Finite Element Analysis Of Underframe For 5500 Hp WDGS ...
Transcript of Finite Element Analysis Of Underframe For 5500 Hp WDGS ...
Simulation Driven Innovation 1
FINITE ELEMENT ANALYSIS OF
UNDERFRAME FOR 5500 HP WDG5 LOCOMOTIVE
P.C.S.Yadav
Sse/Mp Directorate
Research Designs & Standards
Organisation
Manak Nagar, Lucknow-226 011
R. K. Misra
Ade/Mp Directorate
Research Designs & Standards
Organisation
Manak Nagar, Lucknow-226 011
Anurag Mishra
Dy.Dir/Mp Directorate
Research Designs &
Standards Organisation
Manak Nagar,
Lucknow-226 011
Butchi Babu Nalluri
Design Engineer/Emd
Research Designs & Standards
Organisation
Manak Nagar, Lucknow-226 011
Report. No. MP.MISC-271
JUNE-2011
CONTENTS
Page No.
1.0 Executive Summary 6
2.0 Objective 6
3.0 Background 7
4.0 Modeling Details 7
4.1 Modeling Assumptions 7
4.2 Material Properties and section properties 8
4.3 Locomotive Underframe Description 9
4.4 Model Verification (1g Vertical) 9
5.0 Static Analysis – RDSO and EMD Load Cases 11
5.1 RDSO/EMD Yield Load Cases
5.1.1 1.0g vertical load case
5.1.2 1.0gVe+ Drag load case
5.1.3 1.0g Ve + Buff loadcase
5.1.4 2.0g Vertical loadcase
Anil Kumar Director - Motive Power Directorate/RDSO
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011
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5.1.5 1.0g Ve + (+) 3g longitudinal loadcase
5.1.6 1.0g Ve + (-) 3g longitudinal loadcase
5.1.7 1.0g Ve + (+) 1.5g lateral loadcase
5.1.8 1.0g Ve + (-) 1.5g lateral loadcase
5.1.9 1.0g Ve + 2000KN buffload at buffer loadcase
5.1.10 1.0g Ve + 1500KN buffload at 50 mm below buffer loadcase
5.1.11 1.0g Ve + lifting at cabend jack and cabend bogie attach to underframe
other bogie on rail
5.1.12 1.0g Ve + lifting at radend jack and radend bogie attach to underframe
other bogie on rail
5.1.13 1.0g Ve + lifting at cabend and cabend bogie attach to underframe
other bogie on rail
5.1.14 1.0g Ve + lifting at radend and radend bogie attach to underframe
other bogie on rail
5.1.15 Both end lifting at jack with lifting load of 1.5x (locomotive weight).
5.1.16 1g Ve + 3 TE tractive drag loadcase
5.1.17 Pivot pin load (+) 300 kN/(-)270 kN loadcase
5.1.18 Pivot pin load 3.0g long of bogie weight
5.1.19 Anti-climber load of 45300kg verticle loadcase
5.1.20 400 kN force at buffer diagonaly
5.2 RDSO/EMD Fatigue Load Cases
5.2.1 1.0g Ve + (±) 0.35 loadcase
5.2.2 1.0g Ve + (±) .25g Ve + (±) .5g Lateral
5.2.3 1.0g Ve + (±) .25g Ve + (±) .5g Longitudinal
5.3 RDSO/EMD Torque Loads
5.3.1 Underframe twist analysis for engine torque load of 33896 N-m.
6.0 Modal Analysis 12
6.1 Underframe Natural Frequencies
7.0 Results and discussions 13
8.0 Conclusions 15
List of Tables:-
Table1: Material properties used in the Underframe structure 8
Table2: Underframe Plate Thickness 9
Table3: Locomtive weight Distribution Between Components 10
Table4: Underframe Modal Analysis, Natural Frequencies 12
Table5: Max. Stress , Max. Displacement 13
List of Figures
Fig 1: Locomotive layout 16
Fig 2: The Underframe Structure unigraphics 3D image Top View 16
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Fig 3: The Underframe Structure unigraphics 3D image Bottom View 17
Fig 4: The Underframe Cross-section Details(Dimensions are in mm) 17
Fig 5: Finite Element Model of locomotive underframe 18
Fig. 6 Vertical Displacement, Draft Load 19
Fig. 7 Von Mises Stress of UF Top Plate, Draft Load 19
Fig. 8 Von Mises Stress of UF Top Plate #2 End Side, Draft Load 20
Fig. 9 Von Mises Stress of UF Bottom Plate, Draft Load 20
Fig. 10 Von Mises Stress of UF Bottom Plate #2 End Side, Draft Load 21
Fig. 11 Von Mises Stress of Center Sill #2 End Side, Draft Load 21
Fig. 12 Draft Gear Pocket, Mesh, Loading and Boundary Conditions 22
Fig. 13 Draft Gear Pocket, von Mises stress in the Bottom Plate 23
Fig. 14 Draft Gear Pocket von Mises stress Distribution, Draft Load 23
Fig. 15 Underframe Load Distribution Buff Load 24
Fig. 16 Vertical Displacement Buff Load 24
Fig. 17 Von Mises Stress in the top Plate Buff Load 25
Fig. 18 Von Mises Stress in the Top Plate #1 End Side Buff Load 25
Fig. 19 Von Mises Stress in the Top Plate #2 End Side Buff Load 26
Fig. 20 Von Mises Stress in the Bottom Plate Buff Load 26
Fig. 21 Von Mises Stress in the Bottom Plate #1 End Side Buff Load 27
Fig. 22 Von Mises Stress in the Center Sill #1 End Side Buff Load 27
Fig. 23 Von Mises Stress in the Side Sill #1 End Side Buff Load 28
Fig.24 Von Mises Stress in the Top Plate #2 End Side Buff Load 28
Fig. 25 Draft Gear Pocket Von Mises Stress Bottom Plate Buff Load 29
Fig. 26 Draft Gear Pocket Von Mises Stress Buff Load 29
