Week 2 Railwheel and Track

Objective: To perform a static structural analysis on Railway wheel & Track setup.

Case 1: To compare Deformation, Stress & strain with bearing load of 100000N & 500000N.
Case 2: To include a User Defined Result for total Deformation & Compare the same with inbuilt result.

Case Setup & Execution:

1. Select Static Structural from Workbench & then choose the material structural steel as default for all the parts.
2. Import the geometry and then update the same in model. Edit Model then the part will appear.
3. Select Contact and right click & choose rename based on definition. Flip both the contacts & provide frictional value of 0.2 to wheel & track contact. For 2^nd contact choose frictionless.
4. After that in connections choose Body ground and fix the track. Add one more connection of body ground and provide translational motion to shaft. Also include planar connection.
5. Now moving to mesh select sizing 50mm to few parts and 35 mm to parts which are in contact. This is to get most accurate value of stress strain & Deformation.
6. Next for Analysis setting select no of steps as 5 and make the necessary changes such as Large Deflection on, Force Convergence on etc. Select the minimum and maximum time step
7. Insert Joint load & Select translational motion also in tabular table provide 0 to 500 mm with 100 mm in each step. Now the wheel will travel a distance of 500mm in simulation.
8. Now hide the shaft & apply bearing load in to the inner face of the wheel. Select the y Component & apply 1e-5 N load.
9. Concluding to final step Insert Stress, Strain & Total Deformation. Also include any other user defined categories as required. Hit Solve.

Case 1 Solution : Comparing the two values of Stress strain & Deformation it was observed

Sr No	Bearing load	Stress (Max)	Strain	Deformation(Max)	Life (Max)
1.	1e^5	90.42 Mpa	0.00056911	999.8 mm	1e6
2.	5e^5	407.3 Mpa	0.0025228	999.8 mm	1e6

In this case one we are applying two different Bearing loads with similar boundary conditions & comparing all their values such as stress, strain, deformation & life. All the data is listed above in tabular form. Through the simulation it’s been observed that stress value has increased almost 5 times from 90.42 Mpa to 407.3 Mpa after increasing the bearing load. It is the most effected result of all others. Also if we consider strain then there is also an increment in strain value when the bearing load is increased by 5 times. Life and Total deformation remains the same as we all know that unless and until we change the boundary conditions we cannot observe any major differences in Deformation & life. So it is same in both the Conditions.

Case 2:In this case we have to compare both the bearing load with an user defined criteria for total deformation and compare both values with solver inbuilt deformation function. Now after applying a user defined criteria as (Ux^2+Uy^2+Uz^2) for deformation, there is no remarkable change and the value of deformation remains same 999.8 mm for both the cases as we compare both inbuilt and user defined function for dissimilar bearing loads.

Note - Images are attached for reference with 1e^5 at end for load of 100000N & 5e^5 for 500000N. Life ,Deformation, Stress, Strain files are attached for reference. Simulated data is attached in .wbpz format