High-speed motor train unit wheel CAD / CAE integrated system development method

Abstract

The invention discloses a high-speed motor train unit wheel CAD / CAE (computer-aided design / computer-aided engineering) integrated system development method, which belongs to the technical field of rail transit equipment design, and comprises the following steps: constructing a parameterized CAD template based on a SolidWorks platform, and establishing a mapping relation between wheel geometric parameters and performance indexes; constructing a multi-target CAE (Computer Aided Engineering) analysis template automatically associated with the parameterized CAD template, and carrying out wheel-rail contact stress field simulation and corrected Miner criterion fatigue life prediction under a dynamic load spectrum; a parallel multi-objective optimization engine constructed based on a CAE analysis result and a genetic algorithm is utilized to carry out collaborative optimization between lightweight and fatigue life, and simulation errors are controlled through automatic iteration and closed-loop test verification. Through a closed-loop design process and a multi-source data fusion mechanism, the design efficiency and reliability of the high-speed wheel track system are remarkably improved, the design efficiency is improved, the wheel performance is optimized, and the cost is reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of rail transportation equipment design, and in particular relates to a CAD / CAE integrated system development method for high-speed train wheels. Background Art

[0002] As a key component of EMU bogies, wheels play an important role in rail transit, providing load-bearing, force-generating, and guiding functions. During operation, wheels withstand complex loads from the track and the vehicle body, which can easily lead to fatigue damage, compromising bogie reliability and even causing serious safety incidents such as wheel collapse. Therefore, developing efficient and reliable wheel design methods is crucial for improving EMU bogie design efficiency and ensuring operational safety.

[0003] With the rapid development of high-speed railways, wheel design optimization has become a key technology for improving train performance. However, traditional wheel design methods face the following key challenges: A fragmented CAD / CAE process leads to low design efficiency, making it difficult to achieve multi-dimensional performance optimization and, even more so, to balance performance and cost. The correlation between design parameters and performance indicators is unclear, limiting the application of empirical formulas and resulting in design cycles as long as 3-6 months. Existing methods struggle to achieve multi-objective collaborative optimization and rely on manual experience, which can easily introduce design errors. Summary of the Invention

[0004] The present invention aims to overcome the shortcomings of the existing technology and provide a method for developing a CAD / CAE integrated system for high-speed EMU wheels. By constructing a closed-loop collaborative system combining parametric-driven design and multi-objective simulation analysis, this method automates the entire process of computer-aided design (CAD) geometric modeling, computer-aided engineering (CAE) performance verification, and multi-objective optimization. This significantly improves the efficiency and reliability of wheel design and meets the comprehensive requirements of lightweighting, durability, and structural strength under high-speed operating conditions.

[0005] To achieve the above object, the present invention is implemented by adopting the following technical solutions: In one aspect, the present invention provides a method for developing a high-speed train wheel CAD / CAE integrated system, comprising: Build a parametric CAD template based on the SolidWorks platform and establish a mapping relationship between wheel geometric parameters and performance indicators; Construct a multi-objective CAE analysis template that is automatically associated with a parametric CAD template to simulate the wheel-rail contact stress field and predict fatigue life using the modified Miner criterion under dynamic load spectra; A parallel multi-objective optimization engine built based on CAE analysis results and genetic algorithms is used to coordinate optimization between lightweighting and fatigue life, and simulation errors are controlled through automated iteration and closed-loop testing.

[0006] Furthermore, the method for constructing a parametric CAD template includes: A dedicated parameter interaction interface was developed based on Visual Basic. This interface captured geometric feature changes in the SolidWorks model in real time through a COM interface, triggered the SolidWorks Simulation static analysis module to calculate the maximum equivalent stress value under the corresponding working conditions, and generated a structured data set that was stored in a central database. A dynamic matrix construction module is embedded in the SolidWorks assembly environment. Five design parameters, including wheel diameter, hub thickness, spoke thickness, hub thickness, and hub width, are used as input variables, and an association mapping is established with two performance indicators, including stress distribution and fatigue life, derived from the SolidWorks platform.

