Evaluation of structural safety of a tilting bolster

This study has performed the experimental study to assess the structural safety of a bolster frame that is applied to the bogie system of Korean tilting train. In order to achieve this goal, firstly, loading conditions imposed on the bolster frame were investigated. Based on the international standard and dynamic analysis, the loading conditions were derived. In this study, the dynamic load cases that consider the carbody tilting effect were established. The structural safety of the bolster frame was evaluated by static test under these static loads and the fatigue strength was assessed using Goodman diagram. From the assessment, the bolster frame has satisfied the structural safety. In addition, fatigue test was carried out up to 10 × 10⁶ cycles under tilting load condition established in this study. The inspection of fatigue crack using NDT method was conducted at 6 × 10⁶ and 10 × 10⁶ cycle.     

Calculated and experimental analysis of cause of the appearance of cracks in the running bogie frame of diesel multiple units of Serbian railways

In this paper an analysis of possible causes of crack occurrence on reconstructed diesel multiple units (DMU) exploited on sideline in Serbia was performed. Analyzed DMU were designed in the sixties of the last century in accordance with standards and UIC regulations of that time. During exploitation cracks appeared on the frame of the running bogie and they were locally repaired. With the purpose of eliminating this negative occurrence that has been reducing the availability of DMU, reconstruction of primary suspension and reconstruction of the DMU running bogie frame was performed. The new construction solution of primary suspension is with rubber springs. In the designing of the new running bogie frame fatigue loads were taken into account. After approximately two and a half years of exploitation, cracks appeared again on frames of the running bogie of DMU and they are the subject of this work. This work gives an analysis of the cause of crack occurrence and investigates links between specific exploitation conditions on tracks of Serbian railways and calculations/investigations performed using currently valid UIC regulations. The analysis also includes other influential factors such as welding quality, track quality, DMU and track maintenance quality.     

A Case Study on Fatigue Failure of a Transmission Gearbox Input Shaft

In this paper, a root cause analysis of premature failure of a gearbox input shaft, manufactured of AISI 1045-H, was performed through standard procedures for failure analysis. Shaft failed on cross oil hole through a helical fracture and therefore did not meet bogie 100,000 cycles during the verification with 10 Hz frequency cyclic testing. The fracture in the oil hole implied evidence of fatigue (i.e., beach marks on the fracture surface were clearly visible). Prior to improving the fatigue life and suggesting required remedial actions, mechanism of failure has to be understood, especially the initiating point of cracking. To this end, chemical analysis, microstructural characterization, fractography, hardness measurements, and finite element simulation were used to assess the nature of fracture in detail. The fractography analysis showed that fatigue beach marks originate from transition zone of the case on the cross oil hole. This is possibly due to the fact that torsional strength in this area is lower than torsional fatigue strength which leads to fatigue crack initiation, crack growth, and final fracture. At the end of this paper, proper remedial actions have been proposed.     

地铁A型车辆转向架设计

本文主要介绍了适用于地铁A型车辆的A型车转向架的整体结构、主要技术特点和技术参数,构架、车轴、车轮等重要部件的技术特点及强度计算结果,整车动力学性能计算结果。各项计算结果均满足标准要求。     

A novel bogie design made of glass fibre reinforced plastic

This paper presents a completely new design of a bogie-frame made of glass fibre reinforced composites and its performance under various loading conditions predicted by finite element analysis. The bogie consists of two frames, with one placed on top of the other, and two axle ties connecting the axles. Each frame consists of two side arms and a transom between. The top frame is thinner and more compliant and has a higher curvature compared with the bottom frame. Variable vertical stiffness can be achieved before and after the contact between the two frames at the central section of the bogie to cope with different load levels. Finite element analysis played a very important role in the design of this structure. Stiffness and stress levels of the full scale bogie presented in this paper under various loading conditions have been predicted by using Marc provided by MSC Software. In order to verify the finite element analysis (FEA) models, a fifth scale prototype of the bogie has been made and tested under quasi-static loading conditions. Results of testing on the fifth scale bogie have been used to fine tune details like contact and friction in the fifth scale FEA models. These conditions were then applied to the full scale models. Finite element analysis results show that the stress levels in all directions are low compared with material strengths.     

