CN113806858A - Motor train unit train body design method based on structural topology optimization - Google Patents
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Abstract
The invention provides a motor train unit train body design method based on structural topology optimization, which breaks through the traditional structural design method based on sensitivity analysis and surrogate model of the existing train body, implements the structural topology optimization thought into the train body structural design, and develops a brand-new structural topology optimization motor train unit train body design method by researching the aspects of the size, the shape, the topology comprehensive optimization design and the like of the train body structure.
Description
Technical Field
The invention relates to the field of railway passenger car bodies, in particular to a car body relating method based on structural topology optimization.
Background
At present, the structural design optimization of a rail vehicle body is mainly based on methods such as sensitivity analysis and a proxy model, the shape and the size of the structure are optimized, designers perform corresponding adjustment and optimization on structural details of the vehicle body such as a profile section, an underframe and a side beam on the basis of reasonably optimizing the structural design of the vehicle body according to the actual structural characteristics of the vehicle body and according to the requirements of related design rules, but the existing structural design of the size and the shape has the limitations of high dependence on a design prototype, small scale of design variables, limited space for performance optimization and the like, so that a new structural design method is urgently needed to break through the design limit of size and shape optimization, further improve the lightweight design level of the structural design of the rail vehicle body, and optimize the overall service performance of a rail transit vehicle.
In recent years, the topological optimization technology can obtain a high-performance structural design without depending on the experience of engineers and designers, and is gradually expanded to other fields including fluid, acoustics, electromagnetism, optics and the like, the lightweight technology based on the topological optimization method has become a main development trend of a high-speed train in the future, although the optimization research on the vehicle body structure of the railway vehicle is wide at home and abroad, the size/parameter optimization algorithm is mainly focused, and the research on the aspects of the vehicle body structure design method based on the topological optimization is still insufficient.
Disclosure of Invention
The invention aims to research a brand new design method of a vehicle body structure, which comprises the comprehensive optimization of various design variables such as the size, the shape and the topology of a vehicle body, and provides a comprehensive optimization design method of the size, the shape and the topology of the structure by means of the thought of simulation design and reconstruction and regeneration.
In order to achieve the aim, the invention provides a motor train unit train body design method based on structural topology optimization, which comprises the following steps of:
step 1: on the basis of the characteristics of the existing motor train unit train body structure, the force flow transmission paths of the train body structure in the longitudinal direction, the vertical direction and the transverse direction are analyzed, the bearing characteristics of three-way force flow transmission of the train body structure are researched, and weak parts and strength redundant parts of the structural strength are found. The method comprises the following steps: firstly, dividing a vehicle body structure into a plurality of sectional material parts by taking the positions of welding seams among sectional materials forming the vehicle body as references, selecting the working conditions with the largest influence on the structural strength and worse working conditions to perform calculation and analysis preferentially according to EN12663 standards, extracting the Von-Mises stress sigma of different sectional material parts respectively, and comparing the Von-Mises stress sigma with the allowable stress [ sigma ] of the sectional material part, wherein when the number of nodes [ sigma ]/sigma >0.85 is more than 15% of the total number of the nodes of the sectional material blocks, the strength of the part is considered to be weak; when the number of the nodes of [ sigma ]/sigma <0.60 is more than 35% of the total number of the nodes of the block section bar, the part of the strength is considered to be redundant; the section part with larger redundancy can be obtained through calculation, analysis and judgment, and the part is taken as a key object for next light weight; through calculation of a plurality of vehicle bodies, the underframe lower side beam and the roof upper side beam are light key objects.
