Master's Degree Thesis ISRN: BTH-AMT-EX--2017/D15--SE Stress Analysis of Bogie Frame Structure Chodeshwar Korsa Veera Bhadraiah Dora Bharadwaj Department of Mechanical Engineering Blekinge Institute of Technology Karlskrona, Sweden 2017 Supervisors: U. Sridhar, BHEL, India Ansel Berghuvud, BTH 2 | P a ge Stress Analysis of Bogie Frame Structure Chodeshwar Korsa Veera Bhadraiah Dora Bharadwaj Department of Mechanical Engineering Blekinge Institute of Technology Karlskrona, Sweden 2017 Thesis submitted for completion of Master of Science in Mechanical Engineering with emphasis on Structural Mechanics at the Department of Mechanical Engineering Blekinge Institute of Technology, Karlskrona, Sweden. Abstract: The Bogie frame is an important and integral member of bogie. In Indian Railways, LHB (Linke Hofmann Busch) coaches are used as passenger coaches. They are equipped with FIAT bogie frames. Inorder to overcome the limitations of the existing FIAT bogie frame structure, a new bogie frame structure namely New CASNUB Bogie Frame is designed to equip with LHB coach. The New CASNUB Bogie Frame design is validated by conducting Stress analysis using ANSYS Mechanical APDL software. The stresses induced in both the frame structures are compared. Stresses induced in the New CASNUB Bogie frame are lesser than in the FIAT Bogie frame and are within the allowable stress limits of material used. New CASNUB Bogie Frame can be used as an alternative for LHB coaches in Indian Railways. Keywords: LHB Coaches, FIAT Bogie Frame, New CASNUB Bogie Frame, ANSYS Mechanical APDL, Von Mises Stress. 3 | P a ge Acknowledgement The thesis work is a part of a research project in collaboration between Department of Mechanical Engineering, Blekinge Institute of Technology (BTH), Karlskrona, Sweden and Bharat Heavy Electricals Limited (BHEL), Hyderabad, India. I would like to thank Dr. Ansel Berghuvud, program director of Mechanical Engineering Department in the master degree program, for his support, suggestion and comments during the thesis work. I would like to express my gratitude to Mr. U. Sridhar, Addl. General Manager (EMPM), BHEL Corporate R&D, Hyderabad, India for providing information and support during the thesis work. I would like to express gratitude to Dr. P. Prasanna, Assistant Professor, Mechanical Engineering, JNTUHCEH, Hyderabad for the support in my thesis work. I express my deep sense of gratitude to Mr. J.L.N Rao, AGM, HRM, BHEL, Corporate R&D, Hyderabad for providing permission to work in the reputed organization and necessary help during my thesis. I am grateful to Mr. S K Padhee, AGM, HRD and Mrs. Vijaya Rani, Raj Bhasha Officer, HRD & ATE, BHEL Corporate R&D for rendering their valuable support. I would like to express thanks to Mr. Manish Gupta, Mr. V. Subash Reddy, DNM, BHEL Corporate R&D, Hyderabad, India for help in the thesis. I would also like to thank my friends in India and Sweden for their encouragement and support for the thesis. I would like to prompt thanks to K.V.S. Alekhya for necessary decision and support during the thesis. I would like to dedicate my work to my beloved parents K. Jejerambabu & K. Bhavani, sister Geetha and cousins Venugopal and Lokeshwar for their unconditional love and support. Karlskrona, October 2017 Chodeshwar Korsa Veera Bhadraiah Dora Bharadwaj 4 | P a ge Contents 1 Notations 10 2 Introduction 12 2.1 Background 12 2.2 Bogie Description 13 2.2.1 Bogie Functions 13 2.2.2 Bogie Components 13 2.2.3 Functions of Bogie Frame 17 2.3 FIAT Bogie 17 2.3.1 Technical Description of FIAT Bogie 18 2.4 Problem Description 20 2.5 Problem Statement 21 2.6 Outline of Thesis 21 3 Related Work 23 4 Force Calculations 25 4.1 Forces 25 4.1.1 Vertical Forces 25 4.1.2 Transversal Forces 26 4.1.3 Longitudinal Forces 27 4.1.4 Forces of a