Research On Structural Strength And Fatigue Life Of Hopper Car Body Exported Abroad

Using Hypermesh and Ansys software to analyze the structural strength of an export hopper car,put forward structural improvement measures,and predict the fatigue life of the car body,and then compare and analyze the static analysis and test results of the car body static strength to verify the simulation and test results consistency.According to the characteristics and stress of the car body structure,take a quarter of the car body structure to establish a finite element model,and according to the load specified in Chapter 4 "Design" of AAR Standard C-II(M-1001)"Wagon Design and Manufacturing Specifications" Under working conditions,static strength analysis and buckling stability analysis of the initial plan of the funnel car body were carried out.The static strength calculation results show that the strength of the local structure of the car body(the small funnel of the funnel and the weld of the floor and the side wall)exceeds the allowable stress of the material;the buckling stability analysis results show that the local structure of the car body(at the arc plate of the side wall edge)buckles The factor is less than 1.Carry out a mechanical analysis of the car body structure,propose a structural improvement plan,and perform a simulation analysis on the car body again.The improved funnel car body strength and stability meet the requirements of the standard.According to the AAR standard C-Ⅱ(M-1001)"Truck Design and Manufacturing Specifications" Chapter 7 "Fatigue Design of Freight Cars" 100-ton funnel line load spectrum and fatigue performance parameters of typical joints,estimate that the various parts of the car body Fatigue life under centripetal disk load,longitudinal load and torsional fatigue load spectrum.The calculation results show that the parts with greater fatigue damage of the car body occur in the welding seam between the lower side wall panel and the deflector,and the welding seam between the lower cover plate of the bolster beam and the lower side beam.19.2 million kilometers.Therefore,the fatigue life of the car body meets the design requirements of 5 million kilometers.Car body static strength test is carried out in the laboratory,and according to the simulation calculation results,strain gauges are arranged on the parts where the vehicle body stress is greater to measure the vehicle body stress.Through the comparative analysis of the test measurement results and the simulation data,it is concluded that the test stress of the test points is in good agreement with the calculation results,and the maximum relative error rate reaches 9.8%.The reason for the larger value may be due to a certain human error between the points selected during the test and the points selected by the simulation;during the heavy vehicle test,the weight and copper ore powder contained in the car body caused the car bodyto be affected.The load is concentrated,and the cargo side pressure cannot be simulated realistically.