[0007] Furthermore, the method of constructing a multi-objective CAE analysis template and performing CAE analysis includes: Create parametric analysis studies in SolidWorks Simulation, identify driving dimension parameters in CAD templates, and establish bidirectional associations with design variables; Automatically extract key geometric features such as spoke transition fillet and rim cross-section profile as analysis objects; Define boundary conditions to constrain all degrees of freedom of the hub mounting surface and apply symmetry constraints to the wheel center reference plane; Apply vertical rated load and tangential force generated by simulating braking torque to the rim contact surface; Create a static stress study and enable local mesh refinement to 1 mm at the spoke root, where stress concentration occurs. Set nonlinear contact conditions, determine that the hub bearing mating surfaces are in non-penetration contact, and set the friction coefficient to 0.15; The maximum von Mises stress value of the spoke and the rim deformation cloud map were extracted. The SN curve of CL60 steel was imported into the material library in the fatigue analysis example, and the surface roughness correction factor was set to 0.85. The modified Miner criterion was selected as the cumulative damage model, and the failure threshold was set to 0.95 to generate a crack initiation life distribution cloud map.

[0008] Furthermore, in the process of collaborative optimization between lightweighting and fatigue life, with maximizing fatigue life as the primary goal, under the constraints of bearing stress, contact stress and operating temperature, the lightweight optimization design variables include the wheel spoke thickness and shape, rim thickness, hub thickness and width.

[0009] Furthermore, the multi-objective optimization method for wheels using CAE analysis templates includes: Set the objective function and constraints including minimizing mass and maximizing fatigue life; Determine the design variables, including the web thickness, rim thickness, hub thickness and width, and determine the design variable constraints as contact stress, press-fit stress, and bearing stress; Adjust the wheel CAD model in real time and import the optimized lightweight wheel 3D model into the SolidWorks Simulation module through the integrated design platform; Call the CAE analysis template to sequentially perform wheel-rail contact stress field simulation, modified Miner criterion fatigue life prediction under dynamic load spectrum, and thermal-mechanical coupling analysis of braking conditions; Extract the spoke stress distribution and crack initiation life to verify whether the constraints of contact stress ≤ material allowable strength, press-fit stress ≤ UIC 510-5 standard threshold, and bearing stress ≤ 0.8 times the material yield strength are met; If the simulation results exceed the limit, the closed-loop feedback mechanism is triggered, and the design variables are adjusted and iteratively optimized through the inverse mapping algorithm until all performance indicators are met.

[0010] Furthermore, the wheel geometric parameters include wheel diameter, wheel spoke thickness, hub thickness, hub width, and rim height.

[0011] Furthermore, the final output is a lightweight wheel 3D model that complies with the UIC 510-5 standard, a CAE analysis report, and a parameter optimization recommendation table.

[0012] In another aspect, the present invention provides a high-speed train wheel CAD / CAE integrated system, comprising: Data acquisition and preprocessing module, used to collect high-speed train wheel operation data parameters, and perform data cleaning and standardization processing; A parametric-driven CAD design module, used to build parametric CAD templates based on the SolidWorks platform and establish a mapping relationship between wheel geometric parameters and performance indicators; A multi-objective CAE analysis module is used to build multi-objective CAE analysis templates that are automatically associated with parametric CAD templates to simulate wheel-rail contact stress fields, predict fatigue life under the modified Miner criterion under dynamic load spectra, and perform thermal-mechanical coupling analysis of braking conditions. The multi-objective optimization engine module uses a parallel multi-objective optimization engine built based on CAE analysis results and genetic algorithms to perform collaborative optimization between lightweighting and fatigue life; The integrated design platform module is used to build a unified data interaction platform to enable real-time interaction and synchronization between CAD model modifications and CAE analysis results, forming seamless data transfer between CAD and CAE software. It also outputs lightweight wheel 3D models, CAE analysis reports, and parameter optimization recommendation tables that comply with the UIC 510-5 standard. The closed-loop test verification module is used to verify the control simulation error through automated iteration and closed-loop testing.

[0013] Compared with the existing technology, the beneficial effects achieved by the present invention are as follows: the high-speed EMU wheel CAD / CAE integrated system development method provided by the present invention establishes an automated closed-loop mechanism for CAD modeling and CAE analysis through parametric drive, significantly reduces manual intervention, shortens the design cycle by more than 20%, and effectively improves design efficiency.

[0014] A multi-dimensional performance optimization solution comprehensively considers the structural strength, fatigue performance, and thermodynamic characteristics of the wheel under high-speed operation to achieve comprehensive performance improvements (compared to traditional solutions, the wheel weight is reduced by 10% and the fatigue life is extended by 5%). By integrating test data in real time to optimize simulation models, design reliability can be significantly improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is the CAD / CAE integrated design flow chart of the present invention.

[0016] Figure 2 It is the wheel CAD / CAE integrated design interface of the present invention.

