Design And Research Of Composite Material Wheels

With the development and requirement of rail transit industry,the design and research of new wheels which can provide better performance for vehicles have been gotten attention.In this paper,a composite material wheel consisting of an aluminum alloy wheel disc and a steel rim is designed.The aluminum alloy material is successfully introduced into the wheel structure.The density and elastic modulus of aluminum alloy is low,which can reduce the mass of wheel and improve the radial stiffness of wheel effectively.At the same time,the corrosion resistance of aluminum alloy is very strong,which is very suitable for the operating environment of rail transit vehicles.According to the form of combined wheels and the size requirements of subway wheels,the structure of composite material wheels which are suitable for city rail vehicles is designed.The materials of each part are determined by considering synthetically.The main mechanical property parameters of material of the wheel disc,rim and retaining ring are determined by DVS 1608,EN 13262 and GB/T 1222-2007.According to UIC 510-5and EN 13260 and so on,the maximum tangential load and axial load of the axle and wheel disc,wheel disc and rim fit structure are determined.The range of the axle and wheel disc,wheel disc and rim interference by the fit calculation method of the standard of GB/T 5371 is calculated preliminarily.Based on the results of preliminary calculation,the finite element model of the composite material wheel is established and simulated,and the range of interference which is more in line with the actual structure and the loads are determined.After determining the range of wheel interference,the pre-stresses of a new wheel with the maximum interference and a worn wheel with the minimum interference are analyzed.The results show that the pre-stress distribution of the rim is significantly affected by the thickness of the wheel rim,and the contact stress of the wheel disc and rim is also significantly affected by the status of the wheel.After determining the loads of the strength analysis of composite material wheels according to UIC 510-5,the stress distribution conditions of the wheel under different loads are obtained through the calculation of ANSYS.The maximum stress of each part of the wheel is less than the yield strength of the material,the static strength of the wheel meets the requirements.Under the same loading condition,the stress of the rim is greater when the rim is worn,and the stress of the wheel disc is greater when the rim is new.Based on the uniaxial fatigue criterion,the fatigue strength of the inner surface and the rim and the web areas of the wheel disc are evaluated.It turns out the stress amplitude is less than the allowable stress amplitude,so the fatigue strength meets the design requirements.According to the plane stress method,the program is written to achieve the SWT parameters of mating surfaces by finite element results data.The fretting fatigue of the composite material wheel is analyzed by the SWT parameters.The analysis results show that:the maximum SWT parameters of the axle appear on the about 20mm position from the inner edge,this is the dangerous area to generate fatigue crack on the axle;the maximum SWT parameters of the mating surface on the disc which contacts the axle appear on the inner edge,this is the dangerous area to generate fatigue crack;the maximum SWT parameters of the mating surface on the disc which contacts the rim appear on the middle position,this is the dangerous area to generate fatigue crack;the SWT parameters of the both edges of the mating surface on the rim are all great,these both are dangerous areas to generate fatigue crack on the rim.