Potential Collision 27 4.2 Force Calculations for FIAT Bogie Frame 27 4.3 CASNUB Bogie 29 4.4 Force Calculations for CASNUB Bogie Frame 31 5 Methodology 33 6 Procedure 34 6.1 FIAT Bogie Frame 34 6.2 New CASNUB Bogie Frame 38 7 Stress Analysis 41 7.1 Load Cases for Static Stress Analysis 41 7.1.1 Vertical Load Case 41 7.1.2 Vertical and Transversal Loads Case 41 7.1.3 Vertical, Transversal and Longitudinal Loads 42 Case 5 | P a ge 7.1.4 Potential Collision with Normal Service Loads 42 Case 7.2 Stress Analysis of FIAT Bogie Frame 43 7.2.1 Vertical Load Case 43 7.2.2 Vertical and Transversal Loads Case 46 7.2.3 Vertical Transversal and Longitudinal Loads 48 Case 7.2.4 Potential Collision with Normal Service Load 51 Case 7.3 Stress Analysis of New CASNUB Bogie Frame 53 7.3.1 Vertical Load Case 53 7.3.2 Vertical and Transversal Loads Case 55 7.3.3 Vertical Transversal and Longitudinal Loads 58 Case 7.3.4 Potential Collision with Normal Service Load 60 Case 8 Results and Discussion 63 9 Conclusion 65 10 Future Scope 66 11 References 67 6 | P a ge List of Figures Figure 2.1 FIAT Bogie 18 Figure 2.2 FIAT Bogie Frame 20 Figure 4.1 CASNUB Bogie 30 Figure 6.1 Keypoints plotted for FIAT frame 35 Figure 6.2 FIAT frame structure after joining volumes 36 Figure 6.3 FIAT frame elements of meshed structure 37 Figure 6.4 Keypoints plotted for new CASNUB frame 38 Figure 6.5 New CASNUB frame structure after joining volumes 39 Figure 6.6 New CASNUB frame elements of meshed structure 40 Figure 7.1 FIAT bogie frame structure 43 Figure 7.2 Plot of Vertical loads applied on Bogie frame 44 Figure 7.3 Plot of Von Mises stress distribution with deformed and 45 undeformed edge in vertical load case Figure 7.4 Plot of Vertical and transversal loads applied on Bogie 46 frame Figure 7.5 Plot of Von Mises stress distribution with deformed and 47 undeformed edge in vertical and transversal load case Figure 7.6 Plot of Vertical, transversal and longitudinal loads 49 applied on Bogie frame Figure 7.7 Plot of Von Mises stress distribution with deformed and undeformed edge in vertical, transversal and longitudinal load 50 case Figure 7.8 Plot of loads applied in potential collision with normal 51 service load case 7 | P a ge Figure 7.9 Plot of Von Mises stress distribution with deformed and undeformed edge in potential collision with normal service load 52 case Figure 7.10 New CASNUB Bogie frame structure 53 Figure 7.11 Plot of vertical loads applied on Bogie frame 54 Figure 7.12 Plot of Von Mises stress distribution with deformed 55 and undeformed edge in vertical load case. Figure 7.13 Plot of vertical and transversal loads applied on Bogie 56 frame Figure 7.14 Plot of Von Mises stress distribution with deformed 57 and undeformed edge in vertical and transversal load case Figure 7.15 Plot of vertical transversal and longitudinal loads 58 applied on Bogie frame Figure 7.16 Plot of Von Mises stress distribution with deformed and undeformed edge in vertical transversal and longitudinal load 60 case Figure 7.17 Plot of applied loads in potential collision with normal 61 service load case Figure 7.18 Plot of Von Mises stress distribution with deformed and undeformed edge in potential collision with normal service 62 load case 8 | P a ge List of Tables Table 2.1 Technical data of FIAT bogie frame 19 Table 4.1 Technical data of CASNUB bogie frame 30 Table 4.2 Forces on FIAT and CASNUB bogie frames 32 Table 7.1 List of Vertical loads 44 Table 7.2 List of Vertical and transversal loads 47 Table 7.3 List of Vertical, transversal and longitudinal loads 48 Table 7.4 List of loads for Collision load case 51 Table 7.5 List of Vertical loads 54 Table 7.6 List of Vertical and transversal loads 56 Table 7.7 List of Vertical, transversal and longitudinal loads 59 Table 7.8 List of loads for Collision