Application of HyperWorks in railway passenger car

2022-08-06
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The application of HyperWorks in the structural design and optimization of railway passenger cars, Therefore, ensuring that the structure has sufficient strength is a key consideration in the design. At the same time, in order to reduce the axle load and cost, it is necessary to minimize the mass of the foundation braking device in the design process

due to the complex structure of the foundation braking device, the theory and engineering calculation can not effectively analyze the complex stress state of the component. Therefore, it is the best solution to use the finite element analysis method to analyze the strength of the structure in the early design stage. Through the use of HyperMesh software to divide the foundation braking device into six sides, a better lattice quality is obtained, and the function and future development direction of the material tension machine are discussed through the use of high-order elements in the ANSYS simulation analysis software. The finite element analysis can be made into two-color plastic parts to determine the stress distribution of the foundation braking device, and further through the Optistruct software, the structure of the hand brake lever is optimized on the basis of ensuring the strength, The optimal design structure is determined

2 finite element analysis

2.1 finite element model establishment select a suitable jaw and put it into the jaw base

through HyperMesh software, the hexahedral cells of the basic braking device are divided. The whole model is divided into 450811 nodes and 378684 units. See Figure 1 and 2 below for the finite element model

Figure 1 finite element model of foundation brake device

Figure 2 finite element model of original structure of non hand brake lever

2.2 materials and properties

the material parameters of Q235 steel used in the calculation are as follows:

elastic modulus: 206gpa

Poisson's ratio: 0.3

material density: 7.85 e+ 3kg/m3

yield limit: 235mpa

allowable stress: 160mpa

2.3 under load condition

the braking force is applied through the brake air cylinder, The size is 14300n, and the constraint is applied to the brake boom position

2.4 analysis result

the maximum stress of the foundation brake device is 113mpa, which occurs on the non hand brake lever, less than the allowable stress of the material 160MPa. The stress nephogram is shown in Figure 3 and Figure 4 below

Figure 3 stress distribution nephogram of foundation braking device

Figure 4 stress distribution nephogram of non hand brake lever

3 optimization analysis

from the finite element analysis results, it can be seen that the structural stress of non hand brake lever is small and the safety margin is large. In order to reasonably reduce the structural weight, we optimized the structure through Optistruct optimization software to determine the materials that have the least impact on the structural stress, Then the non hand brake lever structure is redesigned to obtain the optimal design structure. Finally, the structure is recalculated to verify the rationality of the optimized structure

Fig. 5 static display of density results of non hand brake lever

3.1 optimization analysis results

from the static display of density results of the structure, it can be seen that the materials in the middle of the front and rear vertical bars contribute little to the structural stress, so the structural weight reduction can be mainly considered from the thickness of the two vertical bars. Therefore, we redesigned the structure, and the optimized structure is shown in Fig. 6

Figure 6 optimized structure of non hand brake lever

4 verification analysis

in order to verify the rationality of the optimized structure, we re analyzed the structure. The maximum stress of the optimized structure is 148mpa, which is less than the allowable material stress of 160MPa, meeting the strength requirements. The stress nephogram is shown in Figure 7 below

Figure 7 cloud chart of structural stress distribution after optimization of non hand brake lever

5 analysis and conclusion

by using HyperWorks software, the "soft" model of the product is used to replace the physical prototype in the early design stage when the function of the product is enhanced. Through the analysis and optimization of the model, not only the production cost can be reduced, but also the high design quality can be obtained, and the release cycle of the product can be shortened, It improves the production efficiency of the enterprise. Therefore, the production of enterprises has a high degree of flexibility and rapid market response ability, which greatly enhances the market competitiveness. (end)

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