Comparative study of static strength and fatigue strength tests and simulation analysis of an exit subway bogie frame

Abstract

The frame is the carrier and substrate of almost all parts on the bogie, which connects the motor drive and a series of suspension devices together through the axle box tie rod, and is used to transmit the vertical force from the car body and to bear the load from the wheel pair in various directions. This thesis is based on EN13749, UIC615-4, JIS E 4207 and JIS E 4208 standards to perform finite element analysis of the bogie frame, and the static and fatigue strength tests of the frame were conducted in the laboratory to compare and analyze the simulation and test results. The results show that the static strength results of the bogie frame are less than the allowable stress of the corresponding material. The maximum stress of the frame in the extraordinary service load occurs in service ten with a stress of 250.44 MPa, which is located at the transition arc between the frame crossbeam and the longitudinal connection beam. In the operating condition load, the maximum stress of the frame occurs in condition eight with a stress of 142.47 MPa, which is located at the transition arc between the frame crossbeam and the longitudinal connection beam. In the JIS service load, the maximum stress of the frame occurs in service ten with a stress of 167.85 MPa, which is located at the weld joint between the bogie frame cross member and the motor hanger. Fatigue assessment by Goodman diagram, the results show that the data are all within the envelope and meet the fatigue assessment requirements. Comparing the results of static strength and finite element simulations, it is concluded that the relative error between simulation and test results is controlled within 20%. After verification of ten million fatigue tests on the bogie frame structure and non-destructive testing at each stage, the results showed no cracks and met the fatigue test evaluation requirements in the standard.