17 Stadler Habenbacher

Fatigue assessment of bogie frames with FEMFAT Johann Habenbacher Sebastian Walch, Matthias Brücker, Alois Starlinger

JC M

Lineare Balkenelemente (B31): Lineare Federelemente (JOINTC): Massenelemente (MASS): Distributing Coupling Elemente(DCOUP3D): Multipoint Constraint Elemente (MPC):

JC(4x)

r = 1 mm Consideration Consideration of metallurgical notch

JC

M combined stress

M JC(4x)

HV

JC

1.40

JC 1.20

JC M

JC(4x)

M JC(4x )

M

JC JC

M JC

JC JC JC

JC(4x )

JC 1.00

JC

JC JC(4x)

JC(4x)

M

M

M

M JC

n o i t a 0.80 s i l i t u f o e e 0.60 r g e d

IIWn. prop. IIWprop (D)^(1/k) FEMFAT (DVS1608) Habenbacher

0.40

JC JC(4x)

M 0.20

M

HV

M

J C

0.00 0

J. Ha Habe benb nbac ache herr - Fa Fati tigue gue as asse sess ssme ment nt of User bogie bo gieMeeting fram fr ames es wi with th FE FEMF MFAT AT International FEMFAT 2011

30

60

90

120

150

180

degree (position of strain gauge)

1

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 In-house FEMFAT FEMFAT database database • Based on on effective effective notch stress stress – enhanced enhanced database database • Fatigue strength modifications (stress ratio, thickness, grinding, …)

3. Treatment Treatment of data from measurements measurements within fatigue assessment method

4. Multi Multiax axial ial loadin loading g

J. Ha Habe benb nbac ache herr - Fa Fatig tigue ue as asse sess ssme ment nt of bo bogie gie fr fram ames es wi with th FE FEMF MFAT AT

2


2. In-house In-house FEMFAT FEMFAT database database • Based on on effective effective notch stress stress – enhanced enhanced database database • Fatigue strength modifications (stress ratio, thickness, grinding, …)

3. Treatment Treatment of data from measurements measurements within fatigue assessment method

4. Multi Multiax axial ial loadin loading g

J. Ha Habe benb nbac ache herr - Fa Fatig tigue ue as asse sess ssme ment nt of bo bogie gie fr fram ames es wi with th FE FEMF MFAT AT

2

Motivation • Stad Stadle lerr Rai Raill 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

J. Ha Habe benb nbac ache herr - Fa Fati tigue gue as asse sess ssme ment nt of bo bogie gie fr fram ames es wi with th FE FEMF MFAT AT

3

Validation and acceptance of the design Validation program EN 13749

Analysis

Laboratory tests

Track tests

• FKM-Guideline

• static tests

• FKM-Guideline

• IIW-Recommendations

• fatigue tests

• IIW-Recommendations

Bogie frame

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

4

Motor bogie frame of a tram


5

Analysis - FE-Model of a bogie frame JC M

Lineare Balkenelemente (B31): Lineare Federelemente (JOINTC): Massenelemente (MASS): Distributing Coupling Elemente(DCOUP3D): Multipoint Constraint Elemente (MPC):

JC(4x)

JC

M

M JC(4x) JC M

JC(4x)

M JC(4x )

M

JC JC

M JC

JC JC JC

JC

JC

JC(4x )

JC JC

JC JC(4x)

JC(4x)

M

M

M JC

M

JC JC(4x) M M

J C

M

Number of elements: Number of nodes: Degree of freedom:


300‘000 400’000 2’200’000

6

Analysis - Sheet thickness • Shell elements for weld seams • Using THK-groups for thickness correction


7

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


8

Definition of weld seams with FEMFAT Visualizer • About 25 different types of weld seams • Consideration of post weld improvements


9

Weld seam definition • About 1200 weld seams are defined with FEMFAT Visualizer


10

Weld seam definition


11

Laboratory tests • 10 - 28 Cylinder for fatigue tests • 10 Mio. Load cycles

Load run 100% loads complete IMA-pr.no.: C041/08-1 Z04/Z05 Q4

100

Q3

Z09

Z08

Z03

75 Z16 Z13

Z12

Z02 SZ4

50 SZ3

25

Z07 ] m m [

SX2

SX1

n o i s r o t e l x a ] N k [ d a o l

Z1

Z14 Z06 V1 (SZ1)

