Week 2 Railwheel and Track

Objective of challenge: 1. To perform the simulation of rail wheel track and execute it by appyling bearing load of 500000N and compare the simulation results of "Total Deformation, Equivalent stress and the life under both the loads".
2. To perform the simulation of rail wheel track and execute it by appyling bearing load of 100000N and compare the "inbuilt result by ANSYS and user defined result of Total Deformation".

Simulation setup configuration as follows:

1. Model as follows

2. Part names are specified as

3. Material applied for Track, Wheel and Shaft is "Structural steel" for case 1 and case 2.

4. For 2 cases Connections configured as

5. For case 1 Mesh size for Track, Wheel and Shaft is 35mm.

For case 2 Mesh sizing as follows

6. Analysis settings configured as shown in below image.

For case 2 bearing load is 100000N

Simulation results are as follows:

Description	Case studies
Material	Structural steel for Rail, wheel and track
Mesh element size	50mm
Mesh face sizing	35mm
Load N-mm	100000
Inbuilt result by ANSYS of Total Deformation	Max 1001.1 mm
User defined result of Total Deformation (Expression = sqrt(Ux^2+Uy^2+Uz^2)	Max 1001.1 mm
Conclusion	Both inbuilt and expression values are obtained same from max. to min. with very small difference.

Description	Case study 1	Case study 2	Comments
Material	Structural steel for Rail, wheel and track	Structural steel for Rail, wheel and track
Mesh element size	50mm	35mm
Mesh face sizing	35mm	-
Bearing Load N-mm	100000	500000
Von-Mises stress	Max 84.64 Mpa	Max 254.71 Mpa	Maximum stress found on between tooth face and flank area of inner side bevel and pinion gear for 3 cases
Life	Max 1.e+006 cycles, Min 1.e+006 cycles	Max 1.e+006 cycles, Min 11015 cycles	Maximum strain found on between tooth face and flank area of inner side bevel and pinion gear for 3 cases
Total Deformation	Max 1001.1 mm	Max 1001.2 mm	Maximum deformation found on tooth top land big radius area for 3 cases
Conclusion	For 2 cases "Total deformation" found no difference. Life cycles maximum obtained as Max 1.e+006 cycles and minimum cycles obtained as Min 11015 cycles. Equivalent stress has major difference.