符合EN-13749規範軌道車輛轉向架疲勞壽命分析與研究

本論文主要是建立一軌道車輛轉向架結構輕量化設計分析流程，此分析流程是結合拓樸最佳化、參數最佳化以及有限元素分析。結構分析包括強度分析、循環負載以及軌道不平整疲勞壽命分析，分析結果必須滿足EN-13749規範之規定。本研究是以捷運電聯車之轉向架做為研究研究探討之標的，轉向架結構整體之重量目標須低於1430 kg。文中是以 TOSCA來進行轉向架結構之拓樸最佳化分析，並結合Isight、ABAQUS及fe-safe來進行串聯分析，針對側框架板厚與補強肋厚度及位置來進行參數最佳化分析。參數最佳化分析所施加之負載，是以EN-13749所規定之過負載及疲勞循環負載為主。依照所建立之輕量化分析流程，本研究所得最終概念設計轉向架結構之重量為1186 kg。轉向架強度分析結果顯示，轉向架之最大von-Mises應力均低於材料之降伏應力，滿足強度需求，循環負載之疲勞壽命分析也滿足107 cycles之要求。另外，軌道不平整疲勞壽命分析結果顯示，在同時考量垂向、定線、左右軌高低及軌距不平整之情況下，本研究所提之轉向架，在軌道等級2~6及行駛速度80 km/h時，其疲勞壽命皆符合歐盟標準EN-13749之規定，其疲勞壽命均大於107 cycles 或30年。

關鍵字

轉向架；輕量化；拓樸最佳化；參數最佳化；強度分析；疲勞壽命分析；軌道不平整

並列摘要

In this thesis, a lightweight design analysis process for a railway bogie frame is proposed. The lightweight analysis process combines topology optimization analysis, parametric optimization analysis and finite element model analysis. The bogie frame structural analysis includes strength analysis, fatigue test analysis and fatigue life analysis due to track irregularity. The results of the structural analysis must satisfy the required specifications of European standard EN-13749. The bogie frame of a Taiwan Mass Rapid Transit (MRT) train is used as a research target. Therefore, the weight of the proposed bogie frame is set to be less than 1430 kg. In this research, the optimization software TOSCA is used for the topology optimization analysis. The parametric optimization software Isight, ABAQUS and fatigue analysis software fe-safe are integrated for parametric analysis of the side frame plate thickness, the thickness and position of the reinforcing rib. The loads used for the parameter optimization analysis are the exceptional load and fatigue test load according to EN-13749. The weight of the final concept design bogie frame obtained from the proposed lightweight analysis process is 1186 kg. The correspending maximum von-Mises stress obtained from the finite element simulation is lower than the yielding stress of the material used in bogie frame. The fatigue life obtained from the fatigue test simulation can also satisfy the required specification of 107 cycles. In addition, the fatigue life analysis due to track irregularities shows that the fatigue life of proposed bogie is larger than 107 cycle or 30 years for train running at track class 2~6 with train speed 80 km/h. In fatigue simulations, the track irregularities include vertical irregularity, alignment irregularity, cross level irregularity and gauge track irregularity simultaneously.