Estimation of remaining fatigue life of railway bogie substructures considering the degradation of axle box vibration: A case study for sanding device

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-04-03 DOI:10.1016/j.engfailanal.2025.109580

Ningrui Yang , Xingwen Wu , Zhenxian Zhang , Bo Zhang , Bo Peng , Yang Liu , Junzuo Liu , Wubin Cai , Maoru Chi , Shulin Liang

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引用次数: 0

Abstract

The bogie system, a critical component of railway vehicles, endures complex cyclic loads from wheel-rail interactions, vehicle motion, and traction-braking forces. Progressive wheel out-of-roundness (OOR) amplifies dynamic loads, induces high-frequency resonance, and accelerates fatigue damage in bogie sub-components such as the sanding device. This study proposes a fatigue life prediction framework that integrates axle box vibration spectrum degradation and wheel-rail coupled vibration into frequency-domain damage estimation. The vibration spectrum evolution is modeled and predicted using a nonlinear Wiener process, capturing the stochastic nature of spectral degradation. The framework combines rigid-flexible coupled simulations, field vibration tests, and frequency-domain fatigue algorithms to quantify the impact of spectral shifts on damage accumulation. The results show that considering both spectral evolution and wheel-rail coupled vibration leads to the predicted earlier failure, with the sanding device’s remaining useful life (RUL) reduced by up to 75 % under severe OOR conditions. This method enables real-time fatigue prediction and iterative recalibration, supporting condition-based maintenance and fatigue-resistant design, ultimately enhancing the reliability and economic efficiency of railway vehicle operations.

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考虑轴箱振动退化的铁路转向架下部结构剩余疲劳寿命估算——以磨砂装置为例

转向架系统是铁路车辆的重要组成部分，承受轮轨相互作用、车辆运动和牵引-制动力的复杂循环载荷。渐进式车轮不圆度（OOR）会放大动载荷，诱发高频共振，加速转向架子部件（如磨砂装置）的疲劳损伤。本文提出了一种将轴箱振动谱退化和轮轨耦合振动集成到频率域损伤估计中的疲劳寿命预测框架。利用非线性维纳过程对振动频谱演化进行了建模和预测，捕捉到了频谱退化的随机性。该框架结合了刚柔耦合模拟、现场振动测试和频域疲劳算法，以量化频谱位移对损伤积累的影响。结果表明，同时考虑频谱演化和轮轨耦合振动会导致预期的更早失效，在严重的OOR条件下，磨砂装置的剩余使用寿命（RUL）减少了75%。该方法可实现实时疲劳预测和迭代再校准，支持基于状态的维护和抗疲劳设计，最终提高铁路车辆运行的可靠性和经济性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.