Fig. 27 Underframe Load Distribution 5.1.4 2.0g Vertical loadcase 30
Fig. 28 Vertical Displacement 5.1.4 2.0g Vertical loadcase 30
Fig. 29 Von Mises Stress in the top Plate 5.1.4 2.0g Vertical loadcase 31
Fig. 30 Von Mises Stress in the Top Plate #1 End Side 5.1.4, 2.0g Vertical loadcase 31
Fig. 31 Von Mises Stress in the Top Plate #2 End Side 5.1.4, 2.0g Vertical loadcase 32
Fig. 32 Von Mises Stress in the Bottom Plate 5.1.4, 2.0g Vertical loadcase 32
Fig. 33 Underframe Load Distribution 5.1.5 1.0g Ve + (+) 3g longitudinal loadcase 33
Fig. 34 Vertical Displacement 5.1.5 1.0g Ve + (+) 3g longitudinal loadcase 33
Fig. 35 Von Mises Stress in the top Plate 5.1.5, 1.0g Ve + (+) 3g longitudinal loadcase
34
Fig. 36 Von Mises Stress in the Top Plate #1 End Side 5.1.5, 1.0g Ve + (+) 3g
longitudinal loadcase. 34
Fig. 37 Von Mises Stress in the Top Plate #2 End Side 5.1.5, 1.0g Ve + (+) 3g
longitudinal loadcase 35
Fig. 38 Von Mises Stress in the Bottom Plate 5.1.5 1.0g Ve + (+) 3g longitudinal
loadcase 35
Fig. 39 Underframe Load Distribution 5.1.5 1.0g Ve + (-) 3g longitudinal loadcase 36
Fig. 40 Vertical Displacement 5.1.5 1.0g Ve + (-) 3g longitudinal loadcase 36
Fig. 41 Von Mises Stress in the top Plate 5.1.5, 1.0g Ve + (-) 3g longitudinal loadcase
37
Fig. 42 Von Mises Stress in the Top Plate #1 End Side 5.1.5, 1.0g Ve + (-) 3g
longitudinal loadcase 37
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Fig. 43 Von Mises Stress in the Top Plate #2 End Side 5.1.5, 1.0g Ve + (-) 3g
longitudinal loadcase 38
Fig. 44 Von Mises Stress in the Bottom Plate 5.1.5 1.0g Ve + (-) 3g longitudinal
loadcase 38
Fig. 45 Underframe Load Distribution 5.1.7 1.0g Ve + (+) 3g lateral loadcase 39
Fig. 46 Vertical Displacement 5.1.7 1.0g Ve + (+) 1.5g lateral loadcase 39
Fig. 47 Von Mises Stress in the top Plate 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase 40
Fig. 48 Von Mises Stress in the Top Plate #1 End Side 5.1.7, 1.0g Ve + (+) 1.5g lateral
loadcase 40
Fig. 49 Von Mises Stress in the Top Plate #2 End Side 5.1.7, 1.0g Ve + (+) 1.5g lateral
loadcase 41
Fig. 50 Von Mises Stress in the Bottom Plate 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase
41
Fig. 51 Underframe Load Distribution 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 42
Fig. 52 Vertical Displacement 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 43
Fig. 53 Von Mises Stress in the top Plate 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 43
Fig. 54 Von Mises Stress in the Top Plate #1 End Side 5.1.8, 1.0g Ve + (-) 1.5g lateral
loadcase 44
Fig. 55 Von Mises Stress in the Top Plate #2 End Side 5.1.8, 1.0g Ve + (-) 1.5g lateral
loadcase 44
Fig. 56 Von Mises Stress in the Bottom Plate 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase
45
Fig. 57 Underframe Load Distribution 5.1.9 1.0g Ve + 2000KN buffload at buffer
loadcase 46
Fig. 58 Displacement 5.1.9 1.0g Ve + 2000KN buffload at buffer loadcase 46
Fig. 59 Von Mises Stress in the top Plate 5.1.9, 1.0g Ve + 2000KN buffload at buffer
loadcase 47
Fig. 60 Von Mises Stress in the Bottom Plate 5.1.9, 1.0g Ve + 2000KN buffload at
buffer loadcase 47
Fig. 61 Underframe Load Distribution 5.1.10, 1.0g Ve + 1500KN buffload at 50 mm
below buffer loadcase 48
Fig. 62 Displacement 5.1.10 1.0g Ve + 1500KN buffload at 50 mm below buffer
loadcase 48
Fig. 63 Von Mises Stress in the top Plate 5.1.10, 1.0g Ve + 1500KN buffload at 50 mm
below buffer loadcase 49
Fig. 64 Von Mises Stress in the Bottom Plate 5.1.10 1.0g Ve + 1500KN buffload
at 50 mm below buffer loadcase 50
Fig. 65 Displacement 5.1.11 1.0g Ve + lifting at cabend jack and cabend bogie attach
to underframe other bogie on rail 51
Fig. 66 Von Mises Stress in the top Plate 5.1.11, 1.0g Ve + lifting at cabend jack and
cabend bogie attach to underframe other bogie on rail 52
Fig. 67 Von Mises Stress in the Bottom Plate 5.1.11, 1.0g Ve + lifting at cabend jack
and cabend bogie attach to underframe other bogie on rail 52
Fig. 68 Displacement 5.1.12 1.0g Ve + lifting at radend jack and radend bogie attach
to underframe other bogie on rail 53
Fig. 69 Von Mises Stress in the top Plate 5.1.12, 1.0g Ve + lifting at radend jack and
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radend bogie attach to underframe other bogie on rail 53
Fig. 70 Von Mises Stress in the Bottom Plate 5.1.12, 1.0g Ve + lifting at radend jack
and radend bogie attach to underframe other bogie on rail 54
Fig. 71 Displacement 5.1.13 1.0g Ve + lifting at cabend and cabend bogie attach to
underframe other bogie on rail 54
Fig. 72 Von Mises Stress in the top Plate 5.1.13, 1.0g Ve + lifting at cabend and