[0017] Figure 3 This is a parameterized modeling flow chart of the present invention.

[0018] Figure 4 Wheel CAD parametric design interface.

[0019] Figure 5 This is the multi-objective CAE simulation workflow diagram of the present invention.

[0020] Figure 6 This is the wheel CAE analysis interface of the present invention.

[0021] Figure 7 This is an example of the wheel load stress simulation cloud map of the present invention.

[0022] Figure 8 This is an example of a wheel press-fit stress simulation cloud diagram of the present invention.

[0023] Figure 9 This is an example of the wheel contact stress simulation cloud diagram of the present invention.

[0024] Figure 10 This is an example of the fatigue life analysis cloud diagram of the present invention.

[0025] Figure 11 Execution logic diagram for the optimization algorithm of the present invention. DETAILED DESCRIPTION

[0026] The present invention will be further described below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention.

[0027] An embodiment of the present invention provides a method for developing a CAD / CAE integrated system for high-speed train wheels, comprising the following steps: Step S1: construct a parametric CAD template based on the SolidWorks platform and establish a mapping relationship between wheel geometric parameters and performance indicators; Step S2: Construct a multi-objective CAE analysis template that is automatically associated with the parametric CAD template to perform wheel-rail contact stress field simulation, modified Miner criterion fatigue life prediction under dynamic load spectrum, and thermal-mechanical coupling analysis of braking conditions; Step S3: Use a parallel multi-objective optimization engine built based on CAE analysis results and genetic algorithms to perform collaborative optimization between lightweighting and fatigue life, and control simulation errors through automated iteration and closed-loop testing.

[0028] In addition, an embodiment of the present invention provides a high-speed EMU wheel CAD / CAE integrated system, which includes the following six core modules: data acquisition and preprocessing module, parametric driven CAD design module, multi-objective CAE analysis module, multi-objective optimization engine module, integrated design platform module and closed-loop test verification module.

[0029] In this embodiment, the data acquisition and preprocessing module is used to collect the wheel operation data of the high-speed EMU, covering key parameters such as speed, load, temperature, etc., and then perform data cleaning and standardization processing to provide a reliable basis for subsequent analysis.

[0030] In this embodiment, a parameter-driven CAD design module is used to develop a dedicated parameter interaction interface based on Visual Basic 6.0, capture the geometric feature changes of the SolidWorks model in real time through the COM interface, and trigger the SolidWorks Simulation static analysis module to calculate the maximum equivalent stress value under the corresponding working conditions, and generate a structured data set to be stored in the central database.

[0031] A dynamic matrix building module is embedded in the SolidWorks assembly environment. Five design parameters, such as wheel diameter and rim thickness, are used as input variables and mapped with five performance indicators, such as stress distribution and fatigue life, derived from SolidWorks.

[0032] In this embodiment, the multi-objective CAE analysis module is used to construct a multi-objective CAE analysis template that is automatically associated with the parametric CAD template to perform wheel-rail contact stress field simulation and modified Miner criterion fatigue life prediction under dynamic load spectrum.

[0033] Among them, the construction of multi-objective CAE analysis template covers the following key process steps: 1) Automatically associate CAD model parameters with CAE analysis modules: 2) Create a Parametric Analysis study in SolidWorks Simulation. Use the Model Preparation tool to identify driving dimension parameters (such as rim thickness D1) in the CAD template. Create a bidirectional association between these parameters and the design variables in the Equation Manager. Activate the Geometric Feature Recognition function to automatically extract key geometric features, such as spoke fillets and rim cross-section profile, as analysis targets.

[0034] 3) Define boundary conditions in the "Fixture" module: use the "Fixed Geometry" tool to constrain all degrees of freedom of the hub mounting surface, and apply "Symmetry Constraint" to the wheel center reference plane; 4) Apply load conditions in the "External Load" module: Use the "Force Distribution" function to apply a vertical rated load (15kN for standard conditions) to the rim contact surface, and use the "Remote Load" function to simulate the tangential force generated by the braking torque. 5) Create a "Static Stress" case, select second-order tetrahedral elements for meshing, and enable local mesh refinement to 1 mm in the stress concentration area (spoke root). 6) Set nonlinear contact conditions: define the hub bearing mating surface as a "no penetration" contact pair, and set the friction coefficient to 0.15; 7) After running the solver, use the Result Advisor tool to extract the maximum von Mises stress value of the spoke and the rim deformation contour map. Import the SN curve of CL60 steel from the material library into the Fatigue Analysis example and set the surface roughness correction factor to 0.85.