Step 2: the method comprises the following steps of taking light weight of a vehicle body as a target, researching the matching relation between strength, rigidity, stability, crashworthiness, weight and process of a main bearing structure, a secondary bearing structure and an end safety protection structure of the vehicle body, providing boundary conditions (such as weight indexes, modal indexes, strength standards and the like) of vehicle body design, establishing a vehicle body profile model by combining main profile technical parameters of the vehicle body, and taking determined technical parameters (such as welding seam positions, wire groove positions, door and window opening installation positions and the like) as input parameters of structural topology optimization to form a primary calculation model;
and step 3: since the influence of the mode on the vehicle body structure is large, vehicle body mode analysis is firstly carried out on a calculation model, according to the step 1, the influence of a roof upper edge beam and an underframe lower edge beam on the vehicle body mode is large, topological optimization is carried out by selecting an object as a key point, a topological configuration scheme meeting the vehicle body mode requirement is obtained by defining the density attribute of the material, and other components are simultaneously subjected to structural topological optimization according to the method to obtain a corresponding configuration scheme, so that the configuration scheme of the vehicle body is formed;
and 4, step 4: rebuilding and back-substitution analyzing the topological structure formed in the step 3, checking the static strength and the 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, and thus obtaining an optimal structure topological optimization structure;
and 5: because the topological structure of the section material for forming the vehicle body obtained in the step 4 is complex and is very difficult to form by the current technological means, the engineering design for manufacturing and constructing the topological structure of each section material is needed to meet the requirements of the manufacturing and forming technology and production equipment, so that the topological structure engineering vehicle body structure capable of being manufactured is formed.
Step 6: and (5) re-establishing a calculation model for the configuration-engineered vehicle body structure obtained in the step (5), and carrying out modal, fatigue and static strength analysis again according to EN12663 standard and related technical requirements to find a structure meeting the requirements and obtain the final structure topology optimization vehicle body structure.
Further, the selected width of the motor train unit train body structure is 3360mm, the height from the rail surface is 3950mm, and the length of the train is 25000 mm.
Further, for the part with redundant strength, the 2mm thickness and the welding position of the outer frame of the side beam and the upper side beam of the underframe are reserved, the rest parts are unchanged, after selected loads are loaded respectively, the minimum flexibility is taken as a calculation target, the volume fraction is set to be 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, 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 0-1 structural topology is obtained.
Further, topology optimization is carried out on the weak-strength parts, other weak-strength areas are set as optimization design areas respectively, the thickness and welding positions of the outer frame are kept to be 3-3.5mm, after the rest parts are unchanged, selected loads are loaded respectively, the minimum flexibility is taken as a calculation target, the volume fraction is set to be 20%, weight and stress are taken as constraints, topology optimization is carried out, the original (0-1) discrete variable optimization problem is relaxed, continuously-changed intermediate density is allowed to occur, 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 0-1 structural topology is obtained.
The invention breaks through the traditional sensitivity analysis and surrogate model-based structural design method of the existing train body, carries out the structural topology optimization thought into the train body structural design, and develops a brand-new structural topology optimization train body design method by researching the aspects of the train body structural size, shape, topology comprehensive optimization design and the like, thereby reducing the train body weight to the maximum extent on the premise of ensuring that the performance indexes such as the train body strength, the mode, the fatigue and the like are not changed.
Drawings
FIG. 1 is a flowchart of a method for topologically optimally designing a vehicle body structure;
FIG. 2 is a schematic view of a vehicle body section topology optimization;
FIG. 3 is a schematic view of a vehicle body underframe boundary beam topology optimization;
FIG. 4 is a schematic view of a topological optimization of a roof side rail of a vehicle body;
FIG. 5 is a schematic diagram of vehicle body topology optimization.
Detailed Description
Referring to fig. 1, the invention relates to a novel motor train unit train body structure design method based on structural topology optimization, which optimizes the structural size, shape and topology of the whole train body, reduces the train body mass to the maximum extent, and meets the requirements of the next generation of 400km/h high-speed train set on the train body weight, and the specific implementation scheme comprises the following steps:
1. based on the structural characteristics of the existing series vehicles, the force flow transmission paths of the vehicle body structure in the longitudinal direction, the vertical direction and the transverse direction are analyzed, the bearing characteristics of the vehicle body structure in three-direction force flow transmission are researched, and the weak part and the strength redundant part of the structural strength are found.
