A Comparative Study on the Truck Frame Stiffness with Solid and Beam Element FEA Models

Truck frames should be designed and fabricated with enough rigidity to avoid excessive deflections. Finite element analysis (FEA) plays an important role in all stages of frame designs. While being accurate, 3D solid element FEA models are built upon frame configuration details which are not feasible in the preliminary design stage, partially because of limited available design data of frames and heavy computation costs. This research develops 1D beam element FEA models for simulating frame structures. In this paper, the CAD model of a truck frame is first created. The solid element FEA analysis, which is adopted as the baseline in this study, is subsequently conducted for the stiffness of the frame, Next, beam element FEA analysis is performed for validating the feasibility of the beam element FEA model by comparing the results from the solid and beam element FEA models. It is found that the beam element FEA model can predict the frame stiffness with acceptable accuracy and reduce the computation cost significantly.

Methodology to Evaluate Fatigue Damage of High-Speed Train Welded Bogie Frames Based on On-Track Dynamic Stress Test Data

The current method of estimating the fatigue life of railway structures is to calculating the equivalent stress amplitude based on the measured stress data. However, the random of the measured data is not considered. In this paper, a new method was established to compute the equivalent stress amplitude to evaluate the fatigue damage based on the measurable randomness, since the equivalent stress is the key parameter for assessment of structure fatigue life and load derivation. The equivalent stress amplitude of a high-speed train welded bogie frame was found to obey normal distribution under uniform operation route that verified by on-track dynamic stress data, and the proposed model is, in effect, an improved version of the mathematical model used to calculate the equivalent stress amplitude. The data of a long-term, on-track dynamic stress test program was analyzed to find that the normal distribution parameters of equivalent stress amplitude values differ across different operation route. Thus, the fatigue damage of the high-speed train welded bogie frame can be evaluated by the proposed method if the running schedule of the train is known a priori. The results also showed that the equivalent stress amplitude of the region connected to the power system is more random than in other regions of the bogie frame.

Effect of Increasing Speed on Stress of Biaxial Bogie Frames

Increasing the trains’ speed has always been one of the goals of any railway industry and train manufacturers. Also, the influence of the train speed on bogie’s dynamics has an immense importance. Therefore, it is important to analyze the effect of train speed on the stress distribution in different parts of train structure. In this study the result of the increasing speed on the applied stresses of a biaxial bogie frame has been examined. For this purpose, a biaxial bogie frame has been modeled using finite element analysis. Static and dynamic forces applied on the bogie with biaxial frame have been obtained for different speeds and rail roughness. The Von Mises stresses are adopted as equivalent stresses in the strength calculation. The results show that maximum stress always has been induced in the bogie bowl also the increase in bogie’s speed has remarkable effect on the increment of applied stresses in the bogie frame.

Analysis of the Load-Stress Response Characteristics of the Bogie Frame in Intercity Electric Multiple Unit

Load spectra research for bogie frame requires establishing the load?stress relationship on working condition, which has been omitted by the researchers. With the load?stress of the bogie frame of an intercity Electric Multiple Unit(Hereinafter referred to as EMU) as the research object, an optimization model of the load?stress transfer relationship is established. The load?stress coe cient for EMU bogie frame was calibrated in the laboratory bench and online test was arranged on Dazhou?Chengdu line. Comparison of nonlinear and linear neural networks proves that the linear transitive relation between the load and stress of the bogie frame in the operating process is highly suitable. An optimization model of the load?stress transfer coe cient is obtained. The data calculated with the modified coe cient are closer to the dynamic stress results in the actual operating process than the data calculated with the calibration coe cient. The coe cient of the modified transitive relation is una ected by operating area, empty load, heavy load, or other conditions in the operating process of the intercity EMU. The real loads in actual situations are obtained. The model of online load?stress relationship that is highly suitable for line stress calculation is finally established. The research is helpful for further damage calculation and inferring the time history signal of the load in load spectra research.

Extended intrinsic mean spin tensor for turbulence modelling in non-inertial frame of reference

We investigate the role of extended intrinsic mean spin tensor introduced in this work for turbulence modelling in a non-inertial frame of reference. It is described by the Euclidean group of transformations and, in particular, its significance and importance in the approach of the algebraic Reynolds stress modelling, such as in a nonlinear K-ε model. To this end and for illustration of the effect of extended intrinsic spin tensor on turbulence modelling, we examine several recently developed nonlinear K-ε models and compare their performance in predicting the homogeneous turbulent shear flow in a rotating frame of reference with LES data. Our results and analysis indicate that, only if the deficiencies of these models and the like be well understood and properly corrected, may in the near future, more sophisticated nonlinear K-ε models be developed to better predict complex turbulent flows in a non-inertial frame of reference.

