17 Stadler Habenbacher

8/10/2019 17 Stadler Habenbacher

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M

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JC(4x)

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JC(4x)JC

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JCJC JC

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Lineare Balkenelemente (B31):

JC Lineare Federelemente (JOINTC):

M Massenelemente (MASS):

Distributing Coupling

Elemente(DCOUP3D):

Multipoint Constraint Elemente (MPC):

M

M

M

M

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Elemente(DCOUP3D):


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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 1

Fatigue assessment of bogie frames with FEMFAT

Johann Habenbacher

Sebastian Walch, Matthias Brcker, Alois Starlinger

HV

HV

r = 1 mmConsideration ofmetallurgicalnotch

combined stress

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

0 30 60 90 120 150 180

degree (position of strain gauge)

degreeo

fu

tilisa

tion

IIWn. prop.

IIWprop

(D)^(1/k)

FEMFAT

(DVS1608)

Habenbacher

International FEMFAT User Meeting 2011


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Contents

1. Demands on manufacturer of rolling stock

Validation and acceptance of the design according to EN 13749

Special standards used for certification

2. In-house FEMFAT database

Based on effective notch stress enhanced database

Fatigue strength modifications (stress ratio, thickness, grinding, )

3. Treatment of data from measurements within fatigue assessment method

4. Multiaxial loading


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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


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Validation and acceptance of the design

Analysis

FKM-Guideline

IIW-Recommendations

Laboratory tests

static tests

fatigue tests

Track tests

FKM-Guideline

IIW-Recommendations

Validation program EN 13749

Bogie frame


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Motor bogie frame of a tram


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Analysis - FE-Model of a bogie frame

M

JC

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JC(4x)

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JC(4x

)

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Elemente(DCOUP3D):


M

M

M

M

Number of elements: 300000Number of nodes: 400000Degree of freedom: 2200000


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Analysis - Sheet thickness

Shell elements for weld seams

Using THK-groups for thickness correction


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Analysis - Load cases

About 64 single load cases (FE simulation) 100 load cases (superposition) which represent normal service operating conditions

The loads are derived from standards, simulations, tests or previous experience

20 40 60


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Definition of weld seams with FEMFAT Visualizer

About 25 different types of weld seams

Consideration of post weld improvements


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Weld seam definition

About 1200 weld seams are defined with FEMFAT Visualizer


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Weld seam definition


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Z04/Z05

Z09 Z08

SX1

SX2

Z14

SY1 SY2

SZ4

V1 (SZ1)

SZ3

SZ2

Z02

Z06

Z07

Z11

Z12

Z10

Z13

Q1/ Achs-

verwindung

Z03a

Z03

Z1

Z16

Z01Z19

Q2

Q3Q4

Laboratory tests

10 - 28 Cylinder for fatigue tests 10 Mio. Load cycles

Load run 100% loads complete

IMA-pr.no.: C041/08-1

-125

-100

-75

-50

-25

0

25

50

75

100

0 10 20 30 40 50 60 70

load cycles

load[kN]axletorsion[mm]


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Laboratory tests

100 Stain gauges channels

Comparison with analytical results


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Track tests EN 13749

Fatigue strength Rainflow-counting

Miner rule

(M) (WL, Dm)

aBK


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0

20

40

60

80

100

120

31

3

21

1

21

2

41

1

52

2

41

3

51

1

21

5

41

4

91

3

42

4

Sa,zul[MPa],R

=-1


Comparison of suitable standards for fatigue assessment

DV 952

Effective notch stressFKM Nominal stress

ERRI B12/RP60

DIN 15018 B6

DIN 15018 B5

DVS1612

ERRI B12/RP60

DIN 15018 B6

DIN 15018 B5

Allowable stress amplitudes

at 2 Mio. load cycles


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Regelwerk FKM DVS1612 ERRI B12 RP 60 ERRI B12 RP 60

Bemerkung Wurzelriss, Nr

414, FAT45Linie F-

Kat. D, nicht

geglhtKat. D, geglht

Sa_2Mio,zd_97,5%, R = -1 29 50 41 65

Regelwerk

prEN1993 1-9:

2003 DIN 15018 K4/B6

prCEN/TS 13001-

3-1: 2003 FAT/2

STADLER

Kerbspannungs-konzept

Bemerkung FAT 36 Nr. 452 FAT 63t = 10, ages= 10,

Wurzelriss

Sa_2Mio,zd_97,5%, R = -1 23 27 32 38

"Dauerfestigkeit" einer Doppelkehlnaht unter wechselnder Zug-Druck-

Beanspruchung normal zur Schweissnaht

Large scatter of allowable stress amplitudes and unknown consideration of: crack position (weld root crack or toe crack)

membrane stress and shell bending stress

stress magnification factors due to misalignment

Comparison of suitable standards for fatigue assessment


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Data basis IIW


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Contents










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In-house FEMFAT database

More than 55 weld joints according to IIW recommendations defined Consideration of metallurgical notch effect