[0035] 8) Define dynamic load spectrum: Use the "Event Log" function to load the cyclic load history specified in the ISO 8606 standard, including the amplitude-frequency matrix for five typical load conditions; 9) Select the "Modified Miner Criterion" as the cumulative damage model, set the failure threshold to 0.95, and generate a crack initiation life distribution cloud map.

[0036] In this embodiment, the multi-objective optimization engine module uses a parallel multi-objective optimization engine constructed based on CAE analysis results and genetic algorithms to perform collaborative optimization between lightweighting and fatigue life, with the primary goal of achieving lightweighting while maximizing fatigue life. Under the constraints of multiple aspects such as load-bearing stress, contact stress and operating temperature, the optimized design variables include the wheel spoke thickness and shape, rim thickness, and hub thickness and width.

[0037] In this embodiment, the integrated design platform module is used to build a unified data interaction platform to enable real-time interaction and synchronization between CAD model modifications and CAE analysis results, forming seamless data transfer between CAD and CAE software; and output lightweight wheel 3D models, CAE analysis reports, and parameter optimization recommendation tables that comply with the UIC 510-5 standard. The platform enables designers to view CAD design and CAE analysis results in real time.

[0038] In this embodiment, the closed-loop test verification module is used to verify the control simulation error through automated iteration and closed-loop testing.

[0039] Next, the working principle of the high-speed EMU wheel CAD / CAE integrated system development method of the present invention is described in conjunction with the use and operation of a specific embodiment.

[0040] The high-speed EMU wheel CAD / CAE integrated system development method provided in this embodiment is used to integrate the functions of inputting parameters, building models, solving calculations, and viewing results. The specific steps are as follows.

[0041] Step 1: If Figure 1 As shown in the figure, according to the contents of the CAD / CAE integrated design flow chart, the wheel CAD / CAE integrated design interface is designed using the VB programming language, including the CAD modeling and CAE analysis interfaces. Figure 2 .

[0042] (1) CAD modeling interface.

[0043] Follow the parametric modeling flow chart Figure 3 , based on SolidWorks secondary development, combined with VB to build wheel CAD parametric design interface, such as Figure 4 , input parameters, call the wheel 3D geometric model template established by CAD software SolidWorks, and generate a simulation geometric model.

[0044] The interface includes the wheel diameter text box, wheel spoke thickness text box, hub thickness text box, hub width text box, rim height text box, "Cancel Design" button, "Generate Model" button, and "Jump to CAE Analysis" button.

[0045] The wheel diameter text box is used to enter the wheel diameter, the wheel spoke thickness text box is used to enter the wheel spoke thickness, the hub thickness text box is used to enter the hub thickness, the hub width text box is used to enter the hub width, and the rim height text box is used to enter the rim height. The "Cancel Design" button is used to return to the previous interface, the "Generate Model" button is used to generate the wheel model, and the "Jump CAE Analysis" button is used to call the Solidworks Simulation module.

[0046] (2) CAE analysis interface.

[0047] Import the wheel CAD model into the SolidWorks simulation module and follow the multi-objective CAE simulation workflow diagram, as shown in the following example: Figure 5 , build a multi-objective CAE analysis template.

[0048] Set the contact condition to wheel-rail contact, the boundary condition to fixed rail constraints, and the loading condition to the three wheel loads specified in UIC515-4. The thermal load is an emergency braking condition. Complete load strength, contact strength, thermal-mechanical coupling, and fatigue life analyses.

[0049] The wheel CAE analysis interface is constructed based on the VBA secondary development of SolidWorks, such as Figure 6 The "Wheel Pressing Strength Analysis" button is used to call the press-fitting simulation analysis module, the "Wheel Loading Strength Analysis" button is used to call the load-bearing simulation analysis module, the "Wheel Contact Strength Analysis" button is used to call the contact simulation analysis module, the "Fatigue Life Analysis" button is used to call the fatigue life analysis module, and the "Return" button is used to return to the previous interface. The above four modules prepare basic data for the optimization design, such as Figure 7 、 Figure 8 、 Figure 9 、 Figure 10 shown.

[0050] (3) View the results interface The "View Historical Results" button is used to call previous calculation results, the "Run Analysis" button is used to perform stress analysis after entering the axle weight / friction coefficient / interference, and the "Return to Previous Layer" button is used to return to the CAE analysis interface.