cabend bogie attach to underframe other bogie on rail 55
Fig. 73 Von Mises Stress in the Bottom Plate 5.1.13 1.0g Ve + lifting at cabend and
cabend bogie attach to underframe other bogie on rail 55
Fig. 74 Displacement 5.1.14, 1.0g Ve + lifting at radend and radend bogie attach to
underframe other bogie on rail 56
Fig. 75 Von Mises Stress in the top Plate 5.1.14, 1.0g Ve + lifting at radend and radend
bogie attach to underframe other bogie on rail 56
Fig. 76 Von Mises Stress in the Bottom Plate 5.1.14, 1.0g Ve + lifting at radend and
radend bogie attach to underframe other bogie on rail 57
Fig. 77 Displacement 5.1.15 Both end lifting at jack with lifting load of 1.5x
(locomotive weight). 57
Fig. 78 Von Mises Stress in the top Plate 5.1.15, Both end lifting at jack with lifting
load of 1.5x (locomotive weight). 58
Fig. 79 Von Mises Stress in the Bottom Plate 5.1.15, Both end lifting at jack with
lifting load of 1.5x (locomotive weight). 58
Fig. 80 Displacement 5.1.16 1g Ve + 3 TE tractive drag loadcase 59
Fig. 81 Von Mises Stress in the top Plate 5.1.16, 1g Ve + 3 TE tractive drag loadcase
59
Fig. 82 Von Mises Stress in the Bottom Plate 5.1.16, 1g Ve + 3 TE tractive drag
loadcase 60
Fig. 83 Displacement 5.1.17 Pivot pin load (+) 300 kN/(-)270 kN loadcase 61
Fig. 84 Von Mises Stress in the top Plate 5.1.17, Pivot pin load (+) 300 kN/(-)270 kN
loadcase 62
Fig. 85Von Mises Stress in the Bottom Plate 5.1.17 , Pivot pin load (+) 300 kN/(-)270
kN loadcase 63
Fig. 86 Displacement 5.1.18, Pivot pin load 3.0g long of bogie weight 64
Fig. 87 Von Mises Stress in the top Plate 5.1.18, Pivot pin load 3.0g long of bogie
weight 64
Fig. 88Von Mises Stress in the Bottom Plate 5.1.18, Pivot pin load 3.0g long of bogie
weight 65
Fig. 89 Displacement 5.1.19, Anti-climber load of 45300kg verticle loadcase 66
Fig. 90 Von Mises Stress in the top Plate 5.1.19, Anti-climber load of 45300kg verticle
loadcase 66
Fig. 91Von Mises Stress in the Bottom Plate 5.1.19, Anti-climber load of 45300kg
verticle loadcase 67
Fig. 92 Displacement 5.2.1, 1.0g Ve + (±) 0.35 loadcase 68
Fig. 93 Von Mises Stress in the top Plate 5.2.1, 1.0g Ve + (±) 0.35 loadcase 69
Fig. 94Von Mises Stress in the Bottom Plate 5.2.1, 1.0g Ve + (±) 0.35 loadcase 70
Fig. 95 Displacement 5.2.2, 1.0g Ve + (±) .25g Ve + (±) .5g Lateral 71
Fig. 96 Von Mises Stress in the top Plate 5.2.2, 1.0g Ve + (±) .25g Ve + (±) .5g Lateral
5
72
Fig. 97Von Mises Stress in the Bottom Plate 5.2.2, 1.0g Ve + (±) .25g Ve + (±) .5g
Lateral 73
Fig. 98 Displacement 5.2.3, 1.0g Ve + (±) .25g Ve + (±) .5g Longitudinal 74
Fig. 99 Von Mises Stress in the top Plate 5.2.3, 1.0g Ve + (±) .25g Ve + (±) .5g
Longitudinal 75
Fig. 100Von Mises Stress in the Bottom Plate 5.2.3, 1.0g Ve + (±) .25g Ve + (±) .5g
Longitudinal 76
Fig. 101 Displacement 5.3.1, Underframe twist analysis for engine torque load of
33896 N-m. 77
Fig. 102 Von Mises Stress in the top Plate 5.3.1, Underframe twist analysis for engine
torque load of 33896 N-m. 78
Fig. 103 Von Mises Stress in the Bottom Plate 5.3.1 Underframe twist analysis for
engine torque load of 33896 N-m. 79
Fig. 104 Vertical Displacement 5.1.20 1.0g Ve + 400 kN force on diagonal buffer
Loadcase 79
Fig. 105 Vertical stress 5.1.20 1.0g Ve + 400 kN 400 kN force on diagonal buffer
Loadcase 80
Fig. 106 Vertical Displacement 5.1.20 1.0g Ve + 400 kN force on alternate diagonal
buffer loadcase 80
Fig. 107 Vertical stress 5.1.20 1.0g Ve + 400 kN force on alternate diagonal buffer
loadcase 81
Fig. 108 Underframe Natural Frequenci 81
1.0 EXECUTIVE SUMMARY
Research Designs & Standards Organisation (RDSO) has designed and developed 5500 HP WDG5
locomotive in consultation with EMD. This locomotive has a platform type of locomotive design. All the
equipment loads are transferred through the underframe structure to the bogies and rails. The carbody
structure supports cab equipment, dynamic brake, radiators, cooling fans, electrical components, sand,
etc. The carbody structure has two slip joints. Draft and buff loads are reacted by the underframe
structure. Since WDG5 locomotive development work is conducted in metric units system, all the
displacements and stress distributions are presented in Metric units system.
The underframe was analyzed by using the design criteria provided by RDSO and Electro-Motive Diesel
Inc. internal design criteria. The locomotive has been analyzed for RDSO/EMD linear, fatigue load cases
and one load case for engine torque. The underframe structure was designed for a locomotive running
with three units. All the locomotive components were modeled in Hypermesh and solved in Radioss.
