Preprint. This is the submitted version of a paper presented at ICRI Workshop on Wear and RCF.

Transcription

1 Preprint This is the submitted version of a paper presented at ICRI Workshop on Wear and RCF. Citation for the original published paper: Casanueva, C., Dirks, B., Enblom, R., Hossein Nia, S., Shazamanian Shichani, M. (2016) Integrated simulation of damage: efficient contact modeling, wear-rcf interaction, and longterm evolution. In: ICRI Workshop on Wear and RCF N.B. When citing this work, cite the original published paper. Permanent link to this version:

2 Integrated simulation of damage: efficient contact modeling, wear-rcf interaction, and long-term evolution Carlos Casanueva Assistant Professor in Rail Vehicle Technology KTH, Stockholm, Sweden Carlos Casanueva, PhD (KTH Rail Vehicles) Babette Dirks, PhD (Bombardier Transportation) Roger Enblom, PhD (BT, KTH Rail Vehicles) Saeed Hossein Nia, MSc (KTH Rail Vehicles) Matin Sh. Shichani, PhD (KTH, MiW Rail Technology)

3 KTH Railway Group Key activities: Research and postgraduate education Graduate education Courses for professional engineers Seminars Consulting engineers 2

4 KTH Railway Group Traffic and Logistics Wear and RCF Machine design Eskilstuna C Kjula Eskilstuna-Stockholm Strängnäs Läggesta Nykvarn Södertälje syd Barva Härad Malmby Grundbro Almnäs v ö Flemingsberg Flen 115 Åkers styckebruk Järna Cost effective bridges Electric Energy Conversion Rail Vehicles (Light and with good dynamic and acoustic comfort) soil-steel composite railway bridges Structural Engineering and Bridges 3

5 Wheel and rail damage simulation at KTH Multiscale analysis Vehicle Dynamics Contact Patch Modelling Wear/RCF interaction 4

6 Wheel and rail damage simulation at KTH Multiscale analysis Vehicle Dynamics Contact Patch Modelling Wear/RCF interaction 5

7 Multiscale analysis Contact Patch Modelling Wear/RCF interaction Large scale Vehicle Dynamics Small scale SNCF 6

8 Wheel and rail damage simulation at KTH Multiscale analysis Vehicle Dynamics Contact Patch Modelling Wear/RCF interaction 7

9 Contact patch modelling Important for precise damage calculation Hertz+FASTSIM CONTACT code (most precise) ~ 0.02 second ~ 20 seconds 8

10 Creep Force Pure translational case FASTSIM: FaStrip: M. S. Sichani, R. Enblom, and M. Berg, A novel method to model wheel rail normal contact in vehicle dynamics simulation, Vehicle System Dynamics, vol. 52, no. 12, pp , Dec M. S. Sichani, R. Enblom, and M. Berg, Comparison of non-elliptic contact models: Towards fast and accurate modelling of wheel rail contact, Wear, vol. 314, no. 1 2, pp , Jun

11 ANALYN+FaStrip y = 0 mm y = -11 mm 10

12 Results Hertz+FASTSIM ANALYN+FaStrip CONTACT code ~ 0.02 second ~ 0.12 second ~ 20 seconds 11

13 Energy index in the patch 12

14 Wheel and rail damage simulation at KTH Multiscale analysis Vehicle Dynamics Contact Patch Modelling Wear/RCF interaction 13

15 Basic damage prediction modelling Wear RCF Initial wheel profile Contact data generation Rail profiles Transient simulations Simulation set Wear calculation Wear map Scaling to step limit Wheel profile updating - Metro wheels - Tram rails - Commuter wheels - Freight wagon wheels - Freight loco wheels - Traction and braking - Lubrication - Friction coefficient - Track irregularities - 14

16 Damage prediction modelling application Wear RCF x Wear [m] Crossing Nose Lateral Dimension of Wheel Profile [m] Wing rail Turnout s Longitudinal Dimension [m] 49 C. Casanueva, E. Doulgerakis, P.-A. Jönsson, and S. Stichel, Influence of switches and crossings on wheel profile evolution in freight vehicles, Vehicle System Dynamics, vol. 52, no. sup1, pp , S. Hossein Nia, P.-A. Jönsson, and S. Stichel, Wheel damage on the Swedish iron ore line investigated via multibody simulation, Proceedings of the Institution of Mechanical Engineers, Part F: Journal of Rail and Rapid Transit, vol. 228, no. 6, pp , Aug

17 Wear-RCF interaction Crack growth model + Archard B. Dirks, R. Enblom, and M. Berg, Prediction of wheel profile wear and crack growth comparisons with measurements, Wear. In press. 16

18 Validation Wear t f = flange thickness h f = flange height q r = flange inclination ΔA = worn-off area o = measurements = simulation 17

19 Validation Crack growth c pe = predicted crack length, wear excluded c pi = predicted crack length, wear included c m = measured crack length 18

20 Wear-RCF interaction Surface Fatigue Index + Archard S. Hossein Nia, C. Casanueva, and S. Stichel, Prediction of RCF and wear evolution of iron-ore locomotive wheels, Wear, vol , pp , Sep

21 Wear-RCF interaction 20

22 Validation Long Term Development Lubricated Non-Lubricated 21

23 ICRI Workshop on Wear and RCF, 2-4 August 2016, Vancouver Validation Long Term Development Lubricated Non-Lubricated Bombardier Transportation 22

24 Wheel and rail damage simulation at KTH Software homogenization Statistical wear calculation Uniform wheel wear development RCF long term development Multiscale analysis MBS coding Normal contact Tangential contact Contact Patch Modelling Vehicle Dynamics Wear/RCF interaction Subsurface fatigue Surface Fatigue + Archard Crack growth + Archard Lubrication tribology Improved wear maps 23

25 Applied in EU projects Ongoing Finished (selection) S. Stichel, P.-A. Jönsson, C. Casanueva, and S. Hossein Nia, Modeling and simulation of freight wagon with special attention to the prediction of track damage, International Journal of Railway Technology, vol. 3, no. 1, pp. 1 36,

26 Thanks for your time!