stadlerrail starlinger fatigue design of railway vehicle structures
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StadlerRail_Starlinger_Fatigue_Design_of_Railway_Vehicle_StructuresTRANSCRIPT
Fatigue Design of Railway Vehicle Structures
Alois Starlinger Stadler Rail,
Structural Analysis, Testing and Authorization, Altenrhein, Switzerland
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG
Contents • Introduction • Requirements for the structural
assessment of railway vehicles: – Car Bodies – Bogies
• Acceptance program • Structural analysis • Laboratory Testing • On Track Testing • Conclusions
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG 2
Stadler‘s Sites in Europe Stadler Rail Group: • Fast growth over 20 years • Turnover: 1,5 Billion CHF • 4’700 employees
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG
Stadler Altenrhein: • Center of Structural
Development • Structural Analysis of Car
Bodies and of Bogies • Authorization
3
Introduction into Railway Vehicles : • Small series business:
– From two to 100 vehicles per order – Adjustments for each customer – Time between contract signature and start of passenger service:
• 24 months (until now) • 36 – 48 months if TSI requirements have to be met • Design release requirement: four months after contract signature • Tight delivery schedule (with penalties for delay or for missing authorization)
– Usually no prototypes • No excessive service testing before series production • On track testing with first series vehicle high commercial risk Numerical analyses must capture structural behavior in detail Numerical fatigue assessment must deliver reliable results
– Operational lifetime up to 40 years • Typical costs per unit:
– City tram vehicle (5 wagons): 3 million Euros – Regional train (four wagons): 5 million Euros – High speed train (10 wagons): 15 million Euros
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG 4
Acceptance Program for Car Bodies (EN 12663-1): • Structural analysis:
– Static compressive loads: 1500 kN – Fatigue loads:
• P-II: ax = 1,5 - 2,0 m/s2, ay = 1,5 m/s2, az = 1,5 m/s2 • Static testing • Measurements on track followed by fatigue evaluation for
low floor tram vehicles
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG 5
Acceptance Program for Bogies (EN 13749): • Structural analysis • Static testing • Endurance test: 10 million load cycles • Measurements on track followed by fatigue evaluation
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG 6
Structural Analysis - Modeling: • Finite element analyses of all structural components • Finite element meshes have become extremely fine:
– Car body structures: 12 million degrees of freedom up to 3 million elements
– Bogie frames: 400.000 elements – Shell elements (70%) and Solid elements (30%): linear shape functions
– Local stress gradients have to be captured: • Structural notches (sharp edges, corners, ...) • Large stiffness changes, ...
– 50 single load cases for bogies & 50 combinations
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG 7
Fatigue Assessment - Nominal Stress Approach: • most common in railway design:
– simple, proven praxis – based on section forces and moments analytical method – not appropriate for finite element modeling, since local geometry
effects are captured corresponding stress peaks might be overrated – Strength standards:
IIW recommendations, FKM guideline, DVS 1608, DVS 1612
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Nominal stress evaluation point
Evaluation of FE Results for Nominal Stress Concept According to DVS 1608 Guideline
• Definition of evaluation point: – Enables direct comparison of FE results with test data – Evaluation point positioned into the center of the strain gauge
used in testing – Analogy to ERRI B12 RP17:
• Butt weld: e = 5 (mm) + strain gauge length / 2 • T-type weld: e = 5 (mm) + strain gauge length / 2
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG 9
• Based on IIW-Recommendation XIII-2240-08/XV-1289-08 • According to Seeger / Radaj: Radius r = 1 mm for all materials and
notch details • Notch factors derived for normal stresses transverse to the weld
direction (starting from a sheet thickness of t ≥ 6 mm) • Strength standards: IIW recommendations, FKM guideline, DVS 1608
Fatigue Assessment – Notch Stress Concept for Welds
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• Weld seams identified in FE model by Visualizer • Evaluation according to standard DVS 1608 guideline /
IIW recommendations • Stadler database for notch factors of weld types typical for
railway design • More exact method than nominal stress concept
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Fatigue Analysis – Notch Stress Concept for Welds
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG
Fatigue Analysis - Notch Stress Concept • Automated fatigue stress assessment with FEMFAT • Fatigue stress assessment extrapolation to notch location • Mesh strategy: integration point is located 5 mm away from
weld transition comparison with test results (same location as strain gauges)
• Results: utilization for all welds and all load combinations
12 FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG
FEMFAT Weld –Bogie Frame – Utilization:
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG 13
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 Testing of Bogie Frames (EN 13749): • 10 - 28 hydraulic cylinders for fatigue testing • 10 million load cycles - three phases 100%, 120% and 140%
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
] axl
e to
rsio
n [m
m]
14 FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG
• Around 100 strain gauges channels • Comparison with analytical results
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Laboratory Testing of Bogie Frames (EN 13749):
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG
Laboratory Testing of Bogies (EN 13749):
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG
Testing of Variobahn bogie frame at IMA, Dresden: • 10 million
load cycles
• Criterion: no cracks
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On Track Testing • Requirement in EN 13749 for bogie frames • German Guideline developed by DIN working group with clear definitions for
on track testing: – Measurement length: at least 1/10000 of overall lifetime mileage – Strain gauges per bogie frame type: 30 positions with highest degree of
utilization in numerical analysis – Loading: 2/3 of maximum passenger load – Rain flow counting and classification – Damage accumulation according to Miner rule
• Stadler approach:
– Miner Elementar with„cut off“ at the 50% value of the fatigue strength at 5 million load cycles of S-N-curve
– Allowable damage sum Dm = 1,0
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© Stadler Altenrhein AG
On track testing - Stadler tram vehicles:
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Length Vehicle Year
• Successful on-track testing of Stadler tram vehicles • Measurements followed damage accumulation
On track testing:
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Conclusions: • The structural design of railway vehicles requires special
procedures: – Small series – Individual adjustments for each customer – Short development time – No prototypes
• Sophisticated methods for fatigue assessment are necessary: – Notch stress concept – Database with notch stress factors – Successful application of FEMFAT – Numerical results have been verified by laboratory testing and by on-
track-testing: • Tram car bodies • Bogie frames
FEMFAT User Meeting - May 2013 © Stadler Altenrhein AG 20
Thank you for your attention!