Fatigue strength analysis of a welded railway vehicle structure by different methods

The endurance limit approach with maximum amplitude loading (constant loading amplitude) and the cumulative damage approach with variable amplitude loading are both established methods for the fatigue assessment of the bogie frame of a rolling stock. These methods are presented for the vertical main loading of a bogie frame for a light rail vehicle. Assessments are carried out for the normative load requirements according to the relevant standard EN 13749 [1] and also for a vertical force range spectrum deriving from a multiple body system simulation of this railway vehicle. The multiple body system simulation supplies more realistic loads depending on the actual railway application conditions. These different fatigue assessments allow a comparison of the normative load requirements with realistic load assumptions.In general the stress analysis is based on the nominal stress approach. Additionally, for the area subject to the maximum stress, a notch stress analysis is carried out. The comparison of stress analyses for some selected stress points shows the potential and the advantages of the fatigue assessment with the real loading assumptions and with different evaluation methods.     

Effect of loading type on the fatigue strength of asymmetric and symmetric transverse non‐load carrying attachments

This study considers the effect of bending loading and the symmetry of joints on the fatigue strength of transverse non‐load carrying attachments. Conventionally, the fatigue strength of a welded joint has been determined without taking these factors into account. Experimental and finite element analyses were carried out and both methods showed that both loading type and symmetry have an influence on the fatigue resistance of a welded joint. Under tensile loading, the fatigue strength of asymmetric T‐joints was higher than that of symmetric X‐joints. Respectively, the fatigue resistance of tested joints improved explicitly when the external loading was bending. The finite element analysis was in good agreement with the test results in the joints subjected to tension but gave very conservative results in the joints subjected to bending.     

Fatigue strength investigations of welded details of stiffened plate structures in steel ships

Ships are prone to fatigue due to high cyclic loads mainly caused by waves and changing loading conditions. Therefore, fatigue is an important criterion during design. Different approaches are applied to the fatigue strength assessment. However, the results are varying and the validity of results from small-scale fatigue tests for real structures is sometimes unclear. Therefore, deeper fatigue strength investigations were performed within a German industry-wide joint research project aiming at the harmonization of the approaches. Regarding ship structures, two types of structures were selected for the investigations. The first concerns web frame corners being typical for ro/ro ships from which three models were tested. The associated small-scale specimen is a cruciform joint. The second type is the intersection between longitudinals and transverse web frames, which recently showed fatigue failures in containerships. Five models were tested, three under constant and two under variable amplitude loading. The associated small-scale specimen is a longitudinal attachment on a stiffener top. All large-scale tests showed a relatively long crack propagation phase after first cracks had appeared, calling for a reasonable failure criterion. For the numerical analysis, the nominal, the structural hot-spot as well as the effective notch stress approach have been applied. The latter allows the consideration of the weld shape which could partly explain differences in the observed and calculated failure behaviour. The applicability of the different approaches is quite good if some specific aspects are observed. Insofar the investigations give a good insight into the strength behaviour of complex welded structures and into current problems and opportunities offered by numerical analyses.     

车辆通过道岔时转向架结构系统振动特性研究

建立了考虑线路弹性及把转向架构架视为柔体的高速车辆/线路系统通过道岔运行的三种通用模型。仿真分析了各模型轮对运动状况和作用于弹性构架上的动载荷,将动载荷通过后处理程序转化为适用于FE程序的载荷,借助于ANSYS软件分析了整个构架的应力分布和最大应力位置及应力时间历程变化。在此基础上,分析对比了三种模型的仿真结果并与构架线路动应力试验结果进行了对比,研究了动应力振幅的频谱结果。研究表明不考虑线路的弹性可能造成仿真计算结果偏大,但弹性线路模型亦不宜考虑的过于复杂化;此外,在通过道岔的岔尖时,转向架构架动态应力的振荡频率主要集中在5Hz～17Hz间,且构架动应力的振荡频率由于存在线路弹性而扩宽了其频带。     

Biaxial strength of advanced materials

The concentric ring test has been proposed as the preferred method for testing the flexural strength of bioceramics. If the apparatus used for such tests is proved to be reliable and accurate, it may be adapted to enable cyclic fatigue testing. However, before such adaptions are made, it is necessary to ensure the apparatus operates satisfactorily. The assessment programme involved strain gauge and finite element analyses of both an advanced titanium alloy (IMI 834) and 3 mol% yttria-stabilized zirconia disc specimens and preliminary fatigue tests on IMI 834 discs. The results of the analyses indicate that concentrically loaded discs are exposed to peak biaxial stresses on the tensile surface of the specimen and that these stresses are uniformly distributed within the peak loaded region of the disc. The fatigue response of IMI 834 discs under concentric loading was similar to that under uniaxial tension and torsional loading. The success of this programme will now enable fatigue tests on bioceramic discs to be performed with confidence in the reliability of the test apparatus.     