Notch factors for stress component parallel to the weld seam

Modified notch factors for intersecting weld seams and runout of seams

Ende Kombiniert

C100

C103 x

C102 x

C105 x x

C101 x

C104 x x

C107 x

C109 x x

C106 x

C108 x x

inmitten der Schweissnahtnormal

sehr schlecht nicht gut zugnglich

Schweissnahtende mit Fase (HY-Anarbeitung

stirnseitig)

Schweissnahtende mit Fase (HY-

Anarbeitung stirnseitig)

normal -

schlecht

Schweissnahtende ohne Fase (keine HY-

Anarbeitung stirnseitig)

verschliffen

normal - gut

TypKnotenfarbe Qualitt Bemerkung


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In-house FEMFAT database - Influence of stress ratio

Haigh-diagram with M = 0,15 (according to FKM-guideline)

400 350 300 250 200 150 100 50 0 50 100 150 200 250 300 350 400 450 500 550 600

25

50

75

100

125

150

175

200

S355, Haigh-Diagramm, Normalspannungen

Mittelspannung

Spannungsamplitude

200

0

Sa

Sm( )

600400 Sm

IIW

FKMR = -1 R = 0 R = 0,5

R = -

FEMFAT weld


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In-house FEMFAT database - post weld improvement techniques

Database accounts for (according to IIW Fatigue recommendations) Grinding

Residual stress conditions (peening..)

Remelting of the weld toe (TIG dressing)

DMS 1

DMS2

DMS 8

HY

HY

DMS 4

DMS7

DMS 5

DMS3

DMS6

k= 3

DMS 1DMS 1

DMS2

DMS2

DMS 8DMS 8

HY

HY

DMS 4DMS 4

DMS7

DMS7

DMS 5DMS 5

DMS3

DMS3

DMS6

DMS6

k= 3


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In-house FEMFAT database - Example of weld seam

SID 408

HY DHV

MAT 339 346

HY

DHV

DMS 1

DMS2

DMS 8

DMS 4

DMS7

DMS 5

DMS3

DMS6

k

= 3

343

339

345

341HY

DHV

344

340

346

342

HY

DHV


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Contents










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Contents










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Multiaxial loading simple example

-150.0

-100.0

-50.0

0.0

50.0

100.0

150.0

0.000 1.000 2.000 3.000 4.000 5.000 6.000 7.000stress

time

Stress components

Sx(t)

Sy(t)

Txy(t)

Stress components: Sx = 0

100 MPaSy = 0 MPa

Txy = 100 MPa

Material: Sw = 150 MPa (R = -1)M = 0.3


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Multiaxial loading simple example

Material: Sw = 150 MPa (R = -1)

M = 0.3

notch factors are 1.01

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0 20 40 60 80 100 120 140 160 180degree

utilisation

ax

ay

a_tau

Stress components: Sx = 0

100 MPaSy = 0 MPa

Txy = 100 MPa


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Utilisation to multiaxial loading

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

0 30 60 90 120 150 180

angle (orientation of strain gauge)

degreeofutilisa

tion

IIW n. prop.

IIW prop

(D)^(1/k)

FEMFAT (DVS1608)

Habenbacher


Multiaxial loading of weld seams simple example

Stress: Sx = 0 100 MPa

Sy = 0 MPa

Txy = 100 MPa

Material: Sw = 150 MPa (R = -1)

M = 0.3

notch factors are 1.01


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Multiaxial loading simple example, DVS1608

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT


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Multiaxial loading simple example, DIN 15018


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Multiaxial loading simple example, BS 7608, Sign from Normal Stress



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Multiaxial loading simple example, base material

multiaxial loading, base material

0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60

Automatisch

Normalspannung kritische Schnittebene

Werkstoffcharakteristische Schubspannung

Vergle ichsspannung kritische Schnittebene

Nokleby-Kriterium kritische Schnittebene

Kritische Komponente kritische Schnittebene

Kritische Komponente

reduziert kritische Schnittebene

Vorzeichenbehaftete Mises Spg. 1

(Vorzeichen von max. Hauptnormalspg.)

Vorzeichenbehaftete Mises Spg. 2

(Vorzeichen von hydrostatischer Spg.)

Max./Min. Hauptnormalspannung

Mod. Ve rgleichsspannung

kritische Schnittebene

Skalierte Normalspannung

kritische Schnittebene

criteria

normalized utilisation

Sm=0, Sa=100, Tm=100

FKM


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Summary

Fatigue assessment for rolling stock with FEMFAT

FEMFAT handles complex FE-models

FEMFAT allows for in-house databases

Treatment of data from measurements using FEMFAT scratch files

Cooperative research on multiaxial loading conditions

Conclusion

Successful concept

All bogie frames passed laboratory tests

17 Stadler Habenbacher

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