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Fatigue Strength Evaluation of the Aluminum Car body of Urban Transit Unit by Large Scale Dynamic Load Test

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(1)

대한기계학회 2003년도 추계학술대회 논문집

(2)

Supporting Jig

Distributed Test Load

Concentrated Load by Actuator

5 Springs

CAR BODY CAR BODY

SIDE VIEW

Supporting beam 50-ton Actuator

FRONT VIEW

CAR BODY

Supporting beam 5 Springs

Carbody

P P

(3)

Test Specimen

H.S.M

Actuator DDC Servo Control Adaptive

Control Data Actuation Function Generator Limit Checking Digital I/O Signal Conditioning Readout Valve Driver

Hydraulic Pump

DIGITAL CONTROLLER AC

Controller DC Controller

Strain Amp.

Stroke Load

LVDT Strain Gage PC W/S

Flextestllm

User Interface Station Design Test Design Test Execution Data Storage Data Analysis Digital Oscilloscope Networking Ethemet

Test Specimen

H.S.M

Actuator DDC Servo Control Adaptive

Control Data Actuation Function Generator Limit Checking Digital I/O Signal Conditioning Readout Valve Driver

Hydraulic Pump

DIGITAL CONTROLLER AC

Controller DC Controller

Strain Amp.

Stroke Load

LVDT Strain Gage PC W/S

Flextestllm PC W/S Flextestllm

User Interface Station Design Test Design Test Execution Data Storage Data Analysis Digital Oscilloscope Networking Ethemet

Set-up of prototype aluminum carbody structure

Static load test

Mounting strain gages, LVDTs’, accelerometers Setting actuators and test

equipments

Measuring natural frequency of full loaded carbody

Pre-test for determination of exciting force

Fatigue load test up to 4×10

5

cycles

Continuation of fatigue load test up to 2×10

6

cycles

Investigation of fatigue crack initiation and propagation

Measuring accelerations Measuring stresses and

displacements

1st Door

LEFT SIDE

RIGHT SIDE

Window T/M 2nd Door 3rd Door

4th Door

LA2 (850,000 cycles, 110mm) LA1 (560,000 cycles, 770mm) LB1(560,000 cycles , 180mm

850,000 cycles,770mm ) LB2 (560,000 cycles, 120mm)

LB3 LB4 LD1 (850,000 cycles, 50mm) LC1 (560,000 cycles, 150mm

850,000 cycles, 250mm)

RA1(560,000 cycles, 350mm 850,000 cycles, 770mm) (560,000 cycles, 120mm)

(560,000 cycles, 120mm)

RB1(560,000 cycles, 70mm) RB2(850,000 cycles, 60mm)

RD1(850,000 cycles, 200mm) RC1(560,000 cycles, 90mm)

RE1(1,352,700 cycles, 50mm 2,200,000 cycles, 50mm)

RF1(1,730,110 cycles, 150mm)

LF1 (2,200,000 cycles, 10mm)

대한기계학회 2003년도 추계학술대회 논문집

(4)

0 0.1 0.2 0.3 0.4 0.5 0.6

0 0.2 0.4 0.6 0.8 1

Dis tance From End / Carbody Length

Str e ss R a nge / M e an Str ess

Static Tes t Dy namic Tes t

1 10 100 1000

1.0E+04 1.0E+05 1.0E+06 1.0E+07

Cycles to Failure

Stress Range in MPa

EAA(partial penetration) EAA(one sided fillet) LB3

LC1 LA1 RC1 LD1 RE1 RF1

4 5 6 7 8 9 10

u d e in Mpa .

Failure Criteria

Dynamic Test

Static Test

(5)

대한기계학회 2003년도 추계학술대회 논문집

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