Z10

SZ2 Z01

Z19

SY1 Q1/ Achsverwindung

Z11

0 0

10

20

30

40

50

60

70

-25

-50

-75

-100

Z03a

SY2 Q2

-125 load cycles


12

Laboratory tests 100 Stain gauges channels Comparison with analytical results


13

Track tests – EN 13749 Fatigue strength • Rainflow-counting • Miner rule

(M)

(WL, Dm)


aBK

14

Comparison of suitable standards for fatigue assessment 120

Allowable stress amplitudes at 2 Mio. load cycles

1 100 = R , ] a P M [ l u z , a S

DV 952 DVS1612

DIN 15018 B5

80 60 40

DIN 15018 B6 ERRI B12/RP60

20

FKM Nominal stress

Effective notch stress

0 3 1 3

1 1 2

2 1 2

1 1 4

2 2 5

3 1 4

1 1 5

5 1 2

4 1 4


3 1 9

4 2 4

15

Comparison of suitable standards for fatigue assessment 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

"Dauerfestigkeit" einer Doppelkehlnaht unter wechselnder Zug-DruckBeanspruchung normal zur Schweissnaht Regelwerk Bemerkung

FKM Wurzelriss, Nr 414, FAT45

DVS1612

ERRI B12 RP 60 ERRI B12 RP 60

Linie F-

Kat. D, nicht geglüht

Kat. D, geglüht

50

41

65

Sa_2Mio,zd_97,5%, R = -1

29

Regelwerk

prEN1993 1-9: 2003

Bemerkung

FAT 36

Nr. 452

FAT 63

t = 10, ages = 10, Wurzelriss

Sa_2Mio,zd_97,5%, R = -1

23

27

32

38

STADLER prCEN/TS 13001DIN 15018 K4/B6 Kerbspannungs3-1: 2003 FAT/2 konzept


16

Data basis IIW


17


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


18

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

Knotenfarbe

Ende

C100 C103

Typ Kombiniert x

C102 C105

x x

C101 C104

x x

C107 C109

x x

x

C106 C108

x x

x

x x

Qualität

Bemerkung

normal

inmitten der Schweissnaht

normal - gut

Schweissnahtende mit Fase (HY-Anarbeitung stirnseitig)

normal schlecht

Schweissnahtende ohne Fase (keine HYAnarbeitung stirnseitig)

verschliffen

Schweissnahtende mit Fase (HYAnarbeitung stirnseitig)

sehr schlecht

nicht gut zugänglich


19

In-house FEMFAT database - effective notch stress Based on IIW-Recommendation XIII-2240-08/XV-1289-08


20

In-house FEMFAT database – metallurgical notch Difference between weld root crack or toe crack Approach: Consideration of metallurgical notch effect • internal FEMFAT weld database • consistently with test data

k = 3,7 r = 1 mm Consideration of metallurgical notch

HV

IIW – recommendations

New Approach

HV


21

In-house FEMFAT database - Influence of stress ratio Haigh-diagram with Mσ = 0,15 (according to FKM-guideline)

S355, Haigh-Diagramm, Normalspannungen 200 200 175

R = -1

FKM IIW

e d u t i l p m a S S s a m g n u n n a p S

(

R = 0,5

R=0

150

FEMFAT weld

125

)

R = - ∞100 75

50

25 0 400

350

− 400

300

250

200

150

100

50

0

50

100 S

150

200

250

300

350

400

m

450

500

550

600

600

Mittelspannung


22

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…)

2 S M D

HY

3 S M D

DMS 1

DMS 4

DMS 8

DMS 5

HY

7 S M D

k ⊥ = 3 σ

6 S M D


23

In-house FEMFAT database - Example of weld seam 343

344

HY HY 339

SID 408 HY – DHV MAT 339 – 346

2 S M D

3 S M D

DHV

DHV 346

HY

DMS 4

DMS 8

DMS 5 6 S M D

342

340

345

DMS 1

7 S M D

341

kσ⊥ = 3

DHV


24






25

Treatment of data from measurements Questions: Strain state on inaccessible side Work around: • reading stresses from FEMFAT *.fms data including automatic weld stress correction option • estimation of effective notch stress in weld seam on inaccessible side

