The Research And Manufacture On Anti Rolling Bar System Of CRH380A

Prototype of CRH380A anti-roll bar system (hereinafter referred to as the ARB system) was imported from Japan. In order to promote the localization process, the thesis selects this ARB system as the research object. Based on the prototype interface dimensions, research and redesign on the product structure, material selection, manufacturing process and etc. Calculation and process tests show that all the components can meet the design requirements, and that the ARB system can fully meet the CRH380A EMU vehicle application requirements on structure, stiffness, strength, manufacturing process and etc.Referred to the thesis, the ARB system adopts the interference teeth connection structure, the end supporting type and the adjustable vertical link structure. Substitute for the alloy steel used in the prototype, the torsion bar adopts the spring steel with high yield strength ratio. The levers, the vertical link and the supporting base all adopt the alloy steel as replace of the ordinary carbon steel in the prototype. The supporting bearing uses the Copper matrix graphite structure as the prototype.Calculation shows, under the limit load at21.6kN, in accordance with the Tresca Criterion, the maximum SINT stress of the CRH380A torsion bar comes to559.994MPa<[σ]=1300MPa; the maxi mum shearing stress of the bar comes to279.619MPa<[τ]=745MPa; and the maximum Von Mises stress of the levers comes to432.222MPa<[σ]=650MPa. Therefore, the static strength of both the torsion bar and the levers fully meet the design requirements; and the rest metal components of the CRH380A ARB system, all meet the design requirements of static strength. Under the fatigue loading cycles, the shortest fatigue service life of the torsion bar reached to the infinite life at10million times above, appeared at the root area of the spline teeth, near the tool withdrawal groove; the shortest fatigue service life of the levers and other components also met the fatigue design requirements of10million times above.The torsion bar adopts advanced processes as end forging, surface-shot peening, floating grinding, and etc. The levers, the vertical link and the supporting base all adopt the forging process. After10-million-times fatigue tests, the ARB system has not developed any problem, thus can meet the20-years life requirements of the bogie overall.