ELASTIC-PLASTIC FINITE ELEMENT ANALYSIS OF THREE-DIMENSIONAL CONTACT-IMPACT AT RAIL JOINT

Using the finite element code ANSYS/LS-DYNA, a dynamic finite element modelwith an elastic-linear-kinematic-hardening plastic material is established to analyzeelastic-plastic stresses in the railhead in the impact process of wheel and rail occurring at thegap of rail joint. The model is based on the discrete elastic support condition of the rails, whichis suitable for the actual situation of wheel/track rolling contact. In the analysis the influencesof axle load, yield stress and tangent modulus of rail material on the stresses and strains areinvestigated in detail. The distribution of stresses and strains in the jointed railhead are given.It is found that the axle load, yield stress and tangent modulus of rail material greatly affect thestresses and strains in the railhead during impacting. The study provides a reliable method anduseful datum for the further research on fatigue and wear of railhead and improving the rail jointmode.

THREE-DIMENSIONAL FINITE ELEMENT SIMULATION OF TOTAL KNEE JOINT IN GAIT CYCLE

Based on CT scanning pictures from a volunteer＇s knee joint, a three-dimensional finite element model of the healthy human knee joint is constructed including complete femur, tibia, fibular, patellar and the main cartilage and ligaments. This model was validated using experimental and numerical results obtained from other authors. The pressure distribution of contact surfaces of knee joint are calculated and analyzed under the load action of ‘heel strike＇, ‘single limb stance＇ and ‘toe-off＇. The results of the gait cycle are that the contact areas of medial cartilage are larger than that of lateral cartilage; the contact force and contact areas would grow larger with the load increasing; the pressure of lateral meniscus is steady, relative to the significant variation of peak pressure in medial meniscus; and the peak value of contact pressure on all components are usually found at about 4570 of the gait cycle.

Nonlinear simulation of arch dam cracking with mixed finite element method

This paper proposes a new, simple and efficient method for nonlinear simulation of arch dam cracking from the construction period to the operation period, which takes into account the arch dam construction process and temperature loads. In the calculation mesh, the contact surface of pair nodes is located at places on the arch dam where cracking is possible. A new effective iterative method, the mixed finite element method for friction-contact problems, is improved and used for nonlinear simulation of the cracking process. The forces acting on the structure are divided into two parts： external forces and contact forces. The displacement of the structure is chosen as the basic variable and the nodal contact force in the possible contact region of the local coordinate system is chosen as the iterative variable, so that the nonlinear iterative process is only limited within the possible contact surface and is much more economical. This method was used to simulate the cracking process of the Shuanghe Arch Dam in Southwest China. In order to prove the validity and accuracy of this method and to study the effect of thermal stress on arch dam cracking, three schemes were designed for calculation. Numerical results agree with actual measured data, proving that it is feasible to use this method to simulate the entire process of nonlinear arch dam cracking.

Modeling and Simulation of Valve Cycle in Vein Using an Immersed Finite Element Method

A vein model was established to simulate the periodic characteristics of blood flow and valve deformation in blood-induced valve cycles.Using an immersed finite element method which was modified by a ghost fluid technique,the interaction between the vein and blood was simulated.With an independent solid solver,the contact force between vein tissues was calculated using an adhesive contact method.A benchmark simulation of the normal valve cycle validated the proposed model for a healthy vein.Both the opening orifice and blood flow rate agreed with those in the physiology.Low blood shear stress and maximum leaflet stress were also seen in the base region of the valve.On the basis of the healthy model,a diseased vein model was subsequently built to explore the sinus lesions,namely,fibrosis and atrophy which are assumed stiffening and softening of the sinus.Our results showed the opening orifice of the diseased vein was inversely proportional to the corresponding modulus of the sinus.A drop in the transvalvular pressure gradient resulted from the sinus lesion.Compared to the fibrosis,the atrophy of the sinus apparently improved the vein deformability but simultaneously accelerated the deterioration of venous disease and increased the risk of potential fracture.These results provide understandings of the normal/abnormal valve cycle in vein,and can be also helpful for the prosthesis design.

Simulation on derailment base on a new wheel-rail contact method

The simulation package for special research on derailment of high speed vehicle is established.The process of derailment is different from other behaviors of vehicle dynamics because of large lateral displacement of wheelsets.To get correct results,a new fast algorithm to computing contact force is adopted and the exact geometry analysis is necessary to judge derailment happened.Variation of contact condition and coefficient of friction with speeds are also considered into vehicle-track coupled model.The structure of the package is presented in detail.The results are particular emphasis on investigation influence of maximum track defect,critical vehicle speed and various contact condition on derailment.The simulation can also be used to define the most risk factor leading to derailment.

