, analysis of force flow transmission paths of the body structure in the longitudinal direction, the vertical direction and the transverse direction is carried out, bearing characteristics of three-way force flow transmission of the body structure are researched, and weak parts and strength redundant parts of structural strength are found. The method comprises the following steps: firstly, dividing a vehicle body structure into a plurality of section parts by taking the welding seam positions among section materials forming the vehicle body as a reference, selecting working conditions with the greatest influence on structural strength and worse working conditions to be preferentially calculated and analyzed according to EN12663 standard, respectively extracting Von-Mises stress sigma of different section materials, comparing the Von-Mises stress sigma with allowable stress [ sigma ] of the section materials, and considering that the section strength is weak when the number of [ sigma ]/sigma >0.85 nodes is more than 15% of the total number of the section material nodes; when [ sigma ]/sigma <0.60 nodes number is greater than 35% of the total number of block section nodes, the part strength is considered redundant; the section bar part with larger redundancy can be obtained through calculation, analysis and judgment, and the part is taken as a key object for the next light weight; as is known from the calculation of a plurality of vehicle bodies, the underframe roof side rail and the roof side rail are both lightweight key objects.
Step 2: the method comprises the steps of (1) researching the matching relation of strength, rigidity, stability, crashworthiness, weight and process of a main bearing structure, a secondary bearing structure and an end safety protection structure of a vehicle body with the aim of lightening the vehicle body, providing boundary conditions (such as weight indexes, modal indexes, strength standards and the like) of the vehicle body design, combining main contour technical parameters of the vehicle body, establishing a vehicle body contour model, taking determined technical parameters (such as a welding seam position, a wire slot position, a door and window installation position and the like) as input parameters of structural topology optimization, and forming a preliminary calculation model;
step 3: as the influence of the mode on the vehicle body structure is larger, the vehicle body mode analysis is firstly carried out on the calculation model, and according to the step 1, the influence of the roof side rail and the underframe side rail on the vehicle body mode is larger, the topology optimization is carried out as a key selection object, the topology configuration scheme meeting the vehicle body mode requirement is obtained by defining the density attribute of the material, and other component parts are also subjected to the structure topology optimization according to the method at the same time, so that the corresponding configuration scheme is obtained, and the configuration scheme of the vehicle body is formed;
step 4: performing reconstruction and back-substitution analysis on the topological structure formed in the step 3, and checking the static strength and fatigue performance of the topological structure according to all applicable working conditions required by the EN12663 standard until a structure meeting the EN12663 standard requirement is found, so that an optimal structural topological optimization structure is obtained;
step 5: because the topology configuration of the section bar which is obtained in the step 4 and forms the car body is complex, the shaping is very difficult by the prior art means, the engineering design of the manufacturing construction is needed to be carried out on the topology configuration of each section bar, so that the topology configuration meets the requirements of the manufacturing shaping process and production equipment, and the topology configuration engineering car body structure which can be manufactured is formed.
Step 6: and (3) reestablishing a calculation model of the configuration engineering vehicle body structure obtained in the step (5), carrying out modal, fatigue and static strength analysis again according to the EN12663 standard and related technical requirements, and finding out a structure meeting the requirements to obtain the final structure topology optimization vehicle body structure.
Further, the width of the motor train unit body structure is 3360mm, the height from the rail surface is 3950mm, and the length of the motor train unit body structure is 25000mm.
Further, for the part with redundant strength, the thickness and welding position of the outer frame are reserved for the edge beams of the underframe and the edge beams of the upper frame, the rest parts are unchanged, after the selected loads are respectively loaded, the minimum flexibility is taken as a calculation target, the volume fraction is set to 15%, the weight and the stress are taken as constraints, topology optimization is carried out, the original (0-1) discrete variable optimization problem is relaxed, the continuously-changed intermediate density is allowed to appear, then a proper interpolation relation is established between the elastic modulus of the material and the density of the material, punishment is introduced to eliminate the intermediate density, and finally, the 0-1 structural topology is obtained.
Further, performing topological optimization on the part with weak strength, respectively setting other areas with weak strength as an optimal design area, keeping the thickness of an outer frame to be 3-3.5mm and the welding position, keeping the rest parts unchanged, respectively loading a selected load, setting the volume fraction to be 20% by taking the minimum flexibility as a calculation target, performing topological optimization by taking weight and stress as constraints, loosening the original (0-1) discrete variable optimization problem, allowing continuously-changed intermediate density to appear, then establishing a proper interpolation relation between the elastic modulus of the material and the density of the material, introducing punishment to eliminate the intermediate density, and finally obtaining the 0-1 structural topology.