The method comprises the following steps of taking a motor train unit aluminum alloy train body structure with a certain type adopting hollow sections as a topological optimization object, wherein the width of the section of the train body structure is 3360mm, the height from a rail surface is 3950mm, and the length of a train is 25000 mm; firstly, according to EN-12663 standard, three working conditions which have the largest influence on the structural strength and are most difficult to achieve are selected, and loads in different directions are applied, which are detailed in the following table 1:
TABLE 1 static Strength load Meter
Judging the weak strength part and the redundant strength part according to the calculation result, wherein the judgment conditions are as follows:
TABLE 2 materials for vehicle body and their yield strengths
Taking the broken part of the welding seam as a parting seam, dividing the car body structure into 20 section bar parts, respectively extracting the Von-Mises stress sigma of different section bar parts, and comparing the Von-Mises stress sigma with the allowable stress [ sigma ] of the section bar part material, and when the node number [ sigma ]/sigma >0.85 is more than 15% of the node number of the sectional bar of the parting seam, considering that the part has weak strength;
when the number of [ sigma ]/sigma <0.60 nodes is more than 35% of the number of the nodes of the block section bar, the part of the strength is considered to be redundant; the judgment shows that the lower edge beam of the underframe and the upper edge beam of the section bar of the roof have large redundancy, and the parts are taken as key objects for the next step of light weight.
2. Based on the bearing characteristics of the train body structure of the motor train unit, the influence factors and weight distribution of the service environment of the train are researched by taking the light weight of the train body as a target, and boundary condition schemes of coupling-synergistic effects in various service environments are provided; the main bearing structure and key parts of the vehicle body are used as research objects, the characteristics of lightweight structural design and interconnection relation are analyzed, and the matching relation research of strength, rigidity, stability, weight and process is carried out.
According to the influence 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 in 22 static strength working conditions:
TABLE 3 description of the static Strength calculation
TABLE 4 summary of fatigue calculation conditions
3. Comprehensively considering factors such as the connection reliability of the vehicle body structure, the balance of structural strength and weight, the feasibility of process implementation, the matching of mechanical properties of materials and the like, providing a novel vehicle body structure topology optimization design method; and considering the coupling and synergistic effect of complex factors, and developing the topological optimization and design technical research of the lightweight novel vehicle body structure based on a vehicle body structure topological optimization design method.
In order to solve the problem that the topological optimization method is difficult to realize in a long hollow aluminum profile structure, the method sets the positions of a side beam of an underframe and a side beam of a roof of a car as an optimization design area, keeps the thickness and the welding position of an outer frame of 2mm, keeps the rest parts unchanged, respectively loads selected by a table 3 and a table 4, performs topological optimization by taking minimum flexibility as a calculation target and weight and stress as constraints, and specifically comprises the following steps: the original (0-1) discrete variable optimization problem is relaxed, 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 0-1 structure topology is obtained.
Under the same quality, compared with the original underframe lower edge beam, the underframe lower edge beam with the new configuration has equivalent modal frequency and the flexibility (deformation energy) is changed into 16 percent of the original flexibility.
Under the same mass, the flexibility (deformation energy) of the roof side beam of the new structure is 19.5 percent of the original structure, and is reduced by about 80.5 percent; the frequency is increased by 0.4Hz and 7.6 percent.
On the basis, topological optimization is carried out on the weak-strength parts, other weak-strength areas are set as optimization design areas respectively, the thickness and welding positions of the outer frame are kept to be 3-3.5mm, the rest parts are unchanged, loads are selected from the table 3 and the table 4 respectively, the minimum flexibility is taken as a calculation target, the volume fraction is set to be 20%, the weight and the stress are taken as constraints, and topological optimization is carried out, wherein the specific topological optimization mode comprises the following steps: the original (0-1) discrete variable optimization problem is relaxed, 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, penalty is introduced to eliminate the intermediate density, and finally the 0-1 structure topology is obtained.