The von Mises equivalent stress on the underframe structure for both
RDSO/EMD yield load cases were lower than the material yield stress. The underframe structure
satisfied the design criteria for the RDSO/EMD fatigue load cases. The natural frequencies of the
underframe structure fulfilled EMD Vehicle Technical Specification requirements. The underframe
structure meets all the
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design requirements.
2.0 OBJECTIVE-
The underframe structure should be designed to withstand the operating loads condition for the
RDSO operation as specified in the RDSO/EMD Technical Specifications. Manufacturing method
is to comply with all relevant codes of practice for the fabrication of structures subjected to high
levels of fatigue loadings. The underframe structure must be designed using finite element method.
The finite element model must include primary structural members like draft gear pocket, pivot pin,
fuel tank, cross bearers (stiffeners) etc. The underframe structure must also be designed to withstand
without damage, forces exerted by the dynamic loadings of the locomotive operation.
The design of the underframe structure must be validated for all the RDSO/ EMD design load
cases. This report captures the analytical results using Finite Element Method and full-scale
locomotive vibration test modal results of a similar locomotive.
3.0 BACKGROUND
The WDG5 locomotive is a diesel-electric locomotive with 5500 Horsepower and six AC
traction motors. The approximate weight of the locomotive is 134 tonnes .
This locomotive is equipped with (a) Cab, (b) Electrical Control Locker, (c) alternator, (d)
Engine with electronic unit injection, (e) Equipment Rack, (f) Air Compressor, (g) Cooling Hood
with two cooling fans, and two radiators, (h) Dynamic Brake, (i) Draft Gear and Couplers,(j) Two
HTSC three motor, three axle bogies, (k) Anti-Climber, (1) Cow Catcher, (m) Two Main
Reservoirs, and (n) Blower Motors etc... The locomotive and the equipment layout are shown in
the Figure 1.
The RDSO-WDG5 locomotive is a platform type locomotive. All the hoods are designed to transfer
the equipment load to the underframe. The underframe structure carries all the equipment loads and
transfers loads to bogies. The carbody has two slip joints at both ends of the engine hood.
4.0 MODELING DETAILS
The underframe structure have been analyzed using HYPERWORKS V 10.0 Finite Element
Software. A three dimensional solid geometry of the underframe structure is shown in Figures 2 and 3.
The full underframe FEA model contains 224021 elements and 210619 nodes. The FEA model of
underframe has been modeled with shell element, solid element, spring element, mass element and
rigid element. Centre pivot pin and jacking pad have been modeled with solid element. The weight of
all equipments are included as mass elements.
4.1 MODELING ASSUMPTION
The following assumptions are used for the design of the underframe structure :-
1) The Locomotive underframe structure is modeled with shell element. The primary and
secondary springs are modeled as spring element and pivot pin, jacking pad as solid element.
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2) Mass element for components like cab, e-locker ,inertial hood, engine,
equipment Rack, cooling hood, dynamic brake, are included in the model at CG location.
3) The fuel weight is applied as a load on fuel tank sheets for the inertia load cases.
4) The Alternator weight is included as mass element at the center of gravity of the alternator
and this mass element is connected to the underframe structure at the alternator attachment
bolts.
5) Engine weight is represented with a mass element at centre of gravity of engine
6) The bogies of the locomotive are modeled with mass elements. The bogie side bearer as spring
elements.
7) Cab structure and all equipment in the cab is modeled as mass elements.
8) Cooling fans in the cooling hood structure are modeled as mass element.
9) In the equipment rack structure all the components weights are modeled as
mass element at center of gravity of equipment weight.
10) Dynamic brake equipment is modeled as a mass element at CG location.
11) Air compressor, Sand weight, Coupler weight, number 2-end Traction Motor blower
weight, ballast weight, pipes and cables are modeled as mass elements.
12) The dynamic brake hood and electrical locker structure is modeled with mass elements.
13) Grid, fan and motor is modeled as mass element.
14) Bolted joint of fuel tank are modeled with rigid elements.
4.2 MATERIAL PROPERTIES AND SECTION PROPERTIES
The underframe is constructed with SAILMA 350, IS-2062, IS:5986. Properties are given in the
Table 1. The plate thicknesses are presented in Table 2.
Table 1: Material Properties used in the Underframe Structure
Description SAILMA350 IS-2062
Young's Modulus 200 Gpa 210 GPa Poisson's Ratio 0.27 0.3 Density 7800 kg/m"3 7.85E-09 Ton/cubic mm. Yield Stress 350 MPa 250MPa Ultimate Stress 490-610 MPa 490 MPa Elongation 20% 22mm
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Table 2: Underframe plate thickness
4.3 LOCOMOTIVE UNDERFRAME DESCRIPTION
The underframe structure supports the following components: Cab, E-Locker, Inertial Hood,
Engine Hood, Cooling Hood, and Dynamic Brake Hood, Air Compressor, Equipment Rack, Air
Reservoirs, Blowers, Sand, Batteries, Cables, Pipes and all other equipments etc.
The underframe structure has been built with two depth of underframe 475mm at end and
620mm in the middle of underframe. Underframe section that serves as the main load carrying
member for locomotive. The underframe structure should meet all the design requirements of
internal design criteria.
4.4 MODEL VERIFICATION (1g Vertical)
The finite element mesh of the locomotive, shown in the Figure 5, is used in the analysis. The
underframe structure is connected to the bogies with secondary springs (spring elements). Cab
structure, E-Locker structure, and the entire hood structures are included in the analysis. The
locomotive is analyzed using gravity loading (1g Vertical) to represent the whole locomotive
weight. Radioss is considered for solving the static analysis.The finite element model is verified for
mesh connectivity and for proper component weight distribution. The weights of each individual
components and the entire locomotive are presented in the Table 3. The estimated total locomotive
weight is 134 tonnes.
