Week 2 Railwheel and Track

OBJECTIVE:-

To perform a structural analysis on track and Rail-wheel and also obtain the various results such as Total deformation, Equivalent stress & Life of the model.

PROCEDURE:-

Create a new static structural model, Assign the material as Structural steel and import the geometry provided. If any changes need to be done in the geometry, then edit the geometry with the help of space-claim, otherwise proceed. Open the geometry in the mechanical workbench. Starting woth contacts, assign the contacts in between the hub and wheel and also in between wheel and track.

CONTACTS:-

Wheel and track

Definition type:- Frictional contact

frictional coefficient = 0.3 and; leave all the other settings as default.

Wheel and hub:

Definition type : Frictionless contact, ans leave all the left over parameter settings as default.

After contacts ,assigning joints

PLANAR JOINT

TRANSLATIONAL JOINT

FIXED JOINT

Meshing the component

The default element size for the model is set to 50 mm

Whereas the size for the face/contact area is set to be 35 mm

Analysis setting:-

Applying the criteria for the 1^st step in the analysis setting to be ON for general miscellaneous

Contact miscellaneous Also back stress, strain to be ON under output control section.

Force convergence to be ON, solver type – Direct, Large deflection – ON

And after the 1^st step For the next 2 to 5 steps

Initial time step = 1e-3 and max time step = 0.1 has been set

Also, auto time stepping has turned ON.

Solver type= direct

Large deflection = ON

Force convergence = ON (under non linear contacts)

And also output controls be switched ON

Now defining the load for particular simulation:

Load on wheels for translation , the wheel will travel a distance of 500 mm so in each step assigning a 100 mm increasing displacement,

Apart from this the wheel will also have the bearing load i.e. the load of the carriage will be transferred to the shaft which will ultimately be transferred to the rails, thus applying the bearing load to the mid of the wheel of 1E+5 N.

Post the loads applied let us list down all the required results, in our simulation we need to evaluate results for total deformation, equivalent stress and life of the system:-

All the result parameters can be inserted by :

Right click – insert – equivalent stress

Right click – insert – Fatigue tool - life

Right click – insert – total deformation.

Case Default :-

For 1E+5 N load,solving for analysis:

Total deformation

Equivalent stress

Life cycle of the system

Case 1:-

In case 1 we will be multiplying the bearing load by 5 times and comparing the result with the default results:

Total deformation

Equivalent stress

Life cycle

Case 2:

In case 2,user define result has to be obtained for total deformation of the model. Thus applying the equation – sqrt(Ux^2+Uy^2+Uz^2).

TOTAL DEFORMATION

COMPARISON:-

In between default case and case 1 :

Total deformation 100000 N Total deformation 500000 N

Equivalent stress 100000 N Equivalenst stress 500000 N

Life of model in 100000 N Life of model in 500000 N

	100000 M	500000 N
Total deformation(mm)	1001.3	1001.5
Equivalent stress(MPa)	102.78	429.9
Life of model(in cycles)	1E6	1E6

The maximum values of the parameters are tabulated above.

Form the above comparison it is seen that

1. There is no change in the life cycle of the model in different loading conditions,
2. Total deformation is slightly more in case for 500k N loading compared to 100k N loading.
3. And the Von-mises stress value is greater in case 1 in comparison to default case.

Comparing the default case with user defined case

100000 N case User defined case

The value of total deformation in both the case are same, and no change can be seen in both the results.

CONCLUSION:-

The static structural analysis is performed for the given model with the varying three different cases and the results are tabulated:

	100000 N	500000 N	User defined
Total deformation(mm)	1001.3	1001.5	1001.3
Equivalent stress(MPa)	102.78	429.9
Life of model(in cycles)	1E6	1E6

Here is attached the link for accessing the workbench files:

https://drive.google.com/file/d/1Z-hWIkjX03xaN9yGIWEExwPzgdozfodm/view?usp=sharing