DMS

Inaccessible side

S M D

Strain gauge

Knotennr.: Bottom Grundmaterial: Top Grundmaterial: Schweissnahtmitte Schweissnahtmitte quer: Knotennr.: Bottom Grundmaterial: Top Grundmaterial: Schweissnahtmitte Schweissnahtmitte quer: Knotennr.: Bottom Grundmaterial: Top Grundmaterial: Schweissnahtmitte Schweissnahtmitte quer:

top sp

tp

sn

bottom sp

tp

-5.84E-01 -7.43E-01

1.26E-01 4.28E-01

-1.14E-01 1.22E-02

2.55E-01 3.41E-01

-5.19E-01 2.85E-02

4.13E-01

2.97E+00

-5.64E-02

3.94E-01

2.16E+00

-5.88E-03 -8.84E-03

3.91E-03 -1.45E-02

-5.12E-03 -1.04E-02

2.41E-03 3.83E-03

-2.38E-02 -1.79E-02

-2.94E-02 680754 -3.46E-03 3.62E-02

-1.39E-02

2.43E-02

1.93E-02

4.07E-03

1.35E-02

3.13E-02 4.41E-02

8.80E-02 7.67E-02

-1.88E-02 7.46E-03

-1.47E-02 -1.63E-02

-1.71E-02 4.67E-02

3.40E-01

2.33E-02

-1.91E-01

3.50E-01

5.14E-02

-1.31E-01

sn 680754 5.21E-01 1.16E+00

4.32E-01 680754 2.70E-04 -1.66E-02


1 s m f

2 s m f

3 s m f

26






27

Multiaxial loading – simple example Stress components: Sx = 0 ± 100 MPa

Material: Sw = 150 MPa (R = -1)

Sy = 0 MPa

M = 0.3

Txy = 100 MPa Stress components 150.0

100.0

50.0 s s e r t s

0.0 0.000

Sx(t)

1.000

2.000

3.000

4.000

5.000

6.000

7.000

Sy(t) Txy(t)

-50.0

Multiaxial loading – simple example Material: Sw = 150 MPa (R = -1)

Stress components: Sx = 0 ± 100 MPa Sy = 0 MPa

M = 0.3

Txy = 100 MPa

notch factors are 1.01

utilisation 0.80 0.70 0.60 0.50

ax 0.40

ay a_tau

0.30 0.20 0.10 0.00 0

20

40

60

80

100

120

140

160

180

degree


29

Multiaxial loading of weld seams – simple example Stress:

Sx = 0 ± 100 MPa

Material: Sw = 150 MPa (R = -1)

Sy = 0 MPa

M = 0.3

Txy = 100 MPa

notch factors are 1.01

Utilisation to multiaxial loading 1.40

1.20

IIW n. prop. n 1.00 o i t a s i l 0.80 i t u f o e 0.60 e r g e d 0.40

IIW prop (D)^(1/k) FEMFAT (DVS1608) Habenbacher

0.20

0.00 0

30

60

angle

90

α (orientation

120

150

180

of strain gauge)


30

Multiaxial loading – simple example, DVS1608


Multiaxial loading – simple example, DIN 15018


Multiaxial loading – simple example,– BS 7608, Sign from Normal Stress


Multiaxial loading – simple example, base material

multiaxial loading, base material Sm=0, Sa=±100, Tm=100 Skalierte Normalspannung kritische Schnittebe ne Mod. Ve rglei chsspannung kritische Schnittebene Max./Min. Hauptnormalspannung Vorzeichenbehaftete Mises Spg. 2 (Vorzeiche n von hydrostatischer S pg.) Vorzeichenbehaftete Mises Spg. 1 (Vorzeichen von max. Hauptnormalspg.) Kritische Komponente a i reduziert kritische Schnittebene r e t i r Kritische Komponente kritische S chnittebene c Nokleby-Kriterium kritische Schnittebene

Vergle ichsspannung kritische Schnittebe ne

Werkstoffcharakteristische Schubspannung

FKM

Normalspannung kritische Schnittebene

Automatisch

0.00

0.20

0.40

0.60

0.80

1.00

normalized utilisation


1.20

1.40

1.60

17 Stadler Habenbacher

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