Journal of Jilin University(Engineering and Technology Edition) ›› 2023, Vol. 53 ›› Issue (4): 982-988.doi: 10.13229/j.cnki.jdxbgxb.20210824

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Crashworthiness optimization for frontal⁃end structure of rail vehicle constrained with absorbed energy and crushed displacements

Ben-huai LI1(),Yan-wen LIU1,2,Lu WANG1,Xue-qian CHEN3,Wen-jie ZUO3()   

  1. 1.CRRC Changchun Railway Vehicles Co. ，Ltd. ，Changchun 130062，China
    2.State Key Laboratory of Traction Power，Southwest Jiaotong University，Chengdu 610031，China
    3.School of Mechanical and Aerospace Engineering，Jilin University，Changchun 130022，China
  • Received:2021-08-25 Online:2023-04-01 Published:2023-04-20
  • Contact: Wen-jie ZUO E-mail:lbh1008@163.com;zuowenjie@jlu.edu.cn

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Abstract:

In 2021， CRRC Changchun Railway Vehicles Co.， Ltd. completed the passive safety crash test of the whole electric multiple unit in rail for the first time in the world. However， the crashworthiness optimization method of the front-end energy-absorbing structure of rail vehicles needs to be further studied. Firstly， this paper introduces the equivalent static load method（ESLM） for structural crashworthiness optimization. Secondly， the parametric finite element model of the front-end energy-absorbing structure is created and then verified by experiments. Finally， the ESLM is used to optimize the energy-absorbing structure under the impact condition. The optimization objective is to minimize the mass of the whole structure， the design variables are the plate thickness of the components. The constraint condition is that the collapsed displacement does not violated the allowable value when the absorbed energy of the structure reaches the specified value. The engineering example shows that the ESLM can efficiently solve the crashworthiness optimization problem of the energy-absorbing structure of rail vehicles， which provides a solution for the passive safety design of rail vehicles.

Key words: railway vehicles, collision optimization, equivalent static load method, lightweight design

CLC Number: 

  • U271.91

Fig.1

Schematic diagram of ESLM"

Fig.2

Definition of ESL"

Fig.3

Optimization process of ESLM"

Fig.4

Finite element model of rail vehicle energyabsorption structure"

Fig.5

Quasi-static crashing test"

Fig.6

Quasi-static crashing test device"

Fig.7

Standard finite element model for test calibration"

Fig.8

Comparison of crushing deformation between test and simulation"

Fig.9

History curves of simulation and experimentalcollision force"

Fig.10

Explosion view of energy absorbing structureand its design variables"

Table 1

Crashworthiness optimization results for theenergy absorption structure of rail vehicles"

参 数优化前优化后

吸能

结构

各组

件板

厚

t1/mm32.5
t2/mm62.4
t3/mm31.2
t4/mm52.0
t5/mm33.6
t6/mm31.2
t7/mm34.8
t8/mm83.2
t9/mm68.4
t10/mm62.4
t11/mm62.4
t12/mm42.3
t13/mm104.0
t14/mm58.0
吸能80%时位移/mm850770
质量/kg600516

Fig.11

Iteration history of collapse displacement"

Fig.12

Iteration process for objective function"

Fig.13

Collapse simulation results for optimal model of energy absorption structure"

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