Week 2 Railwheel and Track

WEEK 2: SIMULATION ON RAIL WHEEL AND TRACK

AIM :-

To simulate the Railwheel and track for their lifecycle and the stress, strain, and total deformation provided by the wheel running on the track by the given forces.

OBJECTIVE :-

The main focus of this component is toevaluate the result of the product life cycle and the stress, strain, and total deformation in the static structural material. This component to be examined by tow cases

Case 1: Load of 100000 N.

Case 2: Load of 5 times of 100000N.

And Implement user-defined results and compare both results in all aspects of the evaluation.

INTRODUCTION :-

Rail wheel concept

The train wheel or a rail wheel is specially designed for use of railway tracks. This rolling component (wheel) is especially pushed onto on axle and mounted directly on a railway carriage or locomotive or indirectly we can say boogie. This wheel is cast or forged and is heated or treated to have a specific hardness New wheels are trued, using a lathe, to a specific profile before being pressed onto an axle. All wheels profile must be regularly checked to ensure proper interaction between the rail and wheel. Incorrectly trued or worn out wheels can increase rolling resistance, reduce energy efficiency and many even cause a derailment.

Fig 1: Rail wheel and track

Wheel Geometry and Flange, most train wheels have a conical geometry, which is the initial means of keeping the train motion aligned with the track. The train wheels have a flange on one side to keep the wheels and hence the train, running on the rails when the limits of geometry-based alignment are reached.

Fig 2: Wheels arrangement

PROCEDURE

For the simulation of the rail wheel and track the static structural material which is default has been used to evaluate the result.

First, the geometry is imported and then opened directly in the mechanical module.

Fig 3: Geometry of rail wheel and track

To set up certain parameters and loads for the simulation process of the rail wheel and track the materials is default as structural steel with the property mentioned below.

Fig 4: Properties of static structural

To understand the contact between the rail wheel and track they are renamed based on the definition and then flip contact to the
target.

Two contacts are provided between them:

1) Frictional- Wheel to running rail.

Fig 5: Contact between wheel to running rail

Fig 6: Contact parameters wheel to the rail track

2) Frictionless - shaft to the Wheel.

Fig 7: Contact between the shaft and the wheel.

Fig 8: Contact parameters shaft to the wheel

After giving the parameters the joints to be applied for the application to be run on the simulation process while evaluating the results.

The first joined is applied is the fixed joint for the non-moment of the track while running the wheel on them.

Fig 9: Fixed Joint

Fig 10: Parameters of Fixed Joint

Second is the transitional joint given to the shaft, was the shaft is attached to the wheel the forces act on the shaft will be transational to the wheel.

Fig 11: Transitional Joint shaft

Fig 12: Parameters of Transitional Joint

 The final joint is the planar joint which provided to the wheel.

Fig 13: Planar Joint

 

Fig 14: Parameters of Planar Joint

Mesh 

Element size : 50mm

and the three faces are selected with the facing size around 35mm.

Fig 15: Mesh facing surface

 

Fig 16: Mesh

 

Fig 17: Mesh Statistics

Giving the appropriate parameters in the analysis setting with some joint load that need to apply on the geometry.

Fig 18: Analysis settings

After getting the parameters of the analysis setting two loads are applied

1) Bearing load with the value of 100000N

Fig 19: Bearing load

 

Fig 20: Bearing load parameters

2) Joint displacement

Fig 21: Joint displacement

Fig 22: Joint displacement Parameters

The following parameters need to be evaluated for the result of the rail wheel and track.

• Equivalent Von misses stress.
• Total deformation.
• Life cycle.
• User- defined results.

Fig 23: Define the solution parameters

RESULTS

Case 1 : Bearing load 500KN and 100KN. Compare the results for total deformation, Equivalent stress, and life under both loads.

Bearing Load 100KN

Fig 24: Total deformation

Fig 25: Equivalent stress

Fig 26: The life cycle of track

 

Fig 27: The life of railwheel 

Fig 28: The life cycle of shaft

Bearing Load 500KN 

Fig 29: Total deformation

Fig 30: Equivalent stress

Fig 31: Life of track

Fig 32: Life of wheel

 

Fig 33: Life of wheel

Comparison of results :

Sr.no.	100KN	500KN
Total deformation Min(mm)	0	2.8422e-014
Total deformation Max(mm)	1001.1	1001.1
Total deformation Avg(mm)	367.11	367.11
Equivalent von mises stress Min(Mpa)	4.5556e-010	2.0066e-009
Equivalent von mises stress Max(Mpa)	84.739	326.46
Equivalent von mises stress Avg(Mpa)	1.1504	5.334

Fig 34: Plot for Total deformation(mm)

 

Fig 35: Plot for Equivalent von mises stress

The result shows that the load increases, as the force on the trackwheel simulation the equivalent stress and deformation increases, the force is directly proportional to the stress value. And the life cycle for both loads 1e^16 max.

Case 2: User-defined Result

To evaluate the user-defined result for both loads as I have taken the result for both loads. The expression used to evaluate the result expression used is UX + UY +UZ and the output unit is displacement.

Load 100KN 

Fig 36: User-defined Result

Load 500KN 

 

Fig 37: User-defined Result