Fatigue assessment of bogie frames using FEMFAT

Fatigue assessment of bogie frames with FEMFAT
Johann Habenbacher
Sebastian Walch, Matthias Brcker, Alois Starlinger
JC
M
Lineare Balkenelemente (B31):

Lineare Federelemente (JOINTC):
Massenelemente (MASS):
Distributing Coupling
Elemente(DCOUP3D):
Multipoint Constraint Elemente (MPC):
JC(4x)
M
combined stress
M
JC(4x)
HV
JC
1.40
JC
1.20
JC
M
JC(4x)
JC(4x
)
JC
JC
M
JC
JC
JC
JC
JC(4x
)
JC
1.00
JC
JC
JC(4x)
JC(4x)
M
JC
degree of utilisation
r = 1 mm
Consideration of
metallurgical
notch
JC
0.80
IIW n. prop.
IIW prop
0.60
(D)^(1/k)
FEMFAT
(DVS1608)
Habenbacher
0.40
JC
JC(4x)
M
0.20
HV
J
C
0.00
0
J. Habenbacher - Fatigue
assessment
of User
bogieMeeting
frames with
International
FEMFAT
2011FEMFAT
30
60
90
120
150
180
degree (position of strain gauge)
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
J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT
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
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
Motor bogie frame of a tram
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
JC(4x)
JC
M
JC(4x)
M
JC(4x
)
JC
JC
M
JC
JC
JC
JC
JC
JC
JC(4x
)
JC
JC
JC
JC(4x)
JC(4x)
M
JC
JC
JC(4x)
M
M
J
C
Number of elements:
Number of nodes:
Degree of freedom:
300000
400000
2200000
Analysis - Sheet thickness

Shell elements for weld seams
Using THK-groups for thickness correction
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
Definition of weld seams with FEMFAT Visualizer

About 25 different types of weld seams
Consideration of post weld improvements
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
b
75
Z16
Z13
Z12
Z02
SZ4
50
SZ3
25
load [kN] axle torsion [mm]
Z07
SX2
SX1
Z14
Z1
7
Z06
V1 (SZ1)
Z10
SZ2
Z01
Z19
Z11
0
0
10
20
30
40
50
60
70
-25
-50
-75
-100
SY1
Q1/ Achsverw indung
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

Allowable stress amplitudes
at 2 Mio. load cycles
100
DV 952
DVS1612
DIN 15018 B5
80
60
40
DIN 15018 B6
ERRI B12/RP60
20
FKM Nominal stress
Effective notch stress
424
913
414
215
511
413
522
411
212
211
0
313
Sa,zul [MPa], R = -1
120
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
geglht
Kat. D, geglht
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
Contents

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
C106
C108
x
x
x
x
Qualitt
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 zugnglich
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 M = 0,15 (according to FKM-guideline)
S355, Haigh-Diagramm, Normalspannungen

200
200
Spannungsamplitude
175
R = -1
FKM
150
IIW
125
( )
Sa Sm
R = 0,5
R=0
FEMFAT weld
R = - 100
75
50
25
0
400
350
400
300
250
200
150
100
50
50
100
150
200
250
300
350
400
Sm
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..)
DMS 3
DMS 2
Remelting of the weld toe (TIG dressing)
HY
DMS 8
DMS 5
HY
k = 3
DMS 6
DMS 4
DMS 7
DMS 1
23
In-house FEMFAT database - Example of weld seam

343
344
HY
HY
339
DMS 3
DMS 2
SID 408
HY DHV
MAT 339 346
DHV
DHV
346
HY
DMS 4
DMS 8
DMS 5
DMS 6
342
340
345
DMS 1
DMS 7
341
k = 3
DHV
24
Contents

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
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
4.32E-01
680754
2.70E-04
-1.66E-02
fms1
Knotennr.:
Bottom Grundmaterial:
Top Grundmaterial:
Schweissnahtmitte
Schweissnahtmitte
quer:
Knotennr.:
Top Grundmaterial:
Schweissnahtmitte
Schweissnahtmitte
quer:
Knotennr.:
Top Grundmaterial:
Schweissnahtmitte
Schweissnahtmitte
quer:
tp
fms2
Strain gauge
top
sp
sn
680754
5.21E-01
1.16E+00
fms3
Inaccessible
side
DMS
DMS
26
Contents

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
stress
50.0
0.0
0.000
1.000
2.000
3.000
4.000
5.000
6.000
7.000
Sx(t)
Sy(t)
Txy(t)
-50.0
-100.0
-150.0
time
28
Multiaxial loading simple example

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
Sy = 0 MPa
M = 0.3
Txy = 100 MPa
notch factors are 1.01
Utilisation to multiaxial loading

1.40
1.20
degree of utilisation
IIW n. prop.
1.00
IIW prop
0.80
(D)^(1/k)
FEMFAT (DVS1608)
0.60
Habenbacher
0.40
0.20
0.00
0
30
60
90
120
150
180
angle (orientation 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 Schnittebene
Mod. Vergleichsspannung
kritische Schnittebene
Max./Min. Hauptnormalspannung
Vorzeichenbehaftete Mises Spg. 2
(Vorzeichen von hydrostatischer Spg.)
criteria
Vorzeichenbehaftete Mises Spg. 1

(Vorzeichen von max. Hauptnormalspg.)
Kritische Komponente
reduziert kritische Schnittebene
Kritische Komponente kritische Schnittebene
Nokleby-Kriterium kritische Schnittebene
Vergleichsspannung kritische Schnittebene
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
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
35

Fatigue assessment of bogie frames using FEMFAT

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Fatigue assessment of bogie frames with FEMFAT

Lineare Balkenelemente (B31):

degree (position of strain gauge)

2. In-house FEMFAT database

3. Treatment of data from measurements within fatigue assessment method

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Validation and acceptance of the design

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Motor bogie frame of a tram

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Analysis - FE-Model of a bogie frame

Lineare Balkenelemente (B31):

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Analysis - Sheet thickness

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Analysis - Load cases

About 64 single load cases (FE simulation)

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Definition of weld seams with FEMFAT Visualizer

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Weld seam definition

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Weld seam definition

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Load run 100% loads complete

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Track tests EN 13749

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Comparison of suitable standards for fatigue assessment

FKM Nominal stress

Effective notch stress

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Comparison of suitable standards for fatigue assessment

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

ERRI B12 RP 60 ERRI B12 RP 60

t = 10, ages = 10,

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

Data basis IIW

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

2. In-house FEMFAT database

3. Treatment of data from measurements within fatigue assessment method

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

In-house FEMFAT database

inmitten der Schweissnaht

Schweissnahtende mit Fase (HY-Anarbeitung

Schweissnahtende ohne Fase (keine HYAnarbeitung stirnseitig)

Schweissnahtende mit Fase (HYAnarbeitung stirnseitig)

nicht gut zugnglich

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

In-house FEMFAT database - effective notch stress

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

In-house FEMFAT database metallurgical notch

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

In-house FEMFAT database - Influence of stress ratio

S355, Haigh-Diagramm, Normalspannungen

J. Habenbacher - Fatigue assessment of bogie frames with FEMFAT

In-house FEMFAT database - post weld improvement techniques

Remelting of the weld toe (TIG dressing)