Determination Method on Initial Pretension of Cables in Steel Mega Frame and Prestressed Composite Bracing Structure

Determining initial pretension values of pre-stressed cables is one of the key problems for a steel mega frame and pre-stressed composite bracing structure.Through the mechanical analysis of the composite bracing under vertical loading,the critical factors deciding the initial pretention value were found.According to these factors,a rule for the initial pretension value was put forward.The determination equations were acquired based on the principle of force equilibrium at nodes.The numerical results indicate that the internal force disequilibrium in composite bracings resulted from symmetrical load can be eliminated only in a symmetrical way,so that initial pretention values are decided only by vertical loads.The influencing coefficient leveling method,taking into account interactions between story and story,is accurate and feasible.

Effect of Fe Particle on the Surface Peeling in Cu-Fe-P Lead Frame

Under the surface peeling of Cu- Fe- P lead frame alloy larger Fe particles were observed by energy dispersive spectroscopy. By using the large strain two-dinension plane strain model and elastic plastic finite element method, the cause for peeling damage of Cu-Fe-P lead frame aUoy was investigated. The results show that when the content of Fe particles is more than 30% at local Fe-rich area the intense stress coacentration in the Fe particle would make the Fe particle broken up. The high equivalent stress mutation and the mismatch of equivalent strain 10% at the two sides of intefrace make it easy to develop the crack and peeling damage on finish rolling. The larger Fe particles in the Cu-Fe-P alloy should be avoided.

The Dissimilarities between Graphene and Frame-Like Structures

Modeling and simulation allow methodical variation of material properties beyond the capacity of experimental methods. Due to the hexagonal structure of graphene, it is considered as frame-like structure. In the frame, covalent C-C bonds are taken as beams joined together with carbon atoms placed at the joints. Uniaxial beam elements, defined by their cross-sectional area, material properties, and moment of inertia represent the covalent bonds. The parameters of the beam elements are determined by establishing equivalence between structural and computational mechanics. However, the bonds connecting the carbon atoms do not have physical existence as they are a compromise between attractive and repulsive forces. Also, defects at nanoscale make graphene different from frame-like structure. In addition, the topography of graphene makes it non-linear structure and even the axial loading changes to eccentric loading. Here we show that, by using basic statics principles, disparities between graphene and frame-likes structures can be highlighted.

Controlling of stress and distortion in thin copper plate by welding with trailing peening

Welding with trail peening(WTP) is applied in T1 thin copper plate to reduce the residual stress and distortion firstly,which is the very trouble in copper welding.The main principle for this new technology was presented.To make a complete comparison,both experiments and numerical simulations of thin copper plate were carried out under WTP as well as conventional welding(CW).The results confirm that WTP can reduce longitudinal residual stress in welding joint greatly.The peak value of flexure distortion decreases from 30mm under CW to only 9mm by WTP,that is to say,only 30% of CW.

Fatigue Reliability Assessment of Correlated Welded Web-frame Joints

The objective of this work is to analyze the fatigue reliability of complex welded structures composed of multiple web-frame joints, accounting for correlation effects. A three-dimensional finite element model using the 20-node solid elements is generated. A linear elastic finite element analysis was performed, hotspot stresses in a web-frame joint were analyzed and fatigue damage was quantified employing the S-N approach. The statistical descriptors of the fatigue life of a non-correlated web-frame joint containing several critical hotspots were estimated. The fatigue reliability of a web-frame joint wasmodeled as a series system of correlated components using the Ditlevsen bounds. The fatigue reliability of the entire welded structure with multiple web-frame joints, modeled as a parallel system of non-correlated web-frame joints was also calculated.

Analysis of Residual Thermal Stress in CVD-W Coating as Plasma Facing Material

Chemical vapor deposition-tungsten （CVD-W） coating covering the surface of the plasma facing component （PFC） is an effective method to implement the tungsten material as plasma facing material （PFM） in fusion devices. Residual thermal stress in CVD-W coating due to thermal mismatch between coating and substrate was successfully simulated by using a finite element method （ANSYS 10.0 code）. The deposition parametric effects, i.e., coating thickness and deposition temperature, and interlayer were investigated to get a description of the residual thermal stress in the CVD-W coating-substrate system. And the influence of the substrate materials on the generation of residual thermal stress in the CVD-W coating was analyzed with respect to the CVD-W coating application as PFM. This analysis is beneficial for the preparation and application of CVD-W coating.

