Professional Documents
Culture Documents
Johann Habenbacher
Sebastian Walch, Matthias Brcker, Alois Starlinger
JC
M
JC(4x)
M
combined stress
M
JC(4x)
HV
JC
1.40
JC
1.20
JC
M
JC(4x)
JC(4x
)
JC
JC
M
JC
JC
JC
JC
JC(4x
)
JC
1.00
JC
JC
JC(4x)
JC(4x)
M
JC
degree of utilisation
r = 1 mm
Consideration of
metallurgical
notch
JC
0.80
IIW n. prop.
IIW prop
0.60
(D)^(1/k)
FEMFAT
(DVS1608)
Habenbacher
0.40
JC
JC(4x)
M
0.20
HV
J
C
0.00
0
J. Habenbacher - Fatigue
assessment
of User
bogieMeeting
frames with
International
FEMFAT
2011FEMFAT
30
60
90
120
150
180
Contents
1. Demands on manufacturer of rolling stock
Validation and acceptance of the design according to EN 13749
Special standards used for certification
4. Multiaxial loading
Motivation
Stadler Rail AG
Manufacturer of rolling stock
Headquarters in Switzerland
Department SDZ (Altenrhein)
Strength assessment
Bogie frames, car body shells and components
Special requirements
Period of application is 40 years
Various strength assessments are necessary for the certification
Application of in-house experience to be competitive
Analysis
Laboratory tests
Track tests
FKM-Guideline
static tests
FKM-Guideline
IIW-Recommendations
fatigue tests
IIW-Recommendations
Bogie frame
JC(4x)
JC
M
JC(4x)
JC
M
JC(4x)
M
JC(4x
)
JC
JC
M
JC
JC
JC
JC
JC
JC
JC(4x
)
JC
JC
JC
JC(4x)
JC(4x)
M
JC
JC
JC(4x)
M
M
J
C
Number of elements:
Number of nodes:
Degree of freedom:
300000
400000
2200000
100 load cases (superposition) which represent normal service operating conditions
The loads are derived from standards, simulations, tests or previous experience
20
40
60
10
11
Laboratory tests
10 - 28 Cylinder for fatigue tests
10 Mio. Load cycles
100
Q3
Z09
Z08
Z03
b
75
Z16
Z13
Z12
Z02
SZ4
50
SZ3
25
load [kN] axle torsion [mm]
Z07
SX2
SX1
Z14
Z1
7
Z06
V1 (SZ1)
Z10
SZ2
Z01
Z19
Z11
0
0
10
20
30
40
50
60
70
-25
-50
-75
-100
SY1
Q1/ Achsverw indung
Z03a
SY2
Q2
-125
load cycles
12
Laboratory tests
100 Stain gauges channels
Comparison with analytical results
13
(M)
(WL, Dm)
aBK
14
100
DV 952
DVS1612
DIN 15018 B5
80
60
40
DIN 15018 B6
ERRI B12/RP60
20
424
913
414
215
511
413
522
411
212
211
0
313
Sa,zul [MPa], R = -1
120
15
FKM
Wurzelriss, Nr
414, FAT45
DVS1612
Linie F-
Kat. D, nicht
geglht
Kat. D, geglht
50
41
65
Sa_2Mio,zd_97,5%, R = -1
29
Regelwerk
prEN1993 1-9:
2003
Bemerkung
FAT 36
Nr. 452
FAT 63
Sa_2Mio,zd_97,5%, R = -1
23
27
32
38
STADLER
prCEN/TS 13001DIN 15018 K4/B6
Kerbspannungs3-1: 2003 FAT/2
konzept
16
17
Contents
1. Demands on manufacturer of rolling stock
Validation and acceptance of the design according to EN 13749
Special standards used for certification
4. Multiaxial loading
