easy certification according to en12663 and dvs using fem ... · final strength report for...

Easy certification according to EN12663 and DVS using FEM and LIMIT

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Railway Applications

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A way to certification of railway vehicles according to DVS

Overview of the strength assessment

Challenges for the assessment of welded structures

Types of railway structures: shells vs. volume

Applying the design codes

Interfaces FEM to LIMIT

Generating Reports as part of the documentation for Notified Body, the completeprocedure with LIMIT

Motivation for LIMIT

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Certification according to EN12663 and DVS

Final strength report forcertification

by Notified Body

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Certification according to EN12663 and DVS

Train design3D geometryMaterialsJoints:▪Many welds▪Many bolts, …

Final report for certification

Finite Element Analysis

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Medium sized structures

▪ Bogies

▪ Sheet thickness starting from 5mm

Typical railway structures

Source: Siemens, Austria

Thin walled large structure

▪ Vehicle body

▪ Sheet thickness down to 2mm!

Source: Bombardier, Vienna

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Shell modelling

▪ Reduction of calculation time

▪ Shell thickness is a parameter of shellcan be modified if necessary

▪ Easier extraction of section forces and moments for weld assessment directly available

▪ Automated weld strengthassessment

▪ Report generation

Modelling strategies

Shell modelSource: Siemens, Austria

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Typical railway structures

Solid modelling

▪ No mid surface modelling(faster)

▪ Large thickness of plates can be captured more accurate

▪ More flexibility with different variants

▪ Less singularities and therefore less conservative

Source: Logomotive, Germany

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Certification according to EN12663 and DVS

Train design3D geometryMaterialsJoints:▪Many welds▪Many bolts, …

Final report for certification

Finite Element Analysis

Strength Requirementsaccording to EN12663

Loads depending on vehicle category

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Finding critical loads and load cycle numbers

▪ According to EN12663: minimum of approximately 25 LCs necessary

Assessing large numbers of welds

▪ 500 to 1000 welds in a typical carbody

Applying the design code

Challenges with certification of railway structures

Complex structure

EN 12663Strength requirements

Static and Fatigueo.k.?

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t1

t2 a

Certification according to EN12663 and DVS

Train design3D geometryMaterialsJoints:▪Many welds▪Many bolts, …

Strength Requirementsaccording to EN12663

Loads depending on vehicle category

Final report for certification

Finite Element Analysis

Static assessmentFatigue assessment▪DVS 1612 (steel)▪DVS 1608 (alu)

Weld quality

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Notch cases, one sided fillet weld:

Typical values t1

t2a

Only nominal stress, root:Longitudinal= E4Transverse = F3 + Excentricity!Shear = H-

Notch cases DVS1612

s⊥

sll

t

t2

sll

s⊥

s⊥

t1

Nominal stress, toe:Longitudinal = E4Transverse = E5Shear = H-

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Assessing the welds

Weld Analysis according to DVS1612E.g.: Single sided fillet weld▪ Fillet throat critical => stresses in throat

needed!A.) Using section forces from shell model

B.) Using section forces from solid model & LIMIT sensors

C.) R1-effective notch

Sensors

A.)

B.)

Cracks

Load

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Typical railway structures

Sensor technology

▪ Are used to calculate section forces and moments in solidstructures

▪ Forces and moments are needed for the weld assessment according to DVS1612

▪ Sensors are generated in LIMIT

Source: Logomotive, Germany

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Comparison for different geometries

Degree of Utilization (DoU)

Results

DoU = 4,88DoU = 0,71DoU = 0,85

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Easy certification with LIMIT

FE modelPatran, Hypermesh,

Abaqus/CAE, ANSYS, NX

Design: 3D-CAD

Finite Element Input.bdf, .out, .dat, .inp

FE Results.fil, .odb, .op2, .rst

LIMIT-SOLVERAnalysis

LIMIT-VIEWERPost processing

FE SolverNastran, Abaqus, ANSYS

Midsurfaces and shell elements

3D-CAD

LIMIT-CAEDefinition of assessments

in the GUI

Global iteration loop, changing

geometry

Local loop, e.g. changing weld quality

Not o.k.!

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Easy certification with LIMIT

FE modelPatran, Hypermesh,

Abaqus/CAE, ANSYS, NX

Design: 3D-CAD

Finite Element Input.bdf, .out, .dat, .inp

FE Results.fil, .odb, .op2, .rst

LIMIT-SOLVERAnalysis

LIMIT-VIEWERPost processing

FE SolverNastran, Abaqus, ANSYS

Automated Report Generation:

LIMIT-CAEDefinition of assessments

in the GUI

All welds o.k.!

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t1

t2 a

Certification according to EN12663 and DVS

Train design3D geometryMaterialsJoints:▪Many welds▪Many bolts, …

Strength Requirementsaccording to EN12663

Loads depending on vehicle category

Final report for certification

Finite Element Analysis

Static assessmentFatigue assessment▪DVS 1612 (steel)▪DVS 1608 (alu)

Weld quality

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LIMIT Interfaces to MSC Products

Interfaces to MSC

▪ MSC-MARC (t16)

▪ MSC-NASTRAN (op2)

▪ HDF5 format will be available in the beginning of 2018 for:

- MSC-Apex

- MSC-Nastran

- Patran

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Further LIMIT Interfaces

The Software

in alphabetic order:

▪ ABAQUS

▪ ANSYS

▪ ANSYS LS DYNA

▪ CATIA FE

▪ NX NASTRAN

▪ RADIOSS/OPTISTRUCT

▪ SOLIDWORKS Simulation

▪ LIMIT Universal Interface

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References

▪ AMST-Systemtechnik GmbH

▪ AUDI, Werkzeugkonstruktion, Germany

▪ Bühler AG, Switzerland

▪ China Energine International Ltd.

▪ FEMCOS-Ingenieurbüro mbH, Germany

▪ Gardner Denver Schopfheim GmbH, Germany

▪ Hydromek, Turkey

▪ IBV-Engineering, Germany

▪ IFF Engineering & Consulting GmbH, Germany

▪ Istanbul Technical University, Turkey

▪ K + V Ingenieurgesellschaft mbH, Germany

▪ Ludwig Engel KG, Austria

▪ Liebherr-Transportation Systems GmbH & Co KG

References

▪ LogoMotive GmbH, Germany

▪ MAV-START, Hungary

▪ NEWAG, Poland

▪ PESA Bydgoszcz SA, Poland

▪ Plasser & Theurer, Austria

▪ Prisma Engineering, Austria

▪ RUAG Schweiz AG, Switzerland

▪ Stadler Valencia, Spain

▪ STREICHER Maschinenbau GmbH & Co. KG, Germany

▪ Taiwan Rolling Stock Company, Taiwan

▪ TUV Rheinland Rail Sciences, Inc., Nebraska, USA

▪ Vossloh Locomotives, Kiel

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Apply for a free test license and experience the benefits for your projects!Please contact:Dr. Nikolaus Friedlfriedl@cae-sim-sol.at +43 1 974 89 91-12