4. Aiming at the novel vehicle body structure after topology optimization, from the aspects of a whole vehicle and components, the safety and reliability of the lightweight vehicle body structure designed by the invention are verified through simulation analysis and optimization verification of structures such as static strength, rigidity, fatigue and connecting joints of a vehicle body, parts and materials, coupled vibration analysis of the vehicle body structure and suspension equipment outside the vehicle, and connection reliability analysis of suspension equipment below the vehicle and the vehicle body.
And finally, the section of the newly-configured section is brought into a finite element model of the whole vehicle again, checking is carried out under 22 static strength working conditions, 4 fatigue strength working conditions and 2 modal working conditions, and the section can be obtained through checking, so that the optimized configuration has the low-order frequency of 15.6Hz, the mass of 10.15t, the rigidity of which is improved by 20 percent and the mass of which is reduced by 7.7 percent on the premise of meeting the requirements of EN-12663 on static strength and fatigue strength.
The train body structure designed by the structural topology optimization design method provided by the patent comprises but is not limited to a train body of a motor train unit, other vehicles are adjusted according to the specific requirements of the train body, and the patent only provides a brand-new design method of the train body structure.
A method for designing a motor train unit train body based on structural topology optimization relates to the layout design of application materials in a train body structure, and is suitable for designing a motor train unit train body structure scheme meeting static strength, modal and fatigue characteristics; the invention carries out structural topology optimization design according to the method flow of FIG. 1, which mainly comprises the following steps:
(1) acquiring force flow transmission paths of the vehicle body structure in the longitudinal direction, the vertical direction and the transverse direction, and establishing a structural finite element model of the vehicle body profile on the basis of the bearing characteristics of the three-way force flow transmission of the vehicle body structure by combining main technical parameters of the vehicle body;
(2) aiming at the light weight of the vehicle body, influence factors and weight distribution of the service environment of the vehicle are carried out, boundary conditions (such as weight indexes, modal indexes, strength standards and the like) of the vehicle body design under various service environments are provided, and determined structural topology optimization parameters (such as welding line positions, wire groove positions, door and window positions and the like) are input to form a primary calculation model (see figure 2);
(3) firstly, carrying out vehicle body modal analysis on a calculation model, wherein a vehicle top boundary beam and a chassis bottom boundary beam have large influence on vehicle body modal, and are used as key selection objects for carrying out topological optimization, a topological configuration scheme (shown in figures 3 and 4) meeting the vehicle body modal requirement is obtained by defining the density attribute of a material, and other components are simultaneously subjected to structural topological optimization according to the method to obtain a corresponding configuration scheme, so that the configuration scheme (shown in figure 5) of the vehicle body is formed;
(4) reconstructing and analyzing the topological structure, checking the static strength and the fatigue performance of the topological structure until finding a structure meeting the standard requirement, and thus obtaining an optimal structural topological structure;
(5) the topological structure is engineered to meet the process requirements of manufacturing and forming;
(6) and analyzing the modal, fatigue and static strength of the configuration-engineered 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, which does not simply optimize parameters of a vehicle body structure any more, takes the influence of static strength, mode and fatigue life into consideration in the early stage of design and has important significance for the design of the vehicle body structure.
Claims (4)
1. A motor train unit train body design method based on structural topology optimization is characterized by comprising the following steps:
step 1: on the basis of the characteristics of the existing motor train unit train body structure, the force flow transmission paths of the train body structure in the longitudinal direction, the vertical direction and the transverse direction are analyzed, the bearing characteristics of three-way force flow transmission of the train body structure are researched, and weak parts and strength redundant parts of the structural strength are found. The method comprises the following steps: firstly, dividing a vehicle body structure into a plurality of sectional material parts by taking the positions of welding seams among sectional materials forming the vehicle body as references, selecting the working conditions with the largest influence on the structural strength and worse working conditions to perform calculation and analysis preferentially according to EN12663 standards, extracting the Von-Mises stress sigma of different sectional material parts respectively, and comparing the Von-Mises stress sigma with the allowable stress [ sigma ] of the sectional material part, wherein when the number of nodes [ sigma ]/sigma >0.85 is more than 15% of the total number of the nodes of the sectional material blocks, the strength of the part is considered to be weak; when the number of the nodes of [ sigma ]/sigma <0.60 is more than 35% of the total number of the nodes of the block section bar, the part of the strength is considered to be redundant; the section part with larger redundancy can be obtained through calculation, analysis and judgment, and the part is taken as a key object for next light weight; through calculation of a plurality of vehicle bodies, the underframe lower side beam and the roof upper side beam are light key objects.
