Finite Element Analysis Of Underframe For 5500 Hp WDGS

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  • Simulation Driven Innovation 1

    FINITE ELEMENT ANALYSIS OF

    UNDERFRAME FOR 5500 HP WDG5 LOCOMOTIVE

    P.C.S.Yadav

    Sse/Mp Directorate

    Research Designs & Standards

    Organisation

    Manak Nagar, Lucknow-226 011

    R. K. Misra

    Ade/Mp Directorate

    Research Designs & Standards

    Organisation

    Manak Nagar, Lucknow-226 011

    Anurag Mishra

    Dy.Dir/Mp Directorate

    Research Designs &

    Standards Organisation

    Manak Nagar,

    Lucknow-226 011

    Butchi Babu Nalluri

    Design Engineer/Emd

    Research Designs & Standards

    Organisation

    Manak Nagar, Lucknow-226 011

    Report. No. MP.MISC-271

    JUNE-2011

    CONTENTS

    Page No.

    1.0 Executive Summary 6

    2.0 Objective 6

    3.0 Background 7

    4.0 Modeling Details 7

    4.1 Modeling Assumptions 7

    4.2 Material Properties and section properties 8

    4.3 Locomotive Underframe Description 9

    4.4 Model Verification (1g Vertical) 9

    5.0 Static Analysis RDSO and EMD Load Cases 11

    5.1 RDSO/EMD Yield Load Cases

    5.1.1 1.0g vertical load case

    5.1.2 1.0gVe+ Drag load case

    5.1.3 1.0g Ve + Buff loadcase

    5.1.4 2.0g Vertical loadcase

    Anil Kumar Director - Motive Power Directorate/RDSO

    Research Designs & Standards Organisation

    Manak Nagar, Lucknow-226 011

  • 1

    5.1.5 1.0g Ve + (+) 3g longitudinal loadcase

    5.1.6 1.0g Ve + (-) 3g longitudinal loadcase

    5.1.7 1.0g Ve + (+) 1.5g lateral loadcase

    5.1.8 1.0g Ve + (-) 1.5g lateral loadcase

    5.1.9 1.0g Ve + 2000KN buffload at buffer loadcase

    5.1.10 1.0g Ve + 1500KN buffload at 50 mm below buffer loadcase

    5.1.11 1.0g Ve + lifting at cabend jack and cabend bogie attach to underframe

    other bogie on rail

    5.1.12 1.0g Ve + lifting at radend jack and radend bogie attach to underframe

    other bogie on rail

    5.1.13 1.0g Ve + lifting at cabend and cabend bogie attach to underframe

    other bogie on rail

    5.1.14 1.0g Ve + lifting at radend and radend bogie attach to underframe

    other bogie on rail

    5.1.15 Both end lifting at jack with lifting load of 1.5x (locomotive weight).

    5.1.16 1g Ve + 3 TE tractive drag loadcase

    5.1.17 Pivot pin load (+) 300 kN/(-)270 kN loadcase

    5.1.18 Pivot pin load 3.0g long of bogie weight

    5.1.19 Anti-climber load of 45300kg verticle loadcase

    5.1.20 400 kN force at buffer diagonaly

    5.2 RDSO/EMD Fatigue Load Cases

    5.2.1 1.0g Ve + () 0.35 loadcase

    5.2.2 1.0g Ve + () .25g Ve + () .5g Lateral

    5.2.3 1.0g Ve + () .25g Ve + () .5g Longitudinal

    5.3 RDSO/EMD Torque Loads

    5.3.1 Underframe twist analysis for engine torque load of 33896 N-m.

    6.0 Modal Analysis 12

    6.1 Underframe Natural Frequencies

    7.0 Results and discussions 13

    8.0 Conclusions 15

    List of Tables:-

    Table1: Material properties used in the Underframe structure 8

    Table2: Underframe Plate Thickness 9

    Table3: Locomtive weight Distribution Between Components 10

    Table4: Underframe Modal Analysis, Natural Frequencies 12

    Table5: Max. Stress , Max. Displacement 13

    List of Figures

    Fig 1: Locomotive layout 16

    Fig 2: The Underframe Structure unigraphics 3D image Top View 16

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    Fig 3: The Underframe Structure unigraphics 3D image Bottom View 17