Research on the strain gauge mounting scheme of track wheel force measurement system based on high-speed wheel/rail relationship test rig

Purpose-This paper aims to analyze the stress and strain distribution on the track wheel web surface and study the optimal strain gauge location for force measurement system of the track wheel.Design/methodology/approach-Finite element method was employed to analyze the stress and strain distribution on the track wheel web surface under varying wheel-rail forces.Locations with minimal coupling interference between vertical and lateral forces were identified as suitable for strain gauge installation.Findings-The results show that due to the track wheel web’s unique curved shape and wheel-rail force loading mechanism,both tensile and compressive states exit on the surface of the web.When vertical force is applied,Mises stress and strain are relatively high near the inner radius of 710 mm and the outer radius of 1110mmof the web.Under lateral force,high Mises stress and strain are observed near the radius of 670mmon the inner and outer sides of the web.As the wheel-rail force application point shifts laterally toward the outer side,the Mises stress and strain near the inner radius of 710 mm of the web gradually decrease under vertical force while gradually increasing near the outer radius of 1110 mm of the web.Under lateral force,the Mises stress and strain on the surface of the web remain relatively unchanged regardless of the wheel-rail force application point.Based on the analysis of stress and strain on the surface of the web under different wheel-rail forces,the inner radius of 870 mm is recommended as the optimal mounting location of strain gauges for measuring vertical force,while the inner radius of 1143 mm is suitable for measuring lateral force.Originality/value-The research findings provide valuable insights for determining optimal strain gauge locations and designing an effective track wheel force measurement system.

Simulation of wheel and rail profile wear:a review of numerical models

The development of numerical models able to compute the wheel and rail profile wear is essential to improve the scheduling of maintenance operations required to restore the original profile shapes.This work surveys the main numerical models in the literature for the evaluation of the uniform wear of wheel and rail profiles.The standard structure of these tools includes a multibody simulation of the wheel-track coupled dynamics and a wear module implementing an experimental wear law.Therefore,the models are classified according to the strategy adopted for the worn profile update,ranging from models performing a single computation to models based on an online communication between the dynamic and wear modules.Nevertheless,the most common strategy nowadays relies on an iteration of dynamic simulations in which the profiles are left unchanged,with co-simulation techniques often adopted to increase the computational performances.Work is still needed to improve the accuracy of the current models.New experimental campaigns should be carried out to obtain refined wear coefficients and models,while strategies for the evaluation of both longitudinal and transversal wear,also considering the effects of tread braking,should be implemented to obtain accurate damage models.

Numerical Simulation of Heat Transfer and Deformation of Initial Shell in Soft Contact Continuous Casting Mold Under High Frequency Electromagnetic Field

Heat transfer and deformation of initial solidification shell in soft contact continuous casting mold under high frequency electromagnetic field were analyzed using numerical simulation method; the relative electromagnetic parameters were obtained from the previous studies. Owing to the induction heating of a high frequency electromagnetic field （20 kHz）, the thickness of initial solidification shell decreases, and the temperature of strand surface and slit copper mold increases when compared with the case without the electromagnetic filed. The viscosity of flux de- creases because of the induction heating of the high frequency electromagnetic field, and the dimension of the flux channel increases with electromagnetic pressure; thus, the deformation behavior of initial solidification shell was different before and after the action of high frequency electromagnetic field. Furthermore, the abatement mechanism of oscillation marks under high frequency electromagnetic field was explained.

