Question

Perform a static structural analysis on the Rail wheel 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.

Analysis Systems

Static structural

Geometry

Ensure both wheel, shaft and track are assigned as structural steel

Materials

Structural steel

Model upload.

Upload the model in to the geometry and edit in the model state.

Change the material in the geometry to structural steel.

Contacts

Open the connections and contact and select both contact

And rename based on definition

Flip the contact

First contact with shaft and wheel and

Second contact with wheel and track

Wheel and track contact should be frictional and coefficient 0.3

Shaft and wheel contact should be frictionless

Joints

Make track as grounded from body grounds

Make wheel shaft as Translational joint

Make wheel as planar joint

Coordinate systems

Now check the axis of shaft is along with translational axis so change the coordinate system

Mesh

Insert the sizing for the mesh in surface of the track and wheel only

Analysis settings

Change the step as 5 and

Auto time stepping should be program controlled

Switch on large deflection

Solver type direct

All output control parameters should be yes

Nonlinear controls switch on force convergence as ON

Select all steps up to 5 and set auto time stepping as ON.

Defined by TIME

Carry over time step ON

Minimum time step should be 1e-3

Maximum time step should be 0.1s

Static structural

Insert joint load

Select Translational

DOF X displacement

Type displacement

Magnitude Tabular data

And input in the tabular data as 100, 200 to 500

Select bearing load on the inside surface of the wheel

Defined by component and select as Y component -1e5 for the first case and -5e5 for the five times case.

Solution

Inset the total deformation

Insert the von mises stress and

Insert von mises strain

Insert stress and strain again and select wheel body only

Insert contact tool twice and select only one on one item

First one for the shaft and wheel and second one for the wheel and track

From the contact tool insert pressure on both

Insert a probe and select force reaction and weak spring as boundary condition. Select geometry as wheel body

Insert a user defined result

Put RX in the expression area and select angle in the output unit.

Before the result please check the cores from the tools

Then just hit the solve button

Results

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

Total Deformation 10000 Bearing load

Total Deformation 50000 Bearing load

Equivalent stress at 10000 Bearing load

Equivalent stress at 50000 bearing load

Equivalent strain at 10000 Bearing load

Equivalent strain at 50000 Bearing load

Equivalent stress at wheel only at 10000 Bearing load

Equivalent stress at wheel only at 50000 Bearing load

Equivalent strain at wheel only at 10000 Bearing load

Equivalent strain at wheel only at 50000 Bearing load

Contact tool pressure at wheel 10000 Bearing load

Contact tool pressure at wheel 50000 Bearing load

Contact tool pressure at shaft 10000 Bearing load

Contact tool pressure at shaft 50000 Bearing load

Force reaction at 10000 Bearing load

Force reaction at 50000 Bearing load

User defined result at 10000 Bearing load

User defined result at 50000 Bearing load

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.

Conclusion case 1

Total deformation

when the bearing load is 10000 is 999.84 mm

when the bearing load is 5 x 10000 is 1000.1 mm

Equivalent stress

when the bearing load is 10000 is 98.724 Mpa

when the bearing load is 5 x 10000 is 449.39 Mpa

Equivalent strain

when the bearing load is 10000 is 0.00069

when the bearing load is 5 x 10000 is 0.0028

Equivalent stress on wheel

when the bearing load is 10000 is 84.777 Mpa

when the bearing load is 5 x 10000 is 356.31 Mpa

Equivalent strain on wheel

when the bearing load is 10000 is 0.00047

when the bearing load is 5 x 10000 is 0.0019

Pressure on wheel

when the bearing load is 10000 is 133.85 Mpa

when the bearing load is 5 x 10000 is 591.56 Mpa

Pressure on wheel Shaft

when the bearing load is 10000 is 8.324 Mpa

when the bearing load is 5 x 10000 is 25.434 Mpa

force reaction on the wheel

when the bearing load is 10000 is which is coming in the range of -65574 to 1.2023e+5

when the bearing load is 5 x 10000, which is coming is coming around the range of -2.9723e+5 to 5.6467 e+5

Bearing load of 5 times does not have many effect on the total deformation on the wheel track but it has at least 5 times effect on the equivalent stress on wheel track, wheel and the pressure on the wheel and pressure on the wheel shaft does not have many effect. Almost three times value. Force reaction also having a five times variation in the values.

Conclusion case 2

Total deformation has been found when using the expression USUM in the user defined area and that has been become exactly same as the one we got it from original total deformation, which is at the bearing load of 10000 is 999.84 mm