The invention breaks through the traditional structural design method of the traditional train body based on sensitivity analysis and proxy model, implements the structural topology optimization concept into the structural design of the train body, and invents a brand-new structural topology optimization train body design method by researching the aspects of comprehensive optimization design of the size, shape, topology and the like of the train body, thereby reducing the weight of the train body to the greatest extent on the premise of ensuring that the performance indexes such as the strength, the mode, the fatigue and the like of the train body are unchanged.
Drawings
FIG. 1 is a flow chart of a topology optimization design method of a vehicle body structure;
FIG. 2 is a schematic diagram of topology optimization of a vehicle body section;
FIG. 3 is a schematic diagram of a topology optimization of a body chassis side rail;
FIG. 4 is a schematic diagram of a topology optimization of a roof rail of a vehicle body;
fig. 5 is a schematic diagram of vehicle body topology optimization.
Detailed Description
Referring to fig. 1, the invention discloses a novel motor train unit body structure design method based on structural topology optimization, which optimizes the structural size, shape and topology of the whole motor train unit, reduces the quality of the motor train unit to the maximum extent, meets the requirement of the next generation 400km/h high-speed motor train unit on the weight of the motor train unit, and the specific implementation scheme comprises the following steps:
1. based on the existing series vehicle structural characteristics, the analysis of force flow transmission paths of the vehicle body structure in the longitudinal direction, the vertical direction and the transverse direction is carried out, the bearing characteristics of three-way force flow transmission of the vehicle body structure are researched, and weak parts and strength redundant parts of structural strength are found.
Taking an aluminum alloy car body structure of a motor train unit adopting a hollow section bar of a certain model as a topological optimization object, wherein the section width of the car body structure is 3360mm, the height from a rail surface is 3950mm, and the length of a car is 25000mm; firstly, according to EN-12663 standard, three working conditions which have the greatest influence on the structural strength and are most difficult to reach are selected, and loads in different directions are applied, wherein the following table 1 is detailed:
table 1 static strength load cell
According to the calculation result, judging the weak strength part and the redundant strength part, wherein the judgment conditions are as follows:
TABLE 2 materials for vehicle body and yield strength thereof
Taking the weld joint break as a parting joint, dividing the vehicle body structure into 20 section bar parts, respectively extracting Von-Mises stress sigma of different section bar parts, comparing the Von-Mises stress sigma with allowable stress [ sigma ] of the section bar part material, and considering that the section bar part has weak strength when the number of [ sigma ]/sigma >0.85 nodes is more than 15% of the number of the section bar nodes;
when the number of [ sigma ]/sigma <0.60 nodes is greater than 35% of the number of segmented profile nodes, the partial strength redundancy is considered; the judgment shows that the lower edge beam of the underframe and the upper edge beam of the roof section bar have larger redundancy, and the parts are used as key objects for the next light weight.
2. Based on the bearing characteristics of the structure of the motor train unit body, the body is light, the influence factors and weight distribution of the service environment of the motor train are researched, and a boundary condition scheme of coupling-synergistic effect under various service environments is provided; the main bearing structure and key components of the vehicle body are used as research objects, the characteristics of light structural design and interconnection relation are analyzed, and the matching relation research of strength, rigidity, stability, weight and technology is performed.
According to influencing factors, weight distribution and EN-12663 standard, 5 static strength working conditions and 4 fatigue strength working conditions in tables 3 and 4 are selected as input working conditions from 22 static strength working conditions:
TABLE 3 static intensity calculation Condition
Table 4 fatigue calculation Condition summary
3. Comprehensively considering the factors such as connection reliability, structural strength and weight balance, process implementation feasibility, material mechanical property matching and the like of the vehicle body structure, and providing a novel vehicle body structure topology optimization design method; based on a vehicle body structure topology optimization design method, a novel lightweight vehicle body structure topology optimization and design technology research is developed by considering complex factor coupling and synergistic effects.
In order to solve the problem that the topology optimization method is difficult to realize in a large-length hollow aluminum profile structure, the method sets the positions of an underframe side beam and a roof side beam as an optimization design area, keeps the thickness and the welding position of an outer frame to be 2mm, and the rest parts are unchanged, and after the loads selected in the table 3 and the table 4 are respectively loaded, the minimum flexibility is taken as a calculation target, the volume fraction is set to be 15%, and the weight and the stress are taken as constraints to perform topology optimization, wherein the specific optimization mode comprises the following steps: the original (0-1) discrete variable optimization problem is relaxed, the continuously-changed intermediate density is allowed to appear, then a proper interpolation relation is established between the elastic modulus of the material and the density of the material, punishment is introduced to eliminate the intermediate density, and finally the 0-1 structure topology is obtained.
