| CASE STUDIES |
| FINITE ELEMENT ANALYSIS (FEA) OF NEW RAIL WHEEL APPLICATION |
| Background |
| During the later part of 2006, EWS required replacement wheelsets for their fleet of freight wagons. Due to the high world wide demand for wheelsets EWS was not able to purchase the required wheelsets from its usual suppliers in the timescales required. |
With the procurement of the axle secured, an alternative wheel manufacturer was required. Several companies were approached by EWS to supply an equivalent wheel, one potential supplier was MWL (Brazil) who proposed their K36 wheel design. ESG was tasked to evaluate the proposed wheel design both against UK and European regulatory requirements and submit the necessary documentation to attain approval. |
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| Project Overview |
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The wheel is of an ‘S’ web design, 914mm wheel new diameter, 857mm scrap, with a P5 profile. The wheel had to be capable of operating with several different wagon and bogie types with a maximum axleload of 25.4t.
A 3D model of the wheel was created, imported into Ansys, meshed using a suitable element and mechanical load-case combinations as specified in UIC510-5 were applied to the wheel. The thermal/structural analysis consisted of thermal load-case combinations applied to the wheel which are specific to UK operation.
A Finite Element Analysis of the wheel was undertaken to evaluate its performance during structural and structural/thermal analyses.
Mechanical loads for straight, curving and cross over running track were applied to the wheel with the addition of the interference fit associated with the wheel fitted to the axle.
Thermal loads generated from drag braking for 20mins with a thermal input of 26kW followed by a full emergency brake application for 39s of 156kW applied to the wheel tread covering the swept area of the brake
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Von mises stress plot for a vertical load-case due to straight running track |
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Temperature plot (K) after 1200s of drag braking due to 26kW input. |
| Key Features |
- Requirements of UIC 510-5 and GMRT2466 with regard to approval of new wheel designs
- Understanding and developing structural and thermal analysis techniques
- Selecting suitable elements (mechanical and thermal), element size, generating an accurate but efficient mesh, mechanical and thermal properties
- specification, application of correct loads and constrains and achieving the most accurate and cost effective solution
- Interpreting FEA results, confirming the accuracy of the model, loads, constraints & results
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| Skills Profile |
- In depth knowledge of structural and thermal analysis
- Detailed knowledge of UK and European regulatory requirements
- Expertise in 3D modelling using AutoDesk Inventor
- Expertise in Finite Element Analysis using Ansys
- Knowledge of wheelset design, manufacture and usage
- Understanding of information required by UK Vehicle Approval Bodies
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| Further information contact Simon.Cressey@esg-railconsultancy.co.uk |
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