Lightweight Structure Design And Analysis Of Transition Coupler

High speed railway train towards and intelligent development,order to ensure the smoothness of vehicles at runtime,the use of railway vehicles more and more even smaller hanging vertical clearance contact type coupler,but are almost all 15 of the rescue locomotive equipped with coupler,the vehicle failure in need of repair,of two different forms of coupling cannot directly connect to hang,so you need to transition coupler auxiliary hanging.A railway bureau passenger car depot existing transition coupling structure bulkiness,low material utilization rate,and the need for manual loading and unloading during installation,in the ballast track used once falling off,will cause serious personal injury to maintenance personnel.In this thesis,aiming at higher material utilization rate and lighter structure of transition coupler,a lightweight design scheme of transition coupler was proposed,and ANSYS Workbench software was used to simulate and analyze its strength,stiffness and fatigue strength to confirm the feasibility of the scheme.The main research contents are as follows:The longitudinal dynamics model of the train and the simulation model of single mass point and multiple mass point train are established according to the marshaling situation and force mode of the train during maintenance and rescue.It is found that the smaller the initial braking speed is,the more the number of carriages is,the greater the load on the transition coupler will be,and the higher the load will be generated by the second-stage pressure braking compared with the ordinary braking.Thus,the maximum operating speed is 85km/h.When 16 carriages are transported,the transition coupling bears the maximum tensile load in the traction starting condition and the maximum compression load in the braking condition.A three-dimensional model of the original transition coupler was established,and its structure,working principle,material properties and assessment criteria of strength and stiffness were analyzed.According to the transition of coupling model and the ultimate load,the use of finite element analysis software on the statics analysis,determine the traction start working condition and braking condition,the two extreme conditions transitional coupling strength and stiffness are comply with the design requirements,but there are unreasonable structure,low material utilization,lightweight design space.The variable density method was used to carry out topology optimization analysis on the transition coupler.Combined with the analysis results and the stress characteristics of the transition coupler,the shape of the transition coupler was optimized.The lightweight transition coupler model weighed 80.1kg,which lost 20.2kg compared with the original model.After checking the strength,stiffness and fatigue strength of the lightweight transition coupler model,the feasibility of the lightweight scheme was verified.The comparative analysis results showed that,compared with the original transition coupler,the strength and stiffness of the lightweight transition coupler were improved to a certain extent.TC4 titanium alloy was used as the material of the lightweight transition coupler instead of cast E-grade steel,and the weight of the transition coupler was 46kg.Finite element statics analysis of titanium alloy transition coupler shows that the titanium alloy transition coupler meets the strength and stiffness requirements under traction starting and braking conditions,and the safety factor reaches 2.6,which has certain design allowance.The topology optimization analysis of the titanium alloy transition coupler was carried out by using the variable density method.Combined with the results of topology optimization,the structure lightweight design of the titanium alloy transition coupler was carried out.The weight of the titanium alloy transition coupler was 42.15kg,compared with that of the original transition coupler,the weight was reduced by 58.15kg.After checking the strength,stiffness and fatigue strength of the lightweight titanium alloy transition coupling,it is found that under the traction starting condition and braking condition,the lightweight titanium alloy transition coupling meets the design requirements,and the safety factor has been improved to a certain extent.Through the above research work,on the basis of the existing transition coupler to improve the lightweight transition coupler,on the premise of ensuring the strength and stiffness to meet the normal use requirements,the structure is more reasonable,the material utilization rate is higher.The lightweight analysis process and results of transition couplings can provide detailed analysis scheme and theoretical reference for the structural optimization design of various types of transition couplings and the development of new transition couplings in the future.