Static and Vibration Analysis of an Aluminium and Steel Bus Frame

The transport sector is increasing day by day to satisfy the global market requirement. The bus is still the main mode of intercity transportation in Canada. Despite, an essentially unchanged conception, the total weight of the bus has increased by over 25% during the last three decades. To solve this problem, industrialists have moved to the use of light metals in the transportation field. Therefore, use of lightweight materials, such as aluminum is essential to reduce the total weight of bus. In this study, the focus is on the bus frame as it represents 30% of the total weight and it is the most stressed part of the bus. Its life duration is more important compared to that of all other elements. Thus, a study of the static and vibratory behavior would be very decisive. In this article, two types of analysis are carried out. First is the modal analysis to determine the natural frequencies and the mode shapes using a developed dynamic model of the bus. Because if any of the excitation frequencies coincides with the natural frequencies of the bus frame, then resonance phenomenon occurs. This may lead to excessive deflection, high stress concentration, fatigue of the structure and vehicle discomfort. In this case, the results analysis shows that the natural frequencies are not affected by the change of material. The second type of analysis is the linear static stress analysis to consider the stress distribution and deformation frame pattern under static loads numerically. For the numerical method, the frame is designed using SolidWorks and the analysis is made using Ansys WorkBench. The maximum Von Mises stress obtained for the static loading is in the same order for the three chassis frames studied. But in the case of the aluminium frame, the weight of 764 kg was reduced.

Effect of concrete creep on pre-camber of continuous rigid-frame bridge

The effect of concrete creep on the pre-camber of a long-span pre-stressed concrete continuous rigid-frame bridge constructed by cantilever casting method was investigated.The difference of creep coefficients calculated with two Chinese codes was discussed.Based on the calculations,the pre-camber of a pre-stressed concrete continuous rigid-frame box bridge was computed for construction control purpose.The results show that the short-term creep coefficient and long-term creep coefficient calculated with the CC-1985 are larger than those calculated with the CC-2004,while the medium-term creep coefficient calculated with the CC-1985 is smaller than that calculated with the CC-2004.The difference of creep deformation calculated with these two codes is small,and the influences of concrete creep on the pre-camber for most of the segments are negligible.The deflections and stresses of the box girder measured during the construction stages agree very well with the predictions.

Numerical Simulation of Transient Thermal Stress Field for Laser Metal Deposition Shaping

To decrease thermal stress during laser metal deposition shaping(LMDS)process,it is of great importance to learn the transient thermal stress distribution regularities.Based on the“element life and death”technique of finite element analy- sis(FEA),a three-dimensional multi-track and multi-layer numerical simulation model for LMDS is developed with ANSYS parametric design language(APDL)for the first time,in which long-edge parallel reciprocating scanning paths is introduced. Through the model,detailed simulations of thermal stress during whole metal cladding process are conducted,the generation and distribution regularities of thermal stress are also discussed in detail.Using the same process parameters,the simulation results show good agreement with the features of samples which fabricated by LMDS.

Residual stress and radial stress gradient in polycrystalline diamond compacts

The differential thermal expansion of the polycrystalline diamond layer and the tungsten carbide substrate results in large residual stresses as PDC cutters cooling after sintering.The residual stresses on the top surface of the diamond layer of PDC were measured at five points along the radial direction of PDC using X-ray Diffraction Residual Stress Instrument,thus the stresses and their radial distribution were obtained.The results show that the stresses on the diamond surface are compressive,the biggest stress appears at the central point(about 1200 MPa),and that from the center to the edge of PDC,the magnitude of the stress decreases. A finite element analysis(FEA) was made to check the validity of the testing results.The FEA modeling results were found to correlate well with the measured values.Factors leading to the deviation between XRD experimental measurements and the calculations of residual stress by FEA were also analyzed.