混凝土梁柱子结构连续倒塌动力效应的试验研究

近年来,结构的抗连续倒塌问题在国内外引起了广泛关注。RC框架作为实际工程中最常见的结构形式被广泛研究。然而,已有RC框架梁柱子结构的连续倒塌性能相关研究多基于确定性分析且主要针对静力拆除构件工况。该文基于OpenSees分别建立了典型RC框架梁柱子结构的静力和动力连续倒塌分析有限元模型,通过试验对比验证了模型的准确性。在此基础上,考虑结构截面几何属性、材料特性等不确定性因素,基于拉丁超立方抽样生成不同模型并分析了结构不确定性对RC框架梁柱子结构静力和动力抗连续倒塌性能的影响。参数不确定性分析结果表明：悬链线机制对RC框架梁柱子结构的抗连续倒塌性能十分重要;而以梁端转角达到0.20 rad作为RC框架梁柱子结构动力失效指标在一定程度上偏于保守。参数敏感性分析结果表明：纵筋屈服强度、极限强度为影响RC框架梁柱子结构抗连续倒塌能力的主要因素。     

Fatigue strength assessment of load-carrying cruciform joints with material mismatching in low- and high-cycle fatigue regions based on the effective notch concept

This study examined the applicability of the effective notch concept to the low- and high-cycle fatigue regions for load-carrying cruciform joints. Low- and high-cycle fatigue tests were performed on specimens with various strength matching conditions and incomplete penetration ratio. Fatigue test results revealed that the effect of strength matching becomes obvious in low cycle fatigue region, while, it was negligible in high cycle fatigue region. Different failure patterns can be observed for specimen with different strength mismatching condition in the low cycle fatigue tests. Elasto-plastic finite element analyses were performed under the same conditions as the experiments. The effective notch strains were determined at the crack initiation points. A unique relationship between effective notch strain and fatigue life was obtained regardless of matching condition and incomplete penetration ratio.     

Scale-induced effects on fatigue properties of a cast steel for bogie frames of China railway rolling wagons

A new method is suggested for measuring scale-induced effect on fatigue properties of grade B cast steel for fabricating bogie frames of China railway rolling wagons. One grouped material and three grouped structure-like specimens are machined and fatigued under same stressing amplitude with scale kinetics. Fracture surface observations reveal that fatigue cracks are initiated from weakest material cast shrinking cavity or hot tear. There are distinct fatigue striations, river-like flowers, and second cracks in perpendicular to the fatigue crack growth path on fracture surfaces. Lots of dimples appear in transient fracture zone to indicate a ductile fracture. And more dimples appear for material specimens. The effect is statistically assessed on a phase of specified fatigue strength by comparing random fatigue lives. Interactive effect of the scale and surface quality are taken into account involving in scale change. And then, this effect is extensively employed to cover entire fatigue strength range and, additionally, to address structural scale kinetics.     

Evaluation of giga-cycle fatigue properties of some maraging steels by intermittent ultrasonic fatigue testing

ABSTRACT In evaluating the giga-cycle fatigue strength of some high strength steels, information on the size distribution of nonmetallic inclusions contained in the material is indispensable. To save time and effort of obtaining such data concerning the inclusions, a convenient dissolution method to evaluate the maximum inclusion size is proposed, in place of a conventional method of measuring the inclusion sizes on many cross-sectional areas. Meanwhile, to save time-consuming work of obtaining giga-cycle fatigue properties of some metallic materials, an intermittent ultrasonic fatigue testing method has also been developed. In the present paper, these two newly developed methods were successfully combined to assess the long life fatigue properties of maraging steels as a function of inclusion size.     

