Research And Development Of Low Life Cycle Cost Rubber To Metal Parts Used On Passenger Vehicle Bogies

With the development of society,Eco friendly technology has become the leading technology.With it self's low emission,railway industry is flourishing all over the world.This makes the equipment manufacturers in railway industry do a lot of research on eco friendly technologies.RAMS is one of these technologies which researches on the design,manufacture and usage from systematic point.RAMS technology can reduce the life cycle cost effectively which is widely used by railway industry equipment manufacturers.With the progress of railway industry,it requests higher and higher requirements on safety,comfort and speed of running,which make people pay more attention on noise reduction technologies.And more and more rubber components have been used on railway vehicles to replace the metal components,especially on high speed trains(the speed is more than 200km/h).The life time of existing rubber components is 6~8 years.It means the rubber components shall be replaced 4to 5 times during the service time 40 years of the trains.The life cycle cost(LCC)of the rubber components is high.The task of this research is to develop the rubber suspension components of 200km/h standard bogie platform from one foreign customer,using the method of formula calculation,FEA,test validation and RAMS to increase the design life of the rubber components to 10~12years and to reduce the life cycle cost.This compact train has two types of bogie,with swing arm system as the primary suspension.But the secondary traction system has two kinds.One is the floating traction system composed of traction center and traction blocs.One is single traction rod assembly.The swing arm rubber bush uses the assembly structure of conical rubber sleeve and inner-bar to realize the matching of longitudinal and lateral stiffness.The traction bloc adopts good creep rubber formula to realize the stiffness and relaxation requirements.The traction rod bush innovates by using the structure of tress sections to realize the non-linear property and the high reliability of the traction system.The structure design has been validated by formula calculation and FEA.And then the type test plan has been designed for each rubber components.The type test results have shown the design of the three rubber components can meet the requirements of static stiffness,thermal ageing,relaxation,and fatigue property.And in April to September 2017,TMT has provided the first batch for dynamic test of the bogie.The dynamic test has shown the three rubber components can meet the dynamic requirement of the bogie.This research has used the RAMS to evaluate the life cycle cost of the three rubbercomponents.The RAMS plan has been made for each rubber component separately.DFMECA has been done for the failure modes.The RAMS report has been drawn out.The failure rate,safety and maintenance meet the customer's requirements.Then the life cycle cost of the three rubber components has been analyzed to ensure the LCC meet customer's requirements.