Flexural Stress Homogenization Effects of Interfacial Transition Layers in Modified ZrB2-Al2O3/Epoxy Composites

The effect of interfacial modification on flexural strength of epoxy composites filled with modified ZrB2-Al2O3 composite fillers was investigated in order to explore the stress distribution of modified composites under external load. The mechanical performance of epoxy composites filled with 0 vol%, 1 vol%, 3 vol% and 5 vol% unmodified and modified ZrB2-Al2O3 fillers was characterized by three point bending(TPB) tests. The fracture surfaces of epoxy composites were observed by scanning electronic microscope(SEM). The results showed that the epoxy composite reinforced by 1 vol%modified fillers exhibited the optimal mechanical performance. According to the Von Mises stress contours simulated by finite element models(FEM) and the SEM images, it was shown that the modified ZrB2-Al2O3 multiphase fillers could homogenize the stress in the epoxy composites due to the transition effect resulted from the interfacial modification layers on the surfaces of multiphase fillers. It contributed to the improvement of mechanical performance of epoxy composites further.

Comprehensive investigation of stress intensity factors in rotating disks containing three-dimensional semi-elliptical cracks

Initiation and propagation of cracks in rotating disks may cause catastrophic failures. Therefore, determination of fracture parameters under different working con- ditions is an essential issue. In this paper, a comprehensive study of stress intensity factors （SIFs） in rotating disks containing three-dimensional （3D） semi-elliptical cracks subjected to different working conditions is carried out. The effects of mechanical prop- erties, rotational velocity, and orientation of cracks on SIFs in rotating disks under cen- trifugal loading are investigated. Also, the effects of using composite patches to reduce SIFs in rotating disks are studied. The effects of patching design variables such as mechanical properties, thickness, and ply angle are investigated separately. The modeling and analytical procedure are verified in comparison with previously reported results in the literature.

Numerical simulation of stress behavior of dowel–brick structures in TMSR

As essential elements of the graphite reflector in thorium-based molten salt reactor,dowel–brick structures are used to withstand complex working loads in the reactor core and their failure may lead to serious damage of the graphite reactor core.It is crucial to investigate the stress behavior of dowel–brick structures for safe operation of the graphite reactor.In this study,three groups of finite element analyses and a strain test were carried out to investigate how the geometric parameters of the dowels affect the stress behavior of the dowel–brick structure.The numerical results indicate that the stress behavior of a dowel–brick structure is significantly affected by the diameter,length,and aspect ratio of the dowels.The maximum stress in the lower and upper bricks decreases with an increase in the dowel length.The location of maximum stress on both lower and upper bricks shifts from the root of the socket to the edge of that socket beside the contact region,as the length of the dowel increases.The shift of the maximum stress location occurs earlier for the upper bricks than for the lower bricks.The results of strain tests show good agreement with those of numerical analyses.

基于FEA的升船机复杂焊接结构疲劳强度评估方法及应用

对于焊接金属结构,焊缝的疲劳强度对于结构安全性至关重要。文章针对升船机金属结构和机械设备结构复杂、运转频繁且承受变化载荷的特点,在借鉴Eurocode3及国内相关行业标准的基础上,根据国内实际情况提出了适合升船机结构和载荷特征的基于有限元分析(FEA)的焊接金属结构疲劳强度评估方法,并以齿轮齿条爬升式垂直升船机小齿轮托架机构为例进行了具体的验证。

Stress distribution variations during nanoindentation failure of hard coatings on silicon substrates

Regarding quality inspection of technologically important nanocomposite hard coatings based on Ti,B,Si,C,and N and bioceramics such as hydroxyapatite that are used in small-scale high-precision devices and bio-implants,it is essential to study the failure mechanisms associated with nanoindentation,such as fracture,delamination,and chipping.The stress imposed by the indenter can affect the fracture morphology and the interfacial fracture energy,depending on indenter shape,substrate type,crystallographic properties,pre-existing flaws,internal microcracks,and pre-strain.Reported here are finite-element-based fracture studies that provide insights into the different cracking mechanisms related to the aforementioned failure process,showing that the fracture morphology is affected by the interaction of different cracking events.The interfacial fracture energy,toughness,and residual stress are calculated using existing models with minor adjustments,and it is found that increasing the indenter sharpness improves the shear stress distribution,making the coating more prone to separation.Depending on the prevailing type of stress,the stress distribution beneath the depression results in either crack formation or a dislocation pile-up leading to strain hardening.Different forms of resistances resulting from the indentation process are found to affect the tip–sample conduction,and because of its stronger induced plasticity than that of a Berkovich indenter tip,a sharper cube-corner tip produces more resistance.