ANALYSIS OF THERMAL-ELASTIC STRESS OF WHEEL-RAIL IN ROLLING-SLIDING CONTACT

A coupling thermo-mechanical model of wheel/rail in rolling-sliding contact is put forward using finite element method. The normal contact pressure is idealized as the Hertzian distribution, and the tangential force presented by Carter is used. In order to obtain thermal-elastic stress, the ther-mal-elastic plane stress problem is transformed to an elastic plane stress problem with equivalent fictitious thermal body force and fictitious boundary distributed force. The temperature rise and ther-mal-elastic stress of wheel and rail in rolling-sliding are analyzed. The non-steady state heat transfer between the contact surfaces of wheel and rail, heat-convection and radiation between the wheel/rail and the ambient are taken into consideration. The influences of the wheel rolling speed and wear rate on friction temperature and thermal-elastic stress are investigated. The results show the following： ① For rolling-sliding case, the thermal stress in the thin layer near the contact patch due to the friction temperature rise is severe. The higher rolling speed leads to the lower friction temperature rise and thermal stress in the wheel; ② For sliding case, the friction temperature and thermal stress of the wheel rise quickly in the initial sliding stage, and then get into a steady state gradually. The expansion of the contact patch, due to material wear, can affect the friction temperature rise and the thermal stress during wear process. The higher wear rate generates lower stress. The results can help under-stand the influence of friction temperature and thermal-elastic stress on wheel and rail damage.

THEORETICAL PREDICTION OF TOOL-CHIP CONTACT LENGTH IN ORTHOGONAL METAL MACHINING BY COMPUTER SIMULATION

A method for determination of tool-chip contact length is theoreticallypresented in orthogonal metal machining. By using computer simulation and based on the analyses ofthe elastro-plastic deformation with lagrangian finite element method in the deformation zone, theaccumulated representative length of the low layer, the tool-chip contact length of the chipcontacting the tool rake are calculated, experimental studies are also carried out with 0.2 percentcarbon steel. It is shown that the tool-chip contact lengths obtained from computer simulation havea good agreement with those of measured values.

3D numerical simulation and analysis of railgun gouging mechanism

A gouging phenomenon with a hypervelocity sliding electrical contact in railgun not only shortens the rail lifetime but also affects the interior ballistic performance. In this paper, a 3-D numerical model was introduced to simulate and analyze the generation mechanism and evolution of the rail gouging phenomenon. The results show that a rail surface bulge is an important factor to induce gouging. High density and high pressure material flow on the contact surface, obliquely extruded into the rail when accelerating the armature to a high velocity, can produce gouging. Both controlling the bulge size to a certain range and selecting suitable materials for rail surface coating will suppress the formation of gouging. The numerical simulation had a good agreement with experiments, which validated the computing model and methodology are reliable.

Using Pro/E and ANSYS to Build Finite Element Models

Possible alternatives are studied. By comparing the rail-wheel model constructed by these two packages, the benefits of mixed-use of Pro/E and ANSYS for complex assembly modeling are verified.

Simulation of Fragment Impact on Multi-Layer Targets Using Contact Method

Cased explosives generate highly energetic fragments as their casing breaks up. Due to the complexity of casing fragment related behavior such as embedment, perforation and ricochet, it may be insufficient to use equivalent triangular pressure loading in fragment impact simulations. This simplified method may over- or under-predict the target response. Recently, a procedure using contact techniques has been proposed to overcome such difficulties. It has been shown that the new method has the inherent capability in modeling the multi-piece and multi-hit fragment impact problems in a more realistic way. To investigate the applicability of the proposed method to simulations involving multi-layer penetration, the selected problems of fragment impact on multi-layer targets are described in this paper. It is demonstrated that this method is capable of predicting the complicated multi-layer structural response caused by fragment impact and penetration. Modeling procedures and some technical issues are also discussed.

基于Simulation的电滚筒法兰轴设计

针对活齿减速式滚筒的关键部件-法兰轴特殊结构的设计问题,在选定了符合要求的电动机和活齿减速器之后,以SolidWorks为平台建立法兰轴的数据模型,并利用Simulation进行了有限元静力和模态分析,找出法兰轴的应力、变形分布规律及危险截面所在,得到其临界转速和固有频率,为法兰轴的结构设计和动力学分析提供理论依据。

Numerical Analysis of Rolling-sliding Contact with the Frictional Heat in Rail

Thermal damage caused by frictional heat of rolling-sliding contact is one of the most important failure forms of wheel and rail. Many studies of wheel-rail frictional heating have been devoted to the temperature field, but few literatures focus on wheel-rail thermal stress caused by frictional heating. However, the wheel-rail creepage is one of important influencing factors of the thermal stress In this paper, a thermo-mechanical coupling model of wheel-rail rolling-sliding contact is developed using thermo-elasto-plastic finite element method. The effect of the wheel-rail elastic creepage on the distribution of heat flux is investigated using the numerical model in which the temperature-dependent material properties are taken into consideration. The moving wheel-rail contact force and the frictional heating are used to simulate the wheel rolling on the rail. The effect of the creepage on the temperature rise, thermal strain, residual stress and residual strain under wheel-rail sliding-rolling contact are investigated. The investigation results show that the thermally affected zone exists mainly in a very thin layer of material near the rail contact surface during the rolling-sliding contact. Both the temperature and thermal strain of rail increase with increasing creepage. The residual stresses induced by the frictional heat in the surface layer of rail appear to be tensile. When the creepage is large, the frictional heat has a significant influence on the residual stresses and residual strains of rail. This paper develops a thermo-meehanical coupling model of wheel-rail rolling-sliding contact, and the obtained results can help to understand the mechanism of wheel/rail frictional thermal fatigue.