Step 2: the method comprises the following steps of taking light weight of a vehicle body as a target, researching the matching relation between strength, rigidity, stability, crashworthiness, weight and process of a main bearing structure, a secondary bearing structure and an end safety protection structure of the vehicle body, providing boundary conditions (such as weight indexes, modal indexes, strength standards and the like) of vehicle body design, establishing a vehicle body profile model by combining main profile technical parameters of the vehicle body, and taking determined technical parameters (such as welding seam positions, wire groove positions, door and window opening installation positions and the like) as input parameters of structural topology optimization to form a primary calculation model;
and step 3: since the influence of the mode on the vehicle body structure is large, vehicle body mode analysis is firstly carried out on a calculation model, according to the step 1, the influence of a roof upper edge beam and an underframe lower edge beam on the vehicle body mode is large, topological optimization is carried out by selecting an object as a key point, a topological configuration scheme meeting the vehicle body mode requirement is obtained by defining the density attribute of the material, and other components are simultaneously subjected to structural topological optimization according to the method to obtain a corresponding configuration scheme, so that the configuration scheme of the vehicle body is formed;
and 4, step 4: rebuilding and back-substitution analyzing the topological structure formed in the step 3, checking the static strength and the 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, and thus obtaining an optimal structure topological optimization structure;
and 5: because the topological structure of the section material for forming the vehicle body obtained in the step 4 is complex and is very difficult to form by the current technological means, the engineering design for manufacturing and constructing the topological structure of each section material is needed to meet the requirements of the manufacturing and forming technology and production equipment, so that the topological structure engineering vehicle body structure capable of being manufactured is formed.
Step 6: and (5) re-establishing a calculation model for the configuration-engineered vehicle body structure obtained in the step (5), and carrying out modal, fatigue and static strength analysis again according to EN12663 standard and related technical requirements to find a structure meeting the requirements and obtain the final structure topology optimization vehicle body structure.
2. The method for designing the motor train unit train body based on the structural topology optimization as recited in claim 1, wherein the motor train unit train body structure selected in the step 1 has a width of 3360mm, a height from a rail surface of 3950mm, and a length of 25000 mm.
3. The method for designing the motor train unit train body based on the structural topology optimization as recited in claim 1, wherein the step 3 reduces the design calculation amount by: the method comprises the steps of reserving 2mm thickness and welding positions of an outer frame of a lower edge beam of an underframe and an upper edge beam of a roof, keeping the rest parts unchanged, respectively loading selected loads, taking minimum flexibility as a calculation target, setting volume fraction as 15%, taking weight and stress as constraints, carrying out topology optimization, relaxing 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 a material and the density of the material, introducing punishment to eliminate the intermediate density, and finally obtaining 0-1 structural topology.
4. The method for designing the motor train unit train body based on the structural topology optimization as recited in claim 1, wherein the step 3 is to perform topology optimization on the weak-strength part in the following way: respectively setting other areas with weak strength as optimized design areas, reserving the thickness and welding position of the outer frame of 3-3.5mm, keeping the rest unchanged, respectively loading the selected load, taking the minimum flexibility as a calculation target, setting the volume fraction as 20%, taking the weight and the stress as constraints, carrying out topology optimization, relaxing 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 structure topology.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115238387A (en) * | 2022-07-27 | 2022-10-25 | 中车成型科技(青岛)有限公司 | Topological lightweight method and system for mixed material of rail transit vehicle |
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