Strength Analysis And Optimization Design On New Coal Hopper Body

With the development of the railway and rapid development of rolling stockmanufacturing industry, the market competition of coal hopper car is getting more and morefierce. Under the premise to meet the strength and stiffness, the lightweight of coal hopper carbodywork is one of the important measures for enterprises to gain greater economic benefits.Firstly, static strength of the KM70coal hopper body is analyzed by the finite elementmethod. The bodywork is necessarily simplified, and the geometry model of KM70coalhopper car bodywork is built by SolidWorks software, then it is imported to HyperMesh toextract face and to establish finite element model of the body structure based on shell element,and last the static characteristics of the bodywork is analyzed using ANSYS processingplatform in order to get bodywork stress distribution under five conditions. Strength checkand evaluation for hopper car body are done based on TB/T1335-1996standard, and theresults show that the static strength of the bodywork meets the requirements. Fatigue strengthon the bodywork is assessed according to the modified Goodman-Smith fatigue limit diagram,and the result is that the body does not occur to the destruction and failure under specifiedconditions of fatigue load.Secondly, the vibration of the body structure of coal hopper car in the free modes isresearched in this thesis, and the first-order vertical bending vibration frequency of the bodystructure is24.67874Hz by calculating which is higher than the given value of relevantprovisions (14Hz), so it meets the design requirements. The stability of the KM70coal hoppercar bodywork under the maximum compressive load2250kN is analysed by usingHyperWorks software, and it draws that the first order buckling factor is1.52817which isgreater than1, so the vehicle does not appear instability phenomena.Then, the lightweight on body structure of the coal hopper car is studied in this thesis,and the thickness of38key components of the coal hopper car bodywork is selected as designvariables, and then size optimization of the vehicle body is done under the conditions thatstress constraints and displacement constraints meet TB/T1335-1996standard to achieve thepurpose of the lightest. The result of optimization shows that the quality of the vehicle body islowered by5.89%than the original, and the static strength, modal and linear buckling of theoptimized vehicle body meet the requirements through verification.Finally, topology optimization on the corbel webs of car body is done using the minimum members size and pattern repeat constraints. The results of Topology optimizationshow that the weight of the optimized corbel webs is reduced by39.5%than the original, thatis to reduce the weight of the vehicle body itself, and it meets the design requirements throughthe strength check. Ultimately the total mass of the vehicle body is reduced by6.61%usingsize optimization and topology optimization.