Lightweight Optimization Design and Fatigue Lifetime Analysis for Anti-rolling Torsion Bar of Rail Vehicle

Based on the fatigue strength assessment method in the FKM standard, the lightweight design of a type of anti-rolling torsion bar is studied by using the finite element method. Firstly, the finite element model of the torsion bar structure is constructed by using the Creo software and the HyperMesh software, and then the finite element analysis is carried out by using the ABAQUS software. The numerical simulation results indicate that under the condition of ultimate load 29.2kN, the static strength, anti-rolling stiffness and fatigue strength of the torsion bar are all satisfy with the design requirements. Secondly, the orthogonal numerical test method is utilized to investigate the influence of geometric parameters on the anti-rolling stiffness and Factor of Strength (FOS) value of the torsion bar. Taking the structural geometric parameters as variables and the FOS value as the objective function, a second-order response surface model is established. The single objective and multi-factor optimization design for the torsion bar under the condition of stiffness constraint is conducted by using the Isight software and multi-island genetic algorithm. The results show that, comparing with the original structure, the weight of the optimized structure is reduced by 20.89%, and the static and dynamic strength, and anti-rolling stiffness of the optimized structure are match with the design requirements. Finally, the static and dynamic strength tests for the optimized torsion bar are individually operated at the ultimate load and under two-stage cyclic loading with amplitude 18.0kN and 29.2kN. the results show that the calculated stiffness coefficient is consistent with the test one, and the service lifetime of the torsion bar is satisfy with the design requirement.