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M
JC
M
M
MM
M
MM
M
JC
JC
JC
JC
JC
JC(4x)
JC(4x)
JC(4x)
JC(4x)
JC(4x)
JC(4x)
JC(4x)
JC(4x)JC
JC
JCJC JC
JCJC
JC
JC
JC
Lineare Balkenelemente (B31):
JC Lineare Federelemente (JOINTC):
M Massenelemente (MASS):
Distributing Coupling
Elemente(DCOUP3D):
Multipoint Constraint Elemente (MPC):
M
M
M
M
M
JC
M
M
MM
M
MM
M
JC
JC
JC
JC
JC
JC(4x)
JC(4x)
JC(4x)
JC(4x)
JC(4x)
JC(4x)
JC(4x)
JC(4x)JC
JC
JCJC JC
JCJC
JC
JC
JC
Lineare Balkenelemente (B31):
JC Lineare Federelemente (JOINTC):
M Massenelemente (MASS):
Distributing Coupling
Elemente(DCOUP3D):
Multipoint Constraint Elemente (MPC):
M
M
M
M
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 2
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 3
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 4
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 5
Motor bogie frame of a tram
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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 6
Analysis - FE-Model of a bogie frame
M
JC
M
M
MM
M
MM
M
JC
JC
JC
J
C
JC
JC(4x)
JC(4x)
JC(4x
)
JC(4x)
JC(4x)
JC(4x)
JC(4x)
JC(4x)JC
JC
JCJC JC
JCJC
JC
JC
JC
Lineare Balkenelemente (B31):
JC Lineare Federelemente (JOINTC):
M Massenelemente (MASS):
Distributing Coupling
Elemente(DCOUP3D):
Multipoint Constraint Elemente (MPC):
M
M
M
M
Number of elements: 300000Number of nodes: 400000Degree of freedom: 2200000
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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 7
Analysis - Sheet thickness
Shell elements for weld seams
Using THK-groups for thickness correction
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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 8
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 9
Definition of weld seams with FEMFAT Visualizer
About 25 different types of weld seams
Consideration of post weld improvements
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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 10
Weld seam definition
About 1200 weld seams are defined with FEMFAT Visualizer
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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 11
Weld seam definition
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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 12
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 13
Laboratory tests
100 Stain gauges channels
Comparison with analytical results
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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 14
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
J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 15
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 16
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 17
Data basis IIW
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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 18
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 19
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 22
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 23
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 24
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 25
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 27
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 28
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 29
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
J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 30
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT
Multiaxial loading simple example, DIN 15018
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Multiaxial loading simple example, BS 7608, Sign from Normal Stress
J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT
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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT
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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J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT 35
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