Description Thickness
Bottom Plate 40 mm
Top Plate 18 mm
Centre sill 12 mm
Side sill
10 mm
Floor Plate 5 mm
Bottom Plate 6 mm Top Plate 3mm
Bottom Plate 20mm
Bottom Plate 25mm
Gusset 32mm
Bottom Plate 40mm
Side plate 30mm
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Table 3: Locomotive Equipment weight
Locomotive Weight Distribution
S/No Component Description Weight
(kg)
1 Draft Gear & Coupler #1 End and pilot 1130
2 Cab 2760
3 HVC Cabinet (Control Cabinet) 408
4 Bogie (#1 End) 21328
5 Dynamic Brake Hood 1336
6 Inverter Cabinet (E Locker) 3100
7 TM Blower #1 263
8 Dust Bin / E Locker Blower 312
9 Toilet APL 460
10 Alternator Blower 347
11 Battery Box 824
12 Alternator 8528
13 Air Brake Reservoir (1/2) 107
14 Fuel Tank with Fuel 7725
15 Underframe ASM, UDL and other Eq. 29568
16 Engine 23797
17 Air Brake Reservoir (2/2) 107
18 Air Start Reservoir 742
19 Equipment Rack 2114
20 Air Compressor & Shaft 805
21 Cooling Fan (1/2) 590
22 TM Blower #2 263
23 Bogie (#2 End) 21328
24 Cooling System (Radiators, Piping, Water) 4048
25 Cooling Fan (2/2) 590
26 Air Brake Controller 318
27 Draft Gear & Coupler #2 End and pilot 1130
134028
5.0 STATIC ANALYSIS – RDSO / EMD LOAD CASES
The locomotive underframe has been analyzed for both RDSO and EMD design load cases.
RDSO/EMD load cases only include yield, ultimate load cases and fatigue load cases. The locomotive
underframe has been analyzed for the following design load cases and results are presented in table-5-
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5.1 RDSO/EMD Yield Load Cases
5.1.1 1.0g vertical load case
5.1.2 1.0gVe+ Drag load case- Drag load 1800 kN
5.1.3 1.0g Ve + Buff loadcase- Buff load 4000 kN
5.1.4 2.0g Vertical loadcase
5.1.5 1.0g Ve + (+) 3g longitudinal loadcase
5.1.6 1.0g Ve + (-) 3g longitudinal loadcase
5.1.7 1.0g Ve + (+) 1.5g lateral loadcase
5.1.8 1.0g Ve + (-) 1.5g lateral loadcase
5.1.9 1.0g Ve + 2000KN buffload at buffer loadcase
5.1.10 1.0g Ve + 1500KN buffload at 50 mm below buffer loadcase
5.1.11 1.0g Ve + lifting at cabend jack and cabend bogie attach to underframe
other bogie on rail
5.1.12 1.0g Ve + lifting at radend jack and radend bogie attach to underframe
other bogie on rail
5.1.13 1.0g Ve + lifting at cabend and cabend bogie attach to underframe
other bogie on rail
5.1.14 1.0g Ve + lifting at radend and radend bogie attach to underframe
other bogie on rail
5.1.15 Both end lifting at jack with lifting load of 1.5x (locomotive weight).
5.1.16 1g Ve + 3 TE tractive drag loadcase
5.1.17 Pivot pin load (+) 300 kN/(-)270 kN loadcase
5.1.18 Pivot pin load 3.0g long of bogie weight
5.1.19 Anti-climber load of 45300kg verticle loadcase
5.1.20 400 kN force at diagonal buffer
5.2 RDSO/EMD Fatigue Load Cases
5.2.1 1.0g Ve + (±) 0.35 loadcase
5.2.2 1.0g Ve + (±) .25g Ve + (±) .5g Lateral
5.2.3 1.0g Ve + (±) .25g Ve + (±) .5g Longitudinal
5.3 RDSO/EMD Torque Loads
5.3.1 Underframe twist analysis for engine torque load of 33896 N-m.
6.0 MODAL ANALYSIS
6.1 Underframe Natural Frequencies
The underframe natural frequencies are extracted between 0 to 10 Hz. The four important
underframe frequencies are first bending, second bending, first twist and first lateral bending. The natural
frequencies obtained from Radioss for the underframe are presented in the Table 4.
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Table 4: Underframe Modal Analysis, Natural Frequencies
Natural Frequencies
(Hz)
Description
FEA
First Bending 4.7
First Twist 6.9
Second Bending 7.0
First Lateral Bending 8.54
7.0 RESULTS AND DISCUSSIONS
Table 5: Underframe Stress and Deflection
S.No
.
Load case VonMises
Stress
(MPa)
(*Local
stress near
loading or
reaction
point Which
can be
ignored)
VonMises
Average
Max.
Stress
ignoring
local
stress
(MPa)
Deflection
(mm)
(Including
Spring
Defelction)
Location of Higher
stress
1. 1.0g vertical load case 140.5 140.5 40.16 Middle of underframe
2. 1.0gVe+ Drag load case 152.1 150.1 41.23 Middle of underframe
3. 1.0g Ve + Buff loadcase 278.4 278.4 54.34 Transition of
underframe
4. 2.0g Vertical loadcase 281 281 80.32 Fuel Tank mounting
hole in underframe
5. 1.0g Ve + (+) 3g longitudinal
loadcase
456* 310 34.58 Coupler pocket side
wall
6. 1.0g Ve + (-) 3g longitudinal
loadcase
501* 310 38.9 Coupler pocket side
wall
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7. 1.0g Ve + (+) 1.5g lateral
loadcase
765* 310 78.46 Lateral stopper
8. 1.0g Ve + (-) 1.5g lateral
loadcase
781.5* 315 60.56 Lateral stopper
9. 1.0g Ve + 2000KN buffload at
buffer loadcase
437* 310 1.64 Buffer location
10. 1.0g Ve + 1500KN buffload at
50 mm below buffer loadcase
302 280 1.50 Buffer location
11. 1.0g Ve + lifting at cabend
jack and cabend bogie attach to
underframe other bogie on rail
557* 280 35.39 Jacking pad plate
12. 1.0g Ve + lifting at radend jack
and radend bogie attach to
underframe other bogie on rail
557* 280 35.09 Jacking pad plate
13. 1.0g Ve + lifting at cabend and
cabend bogie attach to
underframe other bogie on rail
589* 345 150.9 Middle of underframe
14. 1.0g Ve + lifting at radend and
radend bogie attach to
underframe other bogie on rail
676* 340 150 Middle of underframe
15. Both end lifting at jack with
lifting load of 1.5x (locomotive
weight).
