| As one of the three major directions of railway freight development,the heavy haul technology plays an important role in promoting the national freight transportation and economic development.At present,the railway freight heavy haul technology has covered almost all big railway nations worldwide.Compared with traditional wagons,the ore open top wagon exported to Guinea shall be replaced with the bogie with 32.5t axle load in the future.Among the three elements(i.e.,the speed,density and weight)of transportation,the speed and density of the heavy haul trains in China occupy the international leading position,however,there is still much room for the research & development of the heavy haul.Therefore,it is of great practical significance to put forward the advanced idea of the new type ore open top wagon,to explore the development direction and method of the ore transportation industry,and to improve the level of railway heavy haul special purpose freight equipment.This paper is aimed at meeting the requirements of the Guinean railway condition,120 marshalling modes,dumper unloading and maximum 106 t loading capacity by replacing bogies in the future.The proposal of a new type of ore special purpose open top wagon(without supporting lever and partition wall at the wagon body,smooth interior,fast unloading flow rate and high net unloading rate)was put forward.In the design process,this paper mainly includes the following aspects:1.The technical characteristics of foreign & domestic open top wagon and existing ore open top wagon in Guinea were analyzed,the connection types of the center sill,side wall,key parts and components,especially the side wall and under frame were compared and selected to form the overall technical proposal of the ore open top wagon exported to Guinea.2.Emphasized on the study of wagon body parts,the finite element analysis software was used to simulate the discrete model of the wagon body to complete the optimization and structure checking.The results showed that the maximum stress occurred at working condition4,and the maximum stress region was at the edge of the center beam web hole.The stress value was 404.47 MPa,which was less than the allowable stress of Q450NQR1,and the maximum stress value in other areas was smaller than the allowable stress.Then the fatigue life of the wagon body was estimated.The relatively short life area appeared at the lap joint between the side post and the corner column.The life was 4.88 million km,which was much greater than the requirement of 1.6 million km design life,and the other areas were far beyond the design life.3.After the prototype manufacturing,the static strength test of the wagon body and the static weighing and torsion test of the wagon under servicing condition have been carried out.The two test results showed that the wagon design proposal met the requirements of relevant standards and the physical performance of the product met the user’s requirements.4.In order to more accurately grasp the difference between the test data and the simulation data to better evaluate the reliability of the product,the test data and simulation data at the corresponding test point of the main large stress values were compared and analyzed.The results showed that the static strength test data and the finite element calculation results are in good uniformity,and the positions of the large stress zone were basically the same.The final technical proposal passed the company level appraisal and the user’s approval.The wagons have been well operated for more than one year since they were delivered to the user in June2019.This paper comprehensively combs the design process of the heavy haul ore open top wagon exported to Guinea,explores and studies the relevant technical and frontier theory of the transportation equipment specialized development,provides technical reference and theoretical support to study the similar type of the wagon,and provides some reference value for the feasibility study of the ore open top wagons for relevant countries. |
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