18
Knotenfarbe
Ende
C100
C103
Typ
Kombiniert
x
C102
C105
x
x
C101
C104
x
x
C107
C109
x
x
C106
C108
x
x
x
x
Qualitt
Bemerkung
normal
normal - gut
normal schlecht
verschliffen
sehr schlecht
19
20
k = 3,7
r = 1 mm
Consideration of
metallurgical
notch
HV
IIW
recommendations
New
Approach
HV
21
Spannungsamplitude
175
R = -1
FKM
150
IIW
125
( )
Sa Sm
R = 0,5
R=0
FEMFAT weld
R = - 100
75
50
25
0
400
350
400
300
250
200
150
100
50
50
100
150
200
250
300
350
400
Sm
450
500
550
600
600
Mittelspannung
22
DMS 3
DMS 2
HY
DMS 8
DMS 5
HY
k = 3
DMS 6
DMS 4
DMS 7
DMS 1
23
344
HY
HY
339
DMS 3
DMS 2
SID 408
HY DHV
MAT 339 346
DHV
DHV
346
HY
DMS 4
DMS 8
DMS 5
DMS 6
342
340
345
DMS 1
DMS 7
341
k = 3
DHV
24
Contents
1. Demands on manufacturer of rolling stock
Validation and acceptance of the design according to EN 13749
Special standards used for certification
4. Multiaxial loading
25
sn
bottom
sp
tp
-5.84E-01
-7.43E-01
1.26E-01
4.28E-01
-1.14E-01
1.22E-02
2.55E-01
3.41E-01
-5.19E-01
2.85E-02
4.13E-01
2.97E+00
-5.64E-02
3.94E-01
2.16E+00
-5.88E-03
-8.84E-03
3.91E-03
-1.45E-02
-5.12E-03
-1.04E-02
2.41E-03
3.83E-03
-2.38E-02
-1.79E-02
-2.94E-02
680754
-3.46E-03
3.62E-02
-1.39E-02
2.43E-02
1.93E-02
4.07E-03
1.35E-02
3.13E-02
4.41E-02
8.80E-02
7.67E-02
-1.88E-02
7.46E-03
-1.47E-02
-1.63E-02
-1.71E-02
4.67E-02
3.40E-01
2.33E-02
-1.91E-01
3.50E-01
5.14E-02
-1.31E-01
4.32E-01
680754
2.70E-04
-1.66E-02
fms1
Knotennr.:
Bottom Grundmaterial:
Top Grundmaterial:
Schweissnahtmitte
Schweissnahtmitte
quer:
Knotennr.:
Bottom Grundmaterial:
Top Grundmaterial:
Schweissnahtmitte
Schweissnahtmitte
quer:
Knotennr.:
Bottom Grundmaterial:
Top Grundmaterial:
Schweissnahtmitte
Schweissnahtmitte
quer:
tp
fms2
Strain gauge
top
sp
sn
680754
5.21E-01
1.16E+00
fms3
Inaccessible
side
DMS
DMS
26
Contents
1. Demands on manufacturer of rolling stock
Validation and acceptance of the design according to EN 13749
Special standards used for certification
4. Multiaxial loading
27
Sy = 0 MPa
M = 0.3
100.0
stress
50.0
0.0
0.000
1.000
2.000
3.000
4.000
5.000
6.000
7.000
Sx(t)
Sy(t)
Txy(t)
-50.0
-100.0
-150.0
time
28
Sy = 0 MPa
M = 0.3
utilisation
0.80
0.70
0.60
0.50
ax
0.40
ay
a_tau
0.30
0.20
0.10
0.00
0
20
40
60
80
100
120
140
160
180
degree
29
Sx = 0 100 MPa
Sy = 0 MPa
M = 0.3
1.20
degree of utilisation
IIW n. prop.
1.00
IIW prop
0.80
(D)^(1/k)
FEMFAT (DVS1608)
0.60
Habenbacher
0.40
0.20
0.00
0
30
60
90
120
150
180
30
criteria
Werkstoffcharakteristische Schubspannung
FKM
Automatisch
0.00
0.20
0.40
0.60
0.80
1.00
normalized utilisation
1.20
1.40
1.60
Summary
Conclusion
Successful concept
All bogie frames passed laboratory tests
35