[0051] Step 2: Write a VB program to implement the background call to the Solidworks software. By calling Solidworks to read the VBA language swp file, it automatically completes operations such as building the wheel model, dividing the mesh, and setting boundary conditions. The following example takes the wheel contact stress calculation as an example.

[0052] The key procedures for calling Solidworks Simulation software in the background are as follows: Sub main() Set swApp = Application.SldWorks Set Part = swApp.ActiveDoc Dim COSMOSWORKSObj As Object Dim CWAddinCallBackObj As Object Set CWAddinCallBackObj = swApp.GetAddInObject("CosmosWorks.CosmosWorks") Set COSMOSWORKSObj = CWAddinCallBackObj.COSMOSWORKS Dim myModelView As Object Set myModelView = Part.ActiveView myModelView.FrameState = swWindowState_e.swWindowMaximized …… Part.GraphicsRedraw2 Part.ClearSelection2 True Part.ClearSelection2 True boolstatus = Part.Extension.SelectByID2("banlungui", "COMPONENT", 0,0, 0, True, 0, Nothing, 0) Dim ActiveDocObj As Object Dim StudyManagerObj As Object Dim LoadsAndRestraintsManagerObj As Object Dim ErrorCodeObj As Long Dim ContactManagerObj As Object Set ActiveDocObj = COSMOSWORKSObj.ActiveDoc() Set StudyManagerObj = ActiveDocObj.StudyManager() Dim StudyObj As Object Set StudyObj = StudyManagerObj.GetStudy(0) Set ContactManagerObj = StudyObj.ContactManager() Dim CWContactComponent As Object Set CWContactComponent = ContactManagerObj.GetContactComponentAt(0) CWContactComponent.ContactComponentBeginEdit CWContactComponent.ContactComponentType = 2 CWContactComponent.ClearanceValue = 151.4729570716 CWContactComponent.ContactComponentEndEdit Part.ClearSelection2 True …… Part.GraphicsRedraw2 Set LoadsAndRestraintsManagerObj = StudyObj.LoadsAndRestraintsManager() Set DispatchObj1 = Part.SelectionManager.GetSelectedObject6(1, -1) Dim ReferenceGeometryDispatchObj2 As Object Set ReferenceGeometryDispatchObj2 = Part.SelectionManager.GetSelectedObject6(2, -1) DispArray = Array(DispatchObj1) Dim CWForceObj As Object Dim DistanceValues ​​As Variant Dim ForceValues ​​As Variant Dim ComponentValues ​​As Variant Dim data(6) As Double data(0) = 1 data(1) = -70000 data(2) = -70000 data(3) = 1 data(4) = 1 data(5) = 1 ComponentValues ​​= data Set CWForceObj = LoadsAndRestraintsManagerObj.AddForce3(0, 0, 0, 0,0, 0, (DistanceValues), (ForceValues), 0, False, 0, 0, 4, 1,(ComponentValues), False, False, (DispArray), ReferenceGeometryDispatchObj2,False, ErrorCodeObj) CWForceObj.ForceBeginEdit CWForceObj.SetForceComponentValues ​​0, 0, 1, 1, -70000, -70000 CWForceObj.ForceEndEdit Part.ClearSelection2 True.

[0053] Step 3: By calling Solidworks to read the VBA language file, operations such as wheel contact stress simulation analysis can be automatically completed.

[0054] In order to solve the problem of wheel-axle contact stress under different axle loads, a CAD / CAE integrated design interface was developed, including interfaces for creating new files, inputting parameters, modeling and solving, and viewing results. According to the test conditions, a wheel contact stress VBA command stream file was written, and the command stream VBA file was converted into a format readable by VB and written into the VB program. The finite element software Solidworks was called through the background of the VB program to realize functions such as automatic modeling, solving, and viewing results.

[0055] Combine Figure 5 Taking the wheel press-fit stress analysis as an example, according to the usage method of the high-speed EMU wheel CAD / CAE integrated system developed above, the specific steps are as follows.

[0056] Step 1. Create a new file and click the "CAD Modeling" button to enter the wheel modeling interface. Enter the model parameters in the input box, using the mm unit system. For example, the wheel diameter is 860mm, the spoke thickness is 28mm, the rim thickness is 68mm, the hub thickness is 85mm, and the hub width is 110mm. Click the "Generate Model" button. The software will read the configuration file in the background and automatically generate the wheel model in SolidWorks.

