Rail Wheel Track Simulation

Objective:

To Perform a static structural analysis on the Railwheel and Track setup and

Case 1: Multiply the bearing load by 5 times and compare the results with the load of 100000 N (As done in week 2 video). Compare the Total Deformation, Equivalent stress and the life under both the loads

Case 2: Implement a User defined result and calculate the Total Deformation from this result and check if it is the same as that obtained by the inbuilt result by ANSYS for a load of 100000 N.

Procedure:

* Open Static structural Project schematic in ANSYS Workbench. and select the required material, in our case Structural steel has taken as rail wheel and track material. and material properties as follows:

Young\'s Modulus = 2e+05 MPa
Poisson\'s Ratio = 0.3
Bulk Modulus = 1.6667e+05 MPa
Shear Modulus = 76923 MPa

* Coming to Geometry, Import the Given Model and open it in Design Moduler to check the Given model.

* Open the Model in Project schematic to start give the inputs for simulation. (Double click on Model Option).

* After opening of Mechanical screen, in the project tree select geometry, under that rename the parts visible accordingly for the identification purpose.

* Under the connections, select contact option and insert two frictional contacts from track to wheela and wheel to Shaft. and select those faces and apply to respective frictional contact.

Interface Treatment

Add Offset, No Ramping

* Insert the joints under connections to define joints between parts.

Joint no.1 Fixed joint: Select the track faces and apply them to fixed joint.

Joint no.2 Translational Joint: Select the shaft face and apply it and also check the Reference Coordination system to check the direction.

Joint no.3 Planer joint: select wheel face to define in which plane moment has to happen.

* Mesh: Implementing face sizing for better results, in our case faces of wheel and track has been sized as 35mm and remaining target length as 50mm

* In the Static structural element select analysis settings:

No. of steps	5
Auto- Time stepping	On
Defined By	Time
Carry over time step	On
Max. Time step	0.1 S
Min. Time Step	0.001 S

* Under the to define load for simulation Select Bearing load for shaft and wheel give input load as 100000N. for this select wheel inside face which is common to shaft and wheel.

* Select shaft face and define displacement as 500mm as 100mm intervels in 5 steps.

* Insert Output requirements under solution as follows: 1. Total Deformation, 2. Equivalent stress, 3. Life.

Results:

Case1: 100000N and 500000N comparesion,

Deformation:

Pic1:100000N and Pic2: 500000N

Equivalent stress:

Life:

Bearing Load	Deformation	Equivalent stress	Life (Min)
100000N	999.31 mm	132.74 MPa	1.1514e5
500000N	999.13 mm	551.25 MPa	1119.5

Case 2:

User Defined results @ 500000N Load condition

With the Help of ANSYS Help, got the formula for User defined results and given input as sqrt(UX^2+UY^2+UZ^2) and observed that, there is no much difference in results.

Conclusion:

1. Total deformation is comparatively same in both the cases.

2. Values of Equivalent stress is higher when load is high, and lower when load is low ( Directly proportional ).