Under the same mass, the chassis lower edge beam with the new structure is equivalent to the original chassis lower edge beam in modal frequency, and the flexibility (deformation energy) is changed into 16 percent of the original one.
Under the same mass, the flexibility (deformation energy) of the roof side rail of the new configuration is 19.5% of that of the original structure, and the flexibility is reduced by about 80.5%; the frequency is raised by 0.4Hz and 7.6%.
On the basis, performing topology optimization on the part with weak strength, respectively setting other areas with weak strength as an optimal design area, keeping the thickness of an outer frame of 3-3.5mm and the welding position, keeping the rest parts unchanged, respectively loading the selected loads of tables 3 and 4, and performing topology optimization by taking the minimum flexibility as a calculation target, setting the volume fraction as 20%, and taking the weight and the stress as constraints, wherein the specific topology optimization mode comprises the following steps: relaxing the original (0-1) discrete variable optimization problem, allowing the continuously-changing intermediate density to appear, then establishing a proper interpolation relation between the elastic modulus of the material and the density of the material, introducing punishment to eliminate the intermediate density, and finally obtaining the 0-1 structural topology.
4. Aiming at the novel vehicle body structure after topological optimization, the safety and the reliability of the lightweight vehicle body structure designed by the invention are verified through simulation analysis and optimization verification of structures such as the vehicle body, parts, materials, such as static strength, rigidity, fatigue, connecting joints and the like, coupling vibration analysis of the vehicle body structure and external suspension equipment and connection reliability analysis of the under-vehicle suspension equipment and the vehicle body.
Finally, the section bar section with the brand new configuration is re-brought into a whole vehicle finite element model, 22 static strength working conditions, 4 fatigue strength working conditions and 2 modal working conditions are checked, and the section bar section is obtained after checking, and the optimized configuration low-order frequency is 15.6Hz, the mass is 10.15t, the rigidity is improved by 20 percent, and the mass is reduced by 7.7 percent on the premise of meeting the EN-12663 static strength and fatigue strength requirements.
The vehicle body structure designed by the structural topology optimization design method provided by the patent comprises, but is not limited to, a motor train unit vehicle body, and other vehicles are adjusted according to specific requirements of the vehicle body, and the patent only provides a brand new design method of the vehicle body structure.
A motor train unit body design method based on structural topology optimization relates to layout design of application materials in a body structure, and is suitable for motor train unit body structure scheme design meeting static strength, modal and fatigue characteristics; the invention carries out structural topology optimization design according to the method flow of FIG. 1, and mainly comprises the following steps:
(1) Acquiring force flow transmission paths of a vehicle body structure in the longitudinal direction, the vertical direction and the transverse direction, and establishing a structure finite element model of a vehicle body contour by combining main technical parameters of the vehicle body on the basis of bearing characteristics of three-dimensional force flow transmission of the vehicle body structure;
(2) Aiming at the light weight of the vehicle body, boundary conditions (such as weight indexes, modal indexes, strength standards and the like) of the vehicle body design under various service environments are proposed for influencing factors and weight distribution of the service environment of the vehicle, and the determined structural topology optimization parameters (such as weld joint positions, wire slot positions, door and window positions and the like) are input to form a preliminary calculation model (see figure 2);
(3) Firstly, carrying out vehicle body modal analysis on a calculation model, carrying out topology optimization as an important selected object because the influence of a roof upper side beam and a chassis lower side beam on the vehicle body modal is large, obtaining a topology configuration scheme meeting the vehicle body modal requirement by defining the density attribute of a material (see fig. 3 and 4), and simultaneously carrying out structure topology optimization on other component parts according to the method to obtain a corresponding configuration scheme so as to form the configuration scheme of the vehicle body (see fig. 5);
(4) Performing back-substitution analysis on the topology configuration reconstruction, and checking the static strength and fatigue performance of the topology configuration until a structure meeting the standard requirement is found, so as to obtain an optimal structure topology structure;
(5) Engineering design is carried out on the topological structure to enable the topological structure to meet the process requirements of manufacturing and forming;
(6) And carrying out modal, fatigue and static strength analysis on the configuration engineering vehicle body structure again to obtain the final structure topology optimization vehicle body structure.
The invention provides a brand-new structural topology optimization vehicle body structure optimization design method, parameter optimization is not carried out on the vehicle body structure simply any more, the influence of static strength, mode and fatigue life is taken into consideration in the early design stage, and the method has important significance for vehicle body structure design.

