基于可靠性的重载货车钩舌疲劳断裂寿命

doi:10.3901/JME.2021.04.210

摘要/Abstract

摘要： 铁路重载货车牵引吨位增加导致钩舌裂纹率急剧上升，现有针对钩舌疲劳断裂的研究还缺乏试验和理论支撑，因此有必要开展基于可靠性的钩舌（16H型）疲劳断裂寿命研究。基于线路实测载荷谱开展了系统的钩舌疲劳断裂台架试验，利用可靠性理论研究钩舌疲劳断裂寿命，然后从疲劳损伤分布的角度，对钩舌危险部位的损伤分布进行了深入分析，实现了与台架试验结果的相互印证。结果表明，在纵向冲击载荷作用下，钩舌主要呈现下牵引凸缘断裂和内腕面断裂两种失效形式，其中下牵引凸缘根部临界裂纹尺寸表面长度为60 mm，深度为23 mm，内腕面临界裂纹长度为90 mm；在99.9%可靠度下，钩舌断裂寿命为47.5万km；钩舌内腕面疲劳断裂寿命是下牵引凸缘断裂情况下疲劳断裂寿命的1.04～1.75倍，寿命差异除偶然误差外还同时存在条件误差；钩舌最大损伤位于下牵引凸缘根部距离内腕面一侧42 mm处，上牵引凸缘根部损伤小于下牵引凸缘根部，内腕面损伤最小，但出现疲劳裂纹的范围最大，易同时萌生多段小裂纹导致断裂。研究工作对重载货车钩舌维修策略的制定和应用安全性具有重要的理论和工程指导价值。

关键词: 重载货车钩舌, 疲劳断裂, 可靠性, 服役寿命, 临界裂纹尺寸, 显著性检验, 疲劳损伤

Abstract: The increase in the tonnage of railway heavy-haul wagon led to a sharp increase in the crack rate of coupler knuckle. The existing research on the fatigue fracture life of the coupler knuckle still lacks test and theoretical support. Therefore，it is necessary to study the fatigue fracture life of coupler knuckle based on reliability. The fatigue bench test of the coupler knuckle is accomplished systematically based on the measured load spectrum of the line，and the fracture life is studied based on reliability theory. Then，from the perspective of fatigue damage distribution，the damage distribution of the dangerous parts of the coupler knuckle is analyzed in depth，and the mutual verification with the results of the bench test is achieved. The results show that the coupler knuckle mainly presents two failure forms of the inner wrist surface fracture and the lower traction flange fracture. The critical crack size at the root of the lower traction flange is 60 mm in length and 23 mm in depth，and the critical crack length at the inner wrist surface is 90 mm. With the reliability of 99.9%，the fracture life of coupler knuckle is 475 000 km. The fracture life in the case of inner wrist surface fracture is 1.04-1.75 times longer than that of the lower traction flange fracture. The difference in life is derived from accidental error but also conditional error. The maximum damage of the coupler knuckle is located at the root of the lower traction flange 42 mm from the side of the inner wrist surface. The damage at root of the upper traction flange is smaller than that of lower traction flange. The damage of the inner wrist surface is the least，but the area of fatigue cracks is the largest，which is easy to produce multiple small cracks and lead to fracture. The research work has important theoretical and engineering guidance value for the formulation of maintenance strategy and application security of heavy-haul wagon’s coupler knuckle.

Key words: heavy-haul wagon’s coupler knuckle, fatigue fracture, reliability, service life, critical crack size, significance test, fatigue damage

中图分类号:

U270

尹敏轩, 朱涛, 杨冰, 徐京涛, 王超, 肖守讷. 基于可靠性的重载货车钩舌疲劳断裂寿命[J]. 机械工程学报, 2021, 57(4): 210-218.

YIN Minxuan, ZHU Tao, YANG Bing, XU Jingtao, WANG Chao, XIAO Shoune. Fatigue Fracture Life of Heavy-haul Wagon’s CouplerKnuckle Based on Reliability[J]. Journal of Mechanical Engineering, 2021, 57(4): 210-218.

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