766* 300 42.68 Jacking pad plate
16. 1g Ve + 3 TE tractive drag
loadcase
327.5 237.5 Middle of underframe
17. Pivot pin load (+) 300 kN/(-
)270 kN loadcase
158.6/145.8 158.6/145.
8
37.6/37.9 Middle of underframe
18. Pivot pin load 3.0g long of
bogie weight
128.6 128.6 37.2 Middle of underframe
19. Anti-climber load of 45300kg
verticle loadcase
427* 320 85 Anticlimber
20. 1.0g vertical load case 400 kN
at buffer diagonal
308 308 84.56 Buffer
21. 1.0g vertical load case 400 kN
at buffer diagonal
325 325 90.6 Buffer
RDSO/EMD Fatigue Load Cases
22. 1.0g Ve + (+) 0.35 loadcase 189.7 189.7 54.2 Fuel Tank mounting
hole in underframe
23. 1.0g Ve + (+) .25g Ve + (+)
.5g Lateral
261.7 261.7 62.51 Lateral stopper
24. 1.0g Ve + (+) .25g Ve + (-) .5g
Lateral
255.9 255.9 61.79 Lateral stopper and
Fuel Tank mounting
hole
25. 1.0g Ve + (-) .25g Ve + (+) .5g
Lateral
258.2 258.2 42.59 Lateral stopper
13
26. 1.0g Ve + (-) .25g Ve + (-) .5g
Lateral
261.7 261.7 42.12 Lateral stopper
27. 1.0g Ve + (+) .25g Ve + (+)
.5g Longitudinal
190 190 45.08 Couple pocket side
wall and Fuel Tank
mounting hole
28. 1.0g Ve + (+) .25g Ve + (-) .5g
Longitudinal
194.4 194.4 46.6 Couple pocket side
wall
29. 1.0g Ve + (-) .25g Ve + (+) .5g
Longitudinal
60.69 60.69 2.5 Couple pocket side
wall
30. 1.0g Ve + (-) .25g Ve + (-) .5g
Longitudinal
143 143 28.08 Couple pocket side
wall
31. 1.0g Ve + (-) 0.35 loadcase 91.35 91.35 26.1 Fuel Tank mounting
hole
RDSO/EMD Torque Loads
32. Underframe twist analysis for
engine torque load of 33896
N-m
32.75 32.75 .48 Engine mounting
The Locomotive underframe is analyzed for both RDSO and EMD design criteria.
For all the load cases, von mises stress plot are presented for underframe structural components.
In some cases, vertical deflection of the underframe structure is presented. * These are local
VonMises stress near loading or reaction point which can be ignored.
Modal analysis
The first four natural frequencies obtained from Radioss and the results are presented in Table 4.
Figures 101 shows the mode shapes of the underframe calculated by using Finite Element Analysis
software Radioss. The four important underframe frequencies are first bending, second bending, first
twist and first lateral bending. The natural frequencies obtained from Finite Element Analysis of the
underframe are presented in the Table 4.
8.0 CONCLUSION
The underframe structure has been analyzed using Radioss .The finite element representation of
the entire locomotive with all of the equipment is included in the analysis. The underframe was
analyzed by using the design criteria provided by RDSO/EMD. The locomotive has been analyzed for
RDSO/EMD yield load cases, RDSO/EMD fatigue load cases and one load case for engine torque.
The von mises stress in the underframe structure for both RDSO/EMD yield load cases
were lower than the material yield stress. The underframe structure satisfied the design criteria
for the RDSO/EMD fatigue load cases. The natural frequencies of the underframe structure
satisfied RDSO/EMD Vehicle Technical Specification requirements. In conclusion,
the underframe structure meets all the design requirements.