Fatigue behaviour of glass fibre reinforced epoxy composites enhanced with nanoparticles

Nanoparticle reinforcement of the matrix in laminates has been recently explored to improve mechanical properties, particularly the interlaminar strength. This study analyses the fatigue behaviour of nanoclay and multiwalled carbon nanotubes enhanced glass/epoxy laminates. The matrix used was the epoxy resin Biresin® CR120, combined with the hardener CH120-3. Multiwalled carbon nanotubes (MWCNTs) 98% and organo-montmorillonite Nanomer I30 E nanoclay were used. Composites plates were manufactured by moulding in vacuum. Fatigue tests were performed under constant amplitude, both under tension–tension and three points bending loadings. The fatigue results show that composites with small amounts of nanoparticles addition into the matrix have bending fatigue strength similar to the obtained for the neat glass fibre reinforced epoxy matrix composite. On the contrary, for higher percentages of nanoclays or carbon nanotubes addition the fatigue strength tend to decrease caused by poor nanoparticles dispersion and formation of agglomerates. Tensile fatigue strength is only marginally affected by the addition of small amount of particles. The fatigue ratio in tension–tension loading increases with the addition of nanoclays and multi-walled carbon nanotubes, suggesting that both nanoparticles can act as barriers to fatigue crack propagation.     

RC框架梁柱子结构抗连续倒塌性能不确定性分析

近年来,结构的抗连续倒塌问题在国内外引起了广泛关注.RC框架作为实际工程中最常见的结构形式被广泛研究.然而,已有RC框架梁柱子结构的连续倒塌性能相关研究多基于确定性分析且主要针对静力拆除构件工况.该文基于OpenSees分别建立了典型RC框架梁柱子结构的静力和动力连续倒塌分析有限元模型,通过试验对比验证了模型的准确性....     

Fatigue assessment of high strength leaf springs based on the FKM guideline

Analytical fatigue strength calculations based on the FKM guideline have been performed for hot tapered and stress‐shot‐peened high‐strength leaf spring specimens subjected to three‐point fatigue bending. The ultimate tensile strength of the decarburized specimens' surface has been approached by means of Rockwell‐C hardness measurements, and used as input for the approximation of its fatigue limit and mean stress sensitivity. Surface roughness and residual stress measurements were performed to take account for the technological life influencing factors. Fatigue tests at a constant mean stress and various stress amplitude levels were performed to determine the specimens' S–N curve and validate the calculation's accuracy. Comparison of calculated with experimentally determined fatigue lives, though satisfactorily, pinpoints the necessity for more accurate implementation of the stress‐shot‐peening process within the FKM guideline.     

Composite heddle frame for high-speed looms

A heddle (or heald) frame is the major part of a loom that produces woven cloth by insertion of weft yarns between warp yarns. Warp yarns are manipulated by many heddles fixed in a heddle frame. Recently, the up and down speed of heddle frames has been increased much for the increase of productivity, which induces higher inertial stresses and vibrations in the heddle frame. Conventional aluminum heddle frames have limits for the speed increase due to their low fatigue flexural strength as well as low bending stiffness. The estimated fatigue life of the aluminum heddle frame was 6 months at 600 rpm and infinite at 400 rpm, which was the same results reported by textile industries. Since carbon fiber epoxy composite materials have high specific fatigue strength (S/ρ), high specific modulus (E/ρ) and high damping capacity, in this paper a composite heddle frame was designed and manufactured. The optimum box type cross-sectional shape of the heddle frame and stacking sequence were determined by finite element analysis. The box type composite structure with several ribs was manufactured with prepregs by the autoclave vacuum bag process. Then the static and dynamic characteristics of the composite heddle frame and the aluminum heddle frame were measured and compared.     

A TORSION-BENDING LOADING FRAME FOR A UNIAXIAL FATIGUE TEST MACHINE

Abstract— A novel mixed-mode loading frame has been designed to fit a uniaxial servo-hydraulic test machine. The frame allows fatigue tests to be performed on circurnferentially slit round bars under combined in-phase torsion and bending loads at positive mean stresses. The growth of fatigue cracks was monitored using a direct current potential drop technique. An empirical equation relating crack depth and voltage is presented.     

Failure analysis of a steam generator superheater drain tube used in a dump

This paper analyses the failure of a superheater drain tube of a steam generator used in a dump to obtain energy from the biogas produced by organic waste. Chemical and microstructure analyses, together with microhardness measurements, have been performed in order to check any possible deviation from the material specification, finding as the only deviation significant increases in hardness in the failure section, suggesting that the failure section is located in the heat affected zone of a nearby weld. Also, the failure mechanism has been analysed by both visual and SEM inspection of the fracture surface, identifying fatigue as the major cause of the final failure, assisted by corrosion processes. The different areas found on the fracture surface suggest that fatigue processes were caused by the maintenance operation consisting of hitting (hammering) the collector tube to which the drain tube is joined. No evidence has been found in relation to any other anomalous operating conditions, such as overpressure or unexpected high temperatures.