The Design of Bullet Train Process Bogie and the Finite Element Analysis of Frame Strength

Abstract

The process bogie is a special equipment for bullet train maintenance. Frame is the main the main load-bearing frame in the process bogie, and its fatigue strength directly affects the safety performance of the entire process bogie. According to the actual maintenance needs, the project design a process bogie. Using the finite element analysis software ANSYS, the finite element model of frame is established, and the frame strength and rigidity is analyzed. Referring to the Bullet train bogie frame strength test (TB/T2368-2005) and the Ministry of Railways vehicles strength design and test standard (TB/T1335-1996), the frame strength is assessed. The analysis results are consistent with the practical application. Introduction With the rapid economic development of China, the development of high-speed railway has now entered a new stage. The safe and stable operation of bullet Train is becoming more and more important. Usually, the daily maintenance of the bullet train is implemented through putting the entire column into the overhaul base for simple maintenance and repair work, but the separation of the bullet train’s body and bogie is needed when the maintenance level reaches three and above, so there is a need to develop a set of equipment which can carry traction body and enable the body to move between different locations. The bullet train’s process bogie is an special equipment which replaces the high-speed bogie of EMU and supports the train body to move between maintenance areas in the process state when different CRH electrical multiple units are in the process of decoding and overhaul, and different maintenance tasks of the high-speed bogie and the train body can be achieved as a result. Truss is one of the key components of process bogie, and it not only is the skeleton of the installation of various parts but also bears and passes the alternating vertical force, horizontal force and longitudinal force. The fatigue strength of truss directly affects the safety of the entire process bogie and is of great importance to the safety, reliability and economy of the railway locomotive vehicle maintenance. Therefore, according to the ministry of railway’s standard-Power bogie frame strength test method TB/T2368-2005) and Railway vehicle strength design and test specification (TB/T1335-1996), static strength and fatigue strength of the process bogie’s frame are analysed and the results can provide insight into the performance of the process bogie frame. The Overall Structure of Process Bogie Figure 1 shows the structure of the process bogie which is consisted of wheel frame, movable typeIIsupport, drive device, driving wheel set, driven wheel set, explosion-proof battery box, and electric control system and so on. The equipment bearing mesa is 180mm height, 28t weight. The mesa width is adjustable, which meets the requirement of CRH1,2,3,5. Work platform uses a fixed two vertical and one horizontal three beam structure with a support device fixed on the upper beam. The wheel axle box is fixed on the bottom of the longitudinal beam. Its structure is simple, bearing capacity is big, and have good matching installation with driving power and power plant. International Conference on Material Science and Application (ICMSA 2015) © 2015. The authors Published by Atlantis Press 926 Fig.1 The overall structure of process bogie Framework Strength Analysis The Construction of Finite Element Model of Framework Based on the structure character of the framework, it can be discretized into solid elements. The mesh of FEM is got by the ANSYS Workbench.SOLID187 element (10 nodes tetrahedral) is used. The number of the total discretized nodes of the framework is 553064, and the number of the elements is 275280. Considering the character that the truss is on the axle box rubber support, we set elastic boundary element on each of the supporting surface. The vertical, lateral and longitudinal stiffness of the boundary element are the three directional stiffness of a series of suspension. There are 12 elastic boundary elements[3]. Under different conditions, there is no restriction to the framework on other positions. In the model, Z coordinate is the forward direction of the vehicle, Y coordinate is the vertical upward direction, X coordinate is the transverse direction[2]. The solid model of the framework is shown in Figure2. The discretized FEM calculation and loading model is shown in Figure3. Fig. 2 The 3D model of the framework Fig. 3 The FEM model of the framework The FEM Calculated Load of the Framework According to the Power bogie frame’s strength test method(TB/T2368-2005). When calculating the calculate the strength of the frame, we must calculate the vertical load, horizontal load in order