[0057] Step 2. Click “Jump to CAE Analysis” and the “Wheel CAE Analysis” interface will pop up. Figure 6 , click "Wheel Press-Fit Analysis" to enter the wheel press-fit analysis interface. Enter the axle interference in the "Interference" input box and the friction coefficient in the "Friction Coefficient" box. Click the "Run Analysis" button. The virtual test software will call SolidWorks to automatically complete the model creation, meshing, boundary condition setting, and stress analysis operations.

[0058] Step 3. After the solution is completed, click the "View Historical Results" button to view the results. The design platform provides a stress cloud result viewing module. Click the "Return to Previous Layer" button to return to the "Wheel CAE Analysis" interface and select the "Fatigue Life Analysis" module. Figure 10 Enter the "Fatigue Life Analysis" interface. Click the "Call Historical Data" drop-down box, select "Wheel Pressing Strength," and click the "Fatigue Life Calculation" button to analyze and calculate fatigue life. The fatigue life cloud chart after analysis and calculation will be displayed in the window. Click "Call Historical Data" to view the historical data analysis results.

[0059] The key procedures for background calling fatigue life analysis are as follows: Sub main() Set swApp = Application.SldWorks Set Part = swApp.ActiveDoc Dim COSMOSWORKSObj As Object Dim CWAddinCallBackObj As Object Set CWAddinCallBackObj = swApp.GetAddInObject("CosmosWorks.CosmosWorks") Set COSMOSWORKSObj = CWAddinCallBackObj.COSMOSWORKS Dim myModelView As Object Set myModelView = Part.ActiveView myModelView.FrameState = swWindowState_e.swWindowMaximized Set myModelView = Part.ActiveView myModelView.FrameState = swWindowState_e.swWindowMaximized Set myModelView = Part.ActiveView myModelView.FrameState = swWindowState_e.swWindowMaximized Dim ActiveDocObj As Object Dim StudyManagerObj As Object Dim LoadsAndRestraintsManagerObj As Object Dim ErrorCodeObj As Long Dim ContactManagerObj As Object Set ActiveDocObj = COSMOSWORKSObj.ActiveDoc() Set StudyManagerObj = ActiveDocObj.StudyManager() Dim StudyObj As Object Set StudyObj = StudyManagerObj.GetStudy(0) ErrorCodeObj = StudyObj.RunAnalysis() ' Zoom In / Out (MouseWheel) Dim swModelView As Object Set swModelView = Part.ActiveView swModelView.Scale2 = 9.87854741946459E-02 Dim swTranslation() As Double ReDim swTranslation(0 To 2) As Double swTranslation(0) = -9.22244102198876E-02 swTranslation(1) = 2.04725681741757E-02 swTranslation(2) = -0.177947715435586 Dim swTranslationVar As Variant swTranslationVar = swTranslation Dim swMathUtils As Object Set swMathUtils = swApp.GetMathUtility() Dim swTranslationVector As MathVector Set swTranslationVector = swMathUtils.CreateVector((swTranslationVar)) swModelView.Translation3 = swTranslationVector …… Sub main() Set swApp = Application.SldWorks Set Part = swApp.ActiveDoc Dim COSMOSWORKSObj As Object Dim CWAddinCallBackObj As Object Set CWAddinCallBackObj = swApp.GetAddInObject("CosmosWorks.CosmosWorks") Set COSMOSWORKSObj = CWAddinCallBackObj.COSMOSWORKS Dim myModelView As Object Set myModelView = Part.ActiveView myModelView.FrameState = swWindowState_e.swWindowMaximized ' Redraw Part.GraphicsRedraw2 Dim ActiveDocObj As Object Dim StudyManagerObj As Object Dim LoadsAndRestraintsManagerObj As Object Dim ErrorCodeObj As Long Dim ContactManagerObj As Object Set ActiveDocObj = COSMOSWORKSObj.ActiveDoc() Set StudyManagerObj = ActiveDocObj.StudyManager() StudyManagerObj.ActiveStudy = 0 Dim motionStudyMgr As Object Set motionStudyMgr = Part.Extension.GetMotionStudyManager() StudyManagerObj.ActiveStudy = 1 Dim NewStudyName As String NewStudyName = "Fatigue 1" Dim CWNewStudy As Object Set CWNewStudy = StudyManagerObj.CreateNewStudy3(NewStudyName, 7, 0,ErrorCodeObj) Step 4: Optimize the analysis results.

[0060] According to the CAE analysis results, the execution logic of the optimization algorithm is carried out according to the verification point, using Figure 11 The wheel multi-objective optimization CAE template established by the flowchart shown completes the wheel multi-objective optimization, optimizes the wheel structure, and improves its strength and wear resistance.