14
FIGURE
9310
354
850
1800
C/L
OF
LO
CO
AIR CONDITIONER
( AIR START)ENG. START MOTORS
TANKFRESH WATER
COMPARTMENTTOILET
EXPANSION TANK
RESERVOIR AIR START
ECC
TCC
GEN. BLOWERDUST BIN/TCC BLOWER
C/L OF CRANK SHAFT
280
9382884
237017135
8655
4559
2208 (
CA
B)
45
14610 BETWEEN PIVOT CENTRES3185
189020051534
1723 T
OP
OF
U/F
1092
Fig. 1 Locomotive Layout
15
Fig. 2 The Underframe Structure Unigraphics 3D Image Top View
Fig. 3 The Underframe Structure U n i g r a p h i c s 3D Image Bottom View
16
Fig. 4 Underframe Cross-Section
17
Fig. 5 Finite Element Model of Locomotive Underframe
Fig. 6 Vertical Displacement, Draft Load
18
Fig.7 Von Mises Stress of UF Top Plate Draft Load
Fig. 8 Von Mises Stress on Top Plate #2 End side, Draft Load
19
Fig. 9 Von Mises Stress on Bottom Plate, Draft Load
Fig. 10 Von Mises Stress of UF Bottom Plate #2 End Side, Draft Load
20
Fig. 11 Von Mises Stress of UF Center Sill #2 End Side, Draft Load
Fig. 12 Draft Gear Pocket, Mesh, Loading and Boundry Conditions
21
Fig. 13 Draft Gear Pocket, von Mises Stress in the Bottom Plate
Fig. 14 Draft Gear Pocket von Mises Stress Distribution, Draft Load
22
Fig. 15 Underframe Load Distribution Buff Load
Fig. 16 Vertical Displacement Buff load
23
Fig.17 Von Mises Stress in the Top Plate Buff Load
Fig.18 Von Mises in the Top Plate #1 End Side Buff Load
24
Fig.19 Von Mises Stress in the Top Plate #2 End Side Buff Load
Fig.20 Von Mises Stress in the Bottom Plate Buff Load
25
Fig.21 Von Mises Stress in the Bottom Plate #1 End Side Buff Load
Fig.22 Von Mises Stress in the Center Sill #1 End Side Buff Load
26
Fig.23 Von Mises Stress in the Side Sill #1 End Side Buff Load
Fig.24 Von Mises Stress in the Top Plate #2 End Side Buff Load
27
Fig. 25 Draft Gear Pocket Von Mises Stress Bottom Plate Buff Load
Fig. 26 Draft Gear Pocket Von Mises Stress Buff Load
28
Fig. 27 Underframe Load Distribution 5.1.4 2.0g Vertical loadcase
Fig. 28 Vertical Displacement 5.1.4 2.0g Vertical loadcase
29
Fig. 29 Von Mises Stress in the top Plate 5.1.4 2.0g Vertical loadcase
Fig. 30 Von Mises Stress in the Top Plate #1 End Side 5.1.4, 2.0g Vertical loadcase
30
Fig. 31 Von Mises Stress in the Top Plate #2 End Side 5.1.4, 2.0g Vertical loadcase
Fig. 32 Von Mises Stress in the Bottom Plate 5.1.4, 2.0g Vertical loadcase
31
Fig. 33 Underframe Load Distribution 5.1.5 1.0g Ve + (+) 3g longitudinal loadcase
Fig. 34 Vertical Displacement 5.1.5 1.0g Ve + (+) 3g longitudinal loadcase
32
Fig. 35 Von Mises Stress in the top Plate 5.1.5, 1.0g Ve + (+) 3g longitudinal
loadcase
Fig. 36 Von Mises Stress in the Top Plate #1 End Side 5.1.5, 1.0g Ve + (+) 3g
longitudinal loadcase
33
Fig. 37 Von Mises Stress in the Top Plate #2 End Side 5.1.5, 1.0g Ve + (+) 3g
longitudinal loadcase
Fig. 38 Von Mises Stress in the Bottom Plate 5.1.5 1.0g Ve + (+) 3g longitudinal
loadcase
34
Fig. 39 Underframe Load Distribution 5.1.5 1.0g Ve + (-) 3g longitudinal loadcase
Fig. 40 Vertical Displacement 5.1.5 1.0g Ve + (-) 3g longitudinal loadcase
35
Fig. 41 Von Mises Stress in the top Plate 5.1.5, 1.0g Ve + (-) 3g longitudinal loadcase
Fig. 42 Von Mises Stress in the Top Plate #1 End Side 5.1.5, 1.0g Ve + (-) 3g
longitudinal loadcase
36
Fig. 43 Von Mises Stress in the Top Plate #2 End Side 5.1.5, 1.0g Ve + (-) 3g
longitudinal loadcase
Fig. 44 Von Mises Stress in the Bottom Plate 5.1.5 1.0g Ve + (-) 3g longitudinal
loadcase
37
Fig. 45 Underframe Load Distribution 5.1.7 1.0g Ve + (+) 1.5g lateral loadcase
Fig. 46 Vertical Displacement 5.1.7 1.0g Ve + (+) 1.5g lateral loadcase
38
Fig. 47 Von Mises Stress in the top Plate 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase
Fig. 48 Von Mises Stress in the Top Plate #1 End Side 5.1.7, 1.0g Ve + (+) 1.5g
lateral loadcase
39
Fig. 49 Von Mises Stress in the Top Plate #2 End Side 5.1.7, 1.0g Ve + (+) 1.5g
lateral loadcase
Fig. 50 Von Mises Stress in the Bottom Plate 5.1.7, 1.0g Ve + (+) 1.5g lateral
loadcase
40
Fig. 51 Underframe Load Distribution 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase
41
Fig. 52 Vertical Displacement 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase
Fig. 53 Von Mises Stress in the top Plate 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase
42
Fig. 54 Von Mises Stress in the Top Plate #1 End Side 5.1.8, 1.0g Ve + (-) 1.5g
lateral loadcase
Fig. 55 Von Mises Stress in the Top Plate #2 End Side 5.1.8, 1.0g Ve + (-) 1.5g
lateral loadcase
43
Fig. 56 Von Mises Stress in the Bottom Plate 5.1.8, 1.0g Ve + (-) 1.5g lateral
loadcase
44
Fig. 57 Underframe Load Distribution 5.1.9 1.0g Ve + 2000KN buffload at buffer
loadcase
Fig. 58 Displacement 5.1.9 1.0g Ve + 2000KN buffload at buffer loadcase
45
Fig. 59 Von Mises Stress in the top Plate 5.1.9, 1.0g Ve + 2000KN buffload at buffer
loadcase
Fig. 60 Von Mises Stress in the Bottom Plate 5.1.9, 1.0g Ve + 2000KN buffload at
buffer loadcase
46
Fig. 61 Underframe Load Distribution 5.1.10, 1.0g Ve + 1500KN buffload at 50 mm
below buffer loadcase