    Fig 4: The Underframe Cross-section Details(Dimensions are in mm) 17

    Fig 5: Finite Element Model of locomotive underframe 18

    Fig. 6 Vertical Displacement, Draft Load 19

    Fig. 7 Von Mises Stress of UF Top Plate, Draft Load 19

    Fig. 8 Von Mises Stress of UF Top Plate #2 End Side, Draft Load 20

    Fig. 9 Von Mises Stress of UF Bottom Plate, Draft Load 20

    Fig. 10 Von Mises Stress of UF Bottom Plate #2 End Side, Draft Load 21

    Fig. 11 Von Mises Stress of Center Sill #2 End Side, Draft Load 21

    Fig. 12 Draft Gear Pocket, Mesh, Loading and Boundary Conditions 22

    Fig. 13 Draft Gear Pocket, von Mises stress in the Bottom Plate 23

    Fig. 14 Draft Gear Pocket von Mises stress Distribution, Draft Load 23

    Fig. 15 Underframe Load Distribution Buff Load 24

    Fig. 16 Vertical Displacement Buff Load 24

    Fig. 17 Von Mises Stress in the top Plate Buff Load 25

    Fig. 18 Von Mises Stress in the Top Plate #1 End Side Buff Load 25

    Fig. 19 Von Mises Stress in the Top Plate #2 End Side Buff Load 26

    Fig. 20 Von Mises Stress in the Bottom Plate Buff Load 26

    Fig. 21 Von Mises Stress in the Bottom Plate #1 End Side Buff Load 27

    Fig. 22 Von Mises Stress in the Center Sill #1 End Side Buff Load 27

    Fig. 23 Von Mises Stress in the Side Sill #1 End Side Buff Load 28

    Fig.24 Von Mises Stress in the Top Plate #2 End Side Buff Load 28

    Fig. 25 Draft Gear Pocket Von Mises Stress Bottom Plate Buff Load 29

    Fig. 26 Draft Gear Pocket Von Mises Stress Buff Load 29

    Fig. 27 Underframe Load Distribution 5.1.4 2.0g Vertical loadcase 30

    Fig. 28 Vertical Displacement 5.1.4 2.0g Vertical loadcase 30

    Fig. 29 Von Mises Stress in the top Plate 5.1.4 2.0g Vertical loadcase 31

    Fig. 30 Von Mises Stress in the Top Plate #1 End Side 5.1.4, 2.0g Vertical loadcase 31

    Fig. 31 Von Mises Stress in the Top Plate #2 End Side 5.1.4, 2.0g Vertical loadcase 32

    Fig. 32 Von Mises Stress in the Bottom Plate 5.1.4, 2.0g Vertical loadcase 32

    Fig. 33 Underframe Load Distribution 5.1.5 1.0g Ve + (+) 3g longitudinal loadcase 33

    Fig. 34 Vertical Displacement 5.1.5 1.0g Ve + (+) 3g longitudinal loadcase 33

    Fig. 35 Von Mises Stress in the top Plate 5.1.5, 1.0g Ve + (+) 3g longitudinal loadcase

    34

    Fig. 36 Von Mises Stress in the Top Plate #1 End Side 5.1.5, 1.0g Ve + (+) 3g

    longitudinal loadcase. 34

    Fig. 37 Von Mises Stress in the Top Plate #2 End Side 5.1.5, 1.0g Ve + (+) 3g

    longitudinal loadcase 35

    Fig. 38 Von Mises Stress in the Bottom Plate 5.1.5 1.0g Ve + (+) 3g longitudinal

    loadcase