Week 2 Railwheel and Track

STATIC STRUCTURAL ANALYSIS ON THE RAILWHEEL AND TRACK SETUP

Objective

Case 1:

To simulate the Railwheel and track for their Total Deformation, Equivalent stress, and Life under both the given loads (100 KN & 500 KN ).

Case 2 :

To Implement a User-defined result and to calculate the Total Deformation from this result and to check if it is the same as that obtained by the in-built result by ANSYS for a load of 100 KN.

Material data

Figure. 1 shows the structural steel's properties in Ansys Workbench engineering data. It was used as the bevel gear model's material input.

Figure. 1 Structural steel Engineering data

Model Geometry

Figure. 2 shows the imported given Railwheel and track model in the mechanical modular.

Figure. 2 Railwheel and track model

Contact and Target faces

Figure. 3 illustrates the contact and target faces of the Railwheel and track. In which the wheel is assigned as “Contact Bodies” and the rail is assigned as “Target Bodies” and this is met to be “Frictional”

Figure. 3 Frictional- Wheel to running rail

Figure. 4 illustrates the contact and target faces of the Railwheel and axle (“Part 2”) . In which the wheel is assigned as “Contact Bodies” and the axle is assigned as “Target Bodies” and this is met to be “Frictionless”

Figure. 4 Frictionless - axle to the wheel

Joint Connections

Figure. 5 illustrates the Fixed connections of the track in which both the side faces are fixed.

Figure. 5 Fixed - Ground to the track

Figure. 6 illustrates the Translational connection of the axle in which axis was corrected in the direction of wheel motion.

Figure. 6 Translational - Ground to the Axle

Figure. 7 illustrates the planar connection of the Wheel.

Figure. 7 Planar - Ground to the Wheel.

Meshing

This meshging has been in two level initially with 50 mm meshing size is carried, after that all the 3 faces (Track uper face, Wheel running face and Adjustment face of wheel running face) has been sized with a mesh size of 35mm. Figure. 8 shows the meshed model of Railwheel and track model.

Figure. 8 Meshed Railwheel and track model

Bearing load

Figure. 9 illustrates the bearing load of the Wheel. Since the load act in the inner face of the wheel hole, the inner face of the wheel hole is loaded with 100 KN and in order to view the loading section the Axle is hidden with the “hide body” command

Figure. 9 Bearing load of the Wheel

Joint displacement

Figure. 10 illustrates Joint displacement of the wheel on track since the displacement is for 500 mm and the number of cycles are assigned as 5 steps in the analysis setting, Each steps will be added 100 mm with the previous one to achieve total 500 mm.

Figure. 10 Joint displacement of the Wheel

Simulation Results

Case 1:

Total Deformation

Figure 11. shows the Total deformation of the Railwheel and track model at 100 KN

Figure 11. Total Deformation at 100 KN Load

Equivalent Stress

Figure 12. shows the Equivalent Stress of the Railwheel and track model at 100 KN

Figure 12. Equivalent Stress at 100 KN Load

Life Cycle

Figure 13. shows the Life Cycle of Railwheel at 100 KN

Figure 13. Life Cycle of Railwheel at 100 KN Load

Figure 14. shows the Life Cycle of track at 100 KN

Figure 14. Life Cycle of track at 100 KN Load

Figure 15. shows the Life Cycle of the axle at 100 KN

Figure 15. Life Cycle of the axle at 100 K N Load

Total Deformation

Figure 16. shows the Total deformation of the Railwheel and track model at 500 KN

Figure 16. Total Deformation at 500 KN Load

Equivalent Stress

Figure 17. shows the Equivalent Stress of the Railwheel and track model at 500 KN

Figure 17. Equivalent Stress at 500 KN Load

Life Cycle

Figure 18. shows the Life Cycle of Railwheel at 500 KN

Figure 18. Life Cycle of Railwheel at 500 K N Load

Figure 19. shows the Life Cycle of track at 500 KN

Figure 19. Life Cycle of track at 500 KN Load

Figure 20. shows the Life Cycle of axle at 500 KN

Figure 20. Life Cycle of axle at 500 KN Load

Case 2:

Figure 21. shows the Total Deformation at 100 KN from User-defined results

Figure 21. Total Deformation at 100 KN from User-defined results

Figure 22. shows the Total Deformation at 500 KN from User-defined results

Figure 22. Total Deformation at 500 KN from User-defined results

Comparison of result

Case 1:

	Bearing load
	100 KN	500 KN
Total Deformation (Minimum)	2.8422e-014 mm	4.2633e-014 mm
Total Deformation (Maximum)	1001.2 mm	1000.9 mm
Equivalent Stress (Minimum)	2.0711e-12 Mpa	2.3497e-9 Mpa
Equivalent Stress (Maximum)	150.13	422.23 Mpa

Case 2:

Bearing load	Total Deformation (Maximum)	Total Deformation from User-defined results (Maximum)
100 KN	1001.2 mm	210.02
500 KN	1000.9 mm	209.13

Conclusion

• We can observe significant increases in Stress and deformation from comparison results.
• User Defined results are different from inbuilt results in both cases but the range of these results are relatable with the minimum and maximum deformation in their cases separately in a ratio i.e, the difference between maximum deformation and minimum deformation is approximately 1mm in both User Defined and inbuilt results.
• We are aware that structural steel has a 250 Mpa tensile yield strength. Therefore, stress has achieved its maximum level of 422.23 Mpa under 500 KN loads. Plastic deformation will therefore occur, as well as permanent deformation.
• As per the results, we can see that fatigue life in both 100 KN loads and 500 KN loads is a maximum of 1e6 cycles for wheel, track, and axel in the model. Within this cycle, the axle has become unsuitable in both cases hence we should avoid higher loads for safety purposes.