[0061] The specific optimization steps are as follows: Set the objective function: minimize mass and maximize fatigue life.

[0062] Constraint conditions: stress ≤ 350MPa.

[0063] Design variables: spoke thickness, rim thickness, hub thickness and width.

[0064] The design variable constraints are contact stress / pressing stress / bearing stress. The design variables are changed to meet the optimization requirements of lightweighting the wheel and maximizing its life.

[0065] According to the results of the multi-objective optimization, the wheel CAD model is adjusted, and the corresponding CAE analysis is performed on the optimized wheel CAD model according to the operation steps described above.

[0066] The optimized lightweight wheel 3D model is imported into the SolidWorks Simulation module through the integrated design platform. The preset multi-objective CAE analysis template is called to sequentially perform wheel-rail contact stress field simulation (based on Hertz theory), modified Miner criterion fatigue life prediction under dynamic load spectrum, and thermal-mechanical coupling analysis of braking conditions.

[0067] The spoke stress distribution, crack initiation life and temperature field data are extracted to verify whether the constraint requirements of contact stress ≤ material allowable strength, press-fit stress ≤ UIC 510-5 standard threshold and bearing stress ≤ 0.8 times the material yield strength are met.

[0068] If the simulation results exceed the limit, the closed-loop feedback mechanism is triggered, and the design variables are adjusted and iteratively optimized through the inverse mapping algorithm until all performance indicators are met.

[0069] The specific multi-objective optimization procedure of Solidworks Simulation software is as follows: Sub main() Set swApp = Application.SldWorks Set Part = swApp.ActiveDoc Dim COSMOSWORKSObj As Object Dim CWAddinCallBackObj As Object Set CWAddinCallBackObj = swApp.GetAddInObject("CosmosWorks.CosmosWorks") Set COSMOSWORKSObj = CWAddinCallBackObj.COSMOSWORKS Dim myModelView As Object Set myModelView = Part.ActiveView myModelView.FrameState = swWindowState_e.swWindowMaximized Dim ActiveDocObj As Object Dim StudyManagerObj As Object Dim LoadsAndRestraintsManagerObj As Object Dim ErrorCodeObj As Long Dim ContactManagerObj As Object Set ActiveDocObj = COSMOSWORKSObj.ActiveDoc() Set StudyManagerObj = ActiveDocObj.StudyManager() ...... ' Zoom In / Out (MouseWheel) Dim swModelView As Object Set swModelView = Part.ActiveView swModelView.Scale2 = 0.160520562863868 Dim swTranslation() As Double ReDim swTranslation(0 To 2) As Double swTranslation(0) = -4.06627356913103E-02 swTranslation(1) = -6.52446654800719E-03 swTranslation(2) = 0.101634593918423 Dim swTranslationVar As Variant swTranslationVar = swTranslation Dim swMathUtils As Object Set swMathUtils = swApp.GetMathUtility() Dim swTranslationVector As MathVector Set swTranslationVector = swMathUtils.CreateVector((swTranslationVar)) swModelView.Translation3 = swTranslationVector Part.ShowNamedView2 "", 7 ' Zoom To Fit Part.ViewZoomtofit2 The optimized wheel design was verified by this analysis system, and the results showed that the performance indicators of the wheel met the design requirements.

[0070] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A method for developing a CAD / CAE integrated system for high-speed train wheels, characterized in that: include: Build a parametric CAD template based on the SolidWorks platform and establish a mapping relationship between wheel geometric parameters and performance indicators; Construct a multi-objective CAE analysis template that is automatically associated with a parametric CAD template to simulate the wheel-rail contact stress field and predict fatigue life using the modified Miner criterion under dynamic load spectra; A parallel multi-objective optimization engine built based on CAE analysis results and genetic algorithms is used to coordinate optimization between lightweighting and fatigue life, and simulation errors are controlled through automated iteration and closed-loop testing.

2. The high-speed train wheel CAD / CAE integrated system development method according to claim 1 is characterized in that: Methods for building parametric CAD templates include: A dedicated parameter interaction interface was developed based on Visual Basic. This interface captured geometric feature changes in the SolidWorks model in real time through a COM interface, triggered the SolidWorks Simulation static analysis module to calculate the maximum equivalent stress value under the corresponding working conditions, and generated a structured data set that was stored in a central database. A dynamic matrix construction module is embedded in the SolidWorks assembly environment. Five design parameters, including wheel diameter, hub thickness, spoke thickness, hub thickness, and hub width, are used as input variables, and an association mapping is established with two performance indicators, including stress distribution and fatigue life, derived from the SolidWorks platform.