Fig. 62 Displacement 5.1.10 1.0g Ve + 1500KN buffload at 50 mm below buffer
loadcase
47
Fig. 63 Von Mises Stress in the top Plate 5.1.10, 1.0g Ve + 1500KN buffload at 50
mm below buffer loadcase
48
Fig. 64 Von Mises Stress in the Bottom Plate 5.1.10 1.0g Ve + 1500KN buffload at
50 mm below buffer loadcase
Fig. 65 Displacement 5.1.11 1.0g Ve + lifting at cabend jack and cabend bogie
attach to underframe other bogie on rail
49
Fig. 65 Displacement 5.1.11 1.0g Ve + lifting at cabend jack and cabend bogie
attach to underframe other bogie on rail
50
Fig. 66 Von Mises Stress in the top Plate 5.1.11, 1.0g Ve + lifting at cabend jack and
cabend bogie attach to underframe other bogie on rail
Fig. 67 Von Mises Stress in the Bottom Plate 5.1.11, 1.0g Ve + lifting at cabend jack
and cabend bogie attach to underframe other bogie on rail
51
Fig. 68 Displacement 5.1.12 1.0g Ve + lifting at radend jack and radend bogie attach
to underframe other bogie on rail
Fig. 69 Von Mises Stress in the top Plate 5.1.12, 1.0g Ve + lifting at radend jack and
radend bogie attach to underframe other bogie on rail
52
Fig. 70 Von Mises Stress in the Bottom Plate 5.1.12, 1.0g Ve + lifting at radend jack
and radend bogie attach to underframe other bogie on rail
Fig. 71 Displacement 5.1.13 1.0g Ve + lifting at cabend and cabend bogie attach to
underframe other bogie on rail
53
Fig. 72 Von Mises Stress in the top Plate 5.1.13, 1.0g Ve + lifting at cabend and
cabend bogie attach to underframe other bogie on rail
Fig. 73 Von Mises Stress in the Bottom Plate 5.1.13 1.0g Ve + lifting at cabend and
cabend bogie attach to underframe other bogie on rail
54
Fig. 74 Displacement 5.1.14, 1.0g Ve + lifting at radend and radend bogie attach to
underframe other bogie on rail
Fig. 75 Von Mises Stress in the top Plate 5.1.14, 1.0g Ve + lifting at radend and
radend bogie attach to underframe other bogie on rail
55
Fig. 76 Von Mises Stress in the Bottom Plate 5.1.14, 1.0g Ve + lifting at radend and
radend bogie attach to underframe other bogie on rail
Fig. 77 Displacement 5.1.15 Both end lifting at jack with lifting load of 1.5x
(locomotive weight).
56
Fig. 78 Von Mises Stress in the top Plate 5.1.15, Both end lifting at jack with lifting
load of 1.5x (locomotive weight).
Fig. 79 Von Mises Stress in the Bottom Plate 5.1.15, Both end lifting at jack with
lifting load of 1.5x (locomotive weight).
57
Fig. 80 Displacement 5.1.16 1g Ve + 3 TE tractive drag loadcase
Fig. 81 Von Mises Stress in the top Plate 5.1.16, 1g Ve + 3 TE tractive drag loadcase
58
Fig. 82 Von Mises Stress in the Bottom Plate 5.1.16, 1g Ve + 3 TE tractive drag
loadcase
59
Fig. 83 Displacement 5.1.17 Pivot pin load (+) 300 kN/(-)270 kN loadcase
60
Fig. 84 Von Mises Stress in the top Plate 5.1.17, Pivot pin load (+) 300 kN/(-)270 kN
loadcase
61
Fig. 85Von Mises Stress in the Bottom Plate 5.1.17 , Pivot pin load (+) 300 kN/
(-)270 kN loadcase
62
Fig. 86 Displacement 5.1.18, Pivot pin load 3.0g long of bogie weight
Fig. 87 Von Mises Stress in the top Plate 5.1.18, Pivot pin load 3.0g long of bogie
weight
63
Fig. 88Von Mises Stress in the Bottom Plate 5.1.18, Pivot pin load 3.0g long of bogie
weight
64
Fig. 89 Displacement 5.1.19, Anti-climber load of 45300kg verticle loadcase
Fig. 90 Von Mises Stress in the top Plate 5.1.19, Anti-climber load of 45300kg
verticle loadcase
65
Fig. 91Von Mises Stress in the Bottom Plate 5.1.19, Anti-climber load of 45300kg
verticle loadcase
66
Fig. 92 Displacement 5.2.1, 1.0g Ve + (±) 0.35 loadcase
67
Fig. 93 Von Mises Stress in the top Plate 5.2.1, 1.0g Ve + (±) 0.35 loadcase
68
Fig. 94Von Mises Stress in the Bottom Plate 5.2.1, 1.0g Ve + (±) 0.35 loadcase
69
Fig. 95 Displacement 5.2.2, 1.0g Ve + (±) .25g Ve + (±) .5g Lateral
70
Fig. 96 Von Mises Stress in the top Plate 5.2.2, 1.0g Ve + (±) .25g Ve + (±) .5g
Lateral
71
Fig. 97Von Mises Stress in the Bottom Plate 5.2.2, 1.0g Ve + (±) .25g Ve + (±) .5g
Lateral
72
Fig. 98 Displacement 5.2.3, 1.0g Ve + (±) .25g Ve + (±) .5g Longitudinal
73
Fig. 99 Von Mises Stress in the top Plate 5.2.3, 1.0g Ve + (±) .25g Ve + (±) .5g
Longitudinal
74
Fig. 100Von Mises Stress in the Bottom Plate 5.2.3, 1.0g Ve + (±) .25g Ve + (±) .5g
Longitudinal
75
Fig. 101 Displacement 5.3.1, Underframe twist analysis for engine torque load of
33896 N-m.
76
Fig. 102 Von Mises Stress in the top Plate 5.3.1, Underframe twist analysis for engine
torque load of 33896 N-m.
77
Fig. 103 Von Mises Stress in the Bottom Plate 5.3.1 Underframe twist analysis for
engine torque load of 33896 N-m.
Fig. 104 Vertical Displacement 5.1.20 1.0g Ve + 400 kN force on diagonal buffer
loadcase
78
Fig. 105 Vertical stress 5.1.20 1.0g Ve + 400 kN 400 kN force on diagonal buffer
loadcase
Fig. 106 Vertical Displacement 5.1.20 1.0g Ve + 400 kN force on alternate diagonal
buffer loadcase
79
Fig. 107 Vertical stress 5.1.20 1.0g Ve + 400 kN force on alternate diagonal buffer
loadcase
Fig. 108 Underframe Natural Frequency
80