Life prediction for rolling contact fatigue crack initiation of kiln wheels

This paper investigates the rolling contact fatigue of kiln wheels with respect to the axis line deflection, which is linear with the applied supporting loads on wheels. Fatigue crack initiation criteria for elastic shakedown, plastic shakedown and ratcheting material responses are applied to assess wheels responses with two sets of axial line deflection. The finite element simulations are performed by using the bilinear material mode for nonlinear and kinematic hardening in ANSYS 11.0. By comparing the results from different critera, it is showed that the low-cycle fatigue is the predominated failure. Results from different axial line deflections indicate that the optimum adjustment can greatly enhance the whole life of the supporting structure.

电气化铁路牵引回流对钢轨磁化的影响研究

针对钢轨产生异常剩磁的现象,建立机车牵引回路三维有限元模型,对钢轨磁化原因进行仿真分析。研究结果表明:机车正常运行时,接触线在钢轨处产生的磁场及钢轨之间互相耦合产生的磁场均小于0.05 mT,远小于实地测量的钢轨剩磁10 mT,影响可以忽略不计;机车牵引电流幅值突变时,钢轨表面产生的磁场可达0.66~0.68 T,该磁场大小经等效计算接近自动过分相区地面磁钢的最小磁场大小1.1 T,从而可能导致机车主断路器异常跳变。

扣件刚度非线性对波磨区轮轨瞬态滚动接触行为的影响

WJ-8型扣件橡胶垫板刚度在长期服役过程中表现出非线性特征,静刚度随荷载增加而降低,为提高三维瞬态滚动接触有限元模型计算精确性,本文以LMA踏面车轮及CHN60型钢轨为基础,基于显式积分算法,将以往研究中线弹性扣件转化为非线性扣件,建立考虑扣件刚度非线性特征的三维轮轨瞬态滚动接触有限元模型,研究刚度非线性对车轮与钢轨波磨间高频动态响应及瞬态接触行为的影响,并重点分析了波磨工况下时频域内轮轨接触力、轴箱加速度的变化信息.结果表明:扣件非线性对轮轨接触力变化影响明显,主要表现为车轮行驶至扣件前端时强振动导致橡胶垫板表现为柔软特性使轮轨接触力减小,车轮行驶至扣件上方时在轴重作用下振动减弱表现为刚硬特性使轮轨接触力增大,轮轨力变化差异最大达到13.1%.

基于Hertz模型的海洋立管束碰撞力计算方法研究

立管是海洋油气开采的关键设备之一,其在流致振动作用下,相邻立管可能会发生振动碰撞损伤。基于Hertz模型,针对不同夹角下的两根立管碰撞的碰撞力计算开展研究。借助有限元方法探讨海洋立管局部碰撞过程,立管的直径选取为工程应用较为广泛的30.48 cm,截取长度基于相关碰撞参与长度来确定,径厚比范围为16~60,分别设置立管碰撞时的速度为0.25 m/s、1.5 m/s、2.4 m/s和3 m/s,分析两根立管夹角和立管径厚比等对于Hertz模型计算精度的影响。研究发现:两根立管夹角越小和径厚比越小,Hertz模型得到的碰撞力误差越大;通过在Hertz模型中添加与径厚比相关的系数,对Hertz模型进行了修正,最终得到了关于立管束碰撞力的精确计算方法。

盘式制动器温度场的分析研究

针对制动器温度场的研究分析,建立额定起重量32 T的钳盘式制动器三维模型,同时在Workbench中添加制动器材料的各个参数,设置摩擦副间的接触关系,施加制动盘和制动衬片载荷、约束,对制动器制动过程产生的温度场进行仿真。使用LM算法建立包括时间、摩擦因数、制动压力、初始转速的多元非线性数学模型,通过Matlab进行回归分析。最终拟合结果和有限元仿真结果吻合,验证了起重机制动器温度模型的正确性。