3. The high-speed train wheel CAD / CAE integrated system development method according to claim 1 is characterized in that: Methods for constructing CAE analysis templates and performing CAE analysis include: Create parametric analysis studies in SolidWorks Simulation, identify driving dimension parameters in CAD templates, and establish bidirectional associations with design variables; Automatically extract key geometric features such as spoke transition fillet and rim cross-section profile as analysis objects; Define boundary conditions to constrain all degrees of freedom of the hub mounting surface and apply symmetry constraints to the wheel center reference plane; Apply vertical rated load and tangential force generated by simulating braking torque to the rim contact surface; Create a static stress study and enable local mesh refinement to 1 mm at the spoke root, where stress concentration occurs. Set nonlinear contact conditions, determine that the hub bearing mating surfaces are in non-penetration contact, and set the friction coefficient to 0.15; The maximum von Mises stress value of the spoke and the rim deformation cloud map were extracted. The SN curve of CL60 steel was imported into the material library in the fatigue analysis example, and the surface roughness correction factor was set to 0.

85. The modified Miner criterion was selected as the cumulative damage model, and the failure threshold was set to 0.95 to generate a crack initiation life distribution cloud map.

4. The high-speed train wheel CAD / CAE integrated system development method according to claim 1 is characterized in that: In the process of collaborative optimization between lightweighting and fatigue life, maximizing fatigue life is the primary goal. Under the constraints of load-bearing stress, contact stress, press-fit stress, operating temperature, and fatigue life, the lightweight optimization design variables include the wheel spoke thickness and shape, rim thickness, and hub thickness and width.

5. The high-speed train wheel CAD / CAE integrated system development method according to claim 1 is characterized in that: The multi-objective wheel optimization method using CAE analysis templates includes: Set the objective function and constraints including minimizing mass and maximizing fatigue life; Determine the design variables, including the web thickness, rim thickness, hub thickness and width, and determine the design variable constraints as contact stress, press-fit stress, and bearing stress; Adjust the wheel CAD model in real time and import the optimized lightweight wheel 3D model into the SolidWorks Simulation module through the integrated design platform; Calling the multi-objective CAE analysis template to sequentially perform wheel-rail contact stress field simulation, modified Miner criterion fatigue life prediction under dynamic load spectrum, and thermal-mechanical coupling analysis of braking conditions; Extract spoke stress distribution, crack initiation life, and temperature field data to verify whether the constraints of contact stress ≤ material allowable strength, press-fit stress ≤ UIC 510-5 standard threshold, and bearing stress ≤ 0.8 times the material yield strength are met; If the simulation results exceed the limit, the closed-loop feedback mechanism is triggered, and the design variables are adjusted and iteratively optimized through the inverse mapping algorithm until all performance indicators are met.

6. The high-speed train wheel CAD / CAE integrated system development method according to claim 1 is characterized in that: The wheel geometric parameters include wheel diameter, wheel spoke thickness, hub thickness, hub width, and rim height.

7. The high-speed train wheel CAD / CAE integrated system development method according to claim 1 is characterized in that: The final output is a lightweight wheel 3D model that complies with the UIC 510-5 standard, a CAE analysis report, and a parameter optimization recommendation table.

8. A high-speed train wheel CAD / CAE integrated system, characterized by: include: A parametric-driven CAD design module, used to build parametric CAD templates based on the SolidWorks platform and establish a mapping relationship between wheel geometric parameters and performance indicators; CAE analysis module, used to build multi-objective CAE analysis templates automatically associated with parametric CAD templates, to simulate wheel-rail contact stress fields, predict fatigue life under the modified Miner criterion under dynamic load spectra, and perform thermal-mechanical coupling analysis of braking conditions; The multi-objective optimization engine module uses a parallel multi-objective optimization engine built based on CAE analysis results and genetic algorithms to perform collaborative optimization between lightweighting and fatigue life; The integrated design platform module is used to build a unified data interaction platform to enable real-time interaction and synchronization between CAD model modifications and CAE analysis results, forming seamless data transfer between CAD and CAE software. It also outputs lightweight wheel 3D models, CAE analysis reports, and parameter optimization recommendation tables that comply with the UIC 510-5 standard. The closed-loop test verification module is used to verify the control simulation error through automated iteration and closed-loop testing.

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