Claims (4)

1. The motor train unit body design method based on structural topology optimization is characterized by comprising the following steps of:
step 1: based on the existing motor train unit body structure characteristics, the analysis of force flow transmission paths of the body structure in the longitudinal direction, the vertical direction and the transverse direction is carried out, the bearing characteristics of three-way force flow transmission of the body structure are researched, and weak parts and strength redundant parts of the structural strength are found, wherein the method comprises the following steps: firstly, dividing a vehicle body structure into a plurality of section parts by taking the welding seam positions among section materials forming the vehicle body as a reference, selecting working conditions with the greatest influence on structural strength and worse working conditions to be preferentially calculated and analyzed according to EN12663 standard, respectively extracting Von-Mises stress sigma of different section materials, comparing the Von-Mises stress sigma with allowable stress [ sigma ] of the section materials, and considering that the section strength is weak when the number of [ sigma ]/sigma >0.85 nodes is more than 15% of the total number of the section material nodes; when [ sigma ]/sigma <0.60 nodes number is greater than 35% of the total number of block section nodes, the part strength is considered redundant; the section bar part with larger redundancy can be obtained through calculation, analysis and judgment, and the part is taken as a key object for the next light weight; as known from calculation of a plurality of vehicle bodies, the underframe lower side beam and the roof upper side beam are both lightweight key objects;
step 2: the method comprises the steps of researching the matching relation of strength, rigidity, stability, crashworthiness, weight and process of a main bearing structure, a secondary bearing structure and an end safety protection structure of a vehicle body with the aim of lightening the vehicle body, providing boundary conditions of the vehicle body design, taking weight indexes, modal indexes and strength standards as the boundary conditions of the vehicle body design, combining technical parameters of the vehicle body contour, establishing a vehicle body contour model, taking the determined technical parameters of a welding seam position, a wire slot position and a door and window mounting position as input parameters of structural topology optimization, and forming a preliminary calculation model;
step 3: firstly, carrying out vehicle body modal analysis on a calculation model, carrying out topology optimization by taking a roof upper side beam and a chassis lower side beam as key selection objects, obtaining a topology configuration scheme meeting the vehicle body modal requirement by defining the density attribute of a material, and simultaneously carrying out structural topology optimization on other component parts according to the method to obtain a corresponding configuration scheme, thereby forming the configuration scheme of the vehicle body;
step 4: performing reconstruction and back-substitution analysis on the topological structure formed in the step 3, and checking the static strength and fatigue performance of the topological structure according to all applicable working conditions required by the EN12663 standard until a structure meeting the EN12663 standard requirement is found, so that an optimal structural topological optimization structure is obtained;
step 5: because the profile topological structure of the automobile body is complex and is difficult to form by the prior art, the engineering design of the manufacturing construction is needed to be carried out on each profile topological structure, so that the requirements of the manufacturing and forming process and production equipment are met, and the automobile body structure with the engineering manufactured topological structure is formed;
step 6: and (3) reestablishing a calculation model of the configuration engineering vehicle body structure obtained in the step (5), carrying out modal, fatigue and static strength analysis again according to the EN12663 standard and related technical requirements, and finding out a structure meeting the requirements to obtain the final structure topology optimization vehicle body structure.
2. The motor train unit body design method based on structural topology optimization of claim 1, wherein the motor train unit body structure in the step 1 is 3360mm in width, 3950mm in height from a rail surface and 25000mm in vehicle length.
3. The motor train unit body design method based on structural topology optimization of claim 1, wherein step 3 reduces design calculation amount by: the method comprises the steps of keeping the thickness and welding position of an outer frame of 2mm on a lower boundary beam of a chassis and an upper boundary beam of a roof, respectively loading selected loads, setting the minimum flexibility as a calculation target, setting the volume fraction as 15%, restricting the weight and the stress, performing topology optimization, relaxing the original 0-1 discrete variable optimization problem, allowing the continuously changed intermediate density to appear, then establishing a proper interpolation relation between the elastic modulus of a material and the density of the material, introducing punishment to eliminate the intermediate density, and finally obtaining the 0-1 structural topology.
4. The motor train unit body design method based on structural topological optimization according to claim 1, wherein the step 3 performs topological optimization on the weak-strength part by the following method, specifically: setting other areas with weak strength as optimal design areas respectively, reserving the thickness and welding position of an outer frame of 3-3.5mm, keeping the rest parts unchanged, respectively loading selected loads, setting the minimum flexibility as a calculation target, setting the volume fraction as 20%, restricting the weight and the stress, performing topology optimization, loosening the original 0-1 discrete variable optimization problem, allowing the continuously-changed intermediate density to appear, then establishing a proper interpolation relation between the elastic modulus of the material and the density of the material, introducing punishment to eliminate the intermediate density, and finally obtaining the 0-1 structural topology.
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