Railwheel and Track

The Railwheel,track model first imported to ansys and then material was set to structural steel for both Cases.

Connections Settings :

The contacts as detected by ansys were changed to rename by its definition and the contact and target were flipped.

First Contact

Second Contact

Joint Settings :

Fixed Joint

Connection Type And Type is set as Above image, then selected the rail-track side faces.

Translational Joint

Connection Type - Body to Ground And Type - Translational is set, then selected the shaft face.

Planer Joint

Connection Type - Body to Ground And Type - Planer is set, then selected the railwheel perpandicular to z-axis face.

Mesh Setting :

The mesh sizing is of 50mm given to the entire body.

Here we are Confirmed that Nodes & Elements are within Problem Limit.

Face Meshing :

mesh sizing of 35mm is given to the top of track and the two faces coming in contact with the track.

Analysis Settings :

The auto time step is set to program controlled in first time step and solver is changed
to direct, From second time step to fifth time step a minimum time step of le-3 is given
and a maximum time step of 0.1s, large deflection is kept on.

Note : Only In Bearing Load, Load is Changing But other step remain exactly the same for both Cases.

Bearing Load

Case 1

Case 2

Joint - Displacement

Running the simulation and getting proper results

Simulation Result :

Total Deformation - Case 1

Total Deformation - Case 2

Equivalent Stress - Case 1

Equivalent Stress - Case 2

User Defined Result - Case 1

User Defined Result - Case 2

Result :

Case 1

Case 2

Conclusion :

1. When the bearing load is increased 5 times to 5e^5 N from 1e^5 N the structure will fail quickly hence its life reduces with 5e^5 N loading as evident from the life plot with 5e\"5 N loading failure starts at 2963th cycle on the rail track whereas failure for le^5N loading starts only at 5.4946e+005 cycles cycle on the rail track. The maximum life is the same for both the loadings and is around 1e^6 cycles.
2. The maximum equivalent stresses induced are also high for loading with 5e^5N and
   are more by a magnitude of 388.34Mpa in comparison to bearing load at 1e^5N.
3. The max value of total deformation are almost same for both the loadings at shaft (1e^5N and 5e^5N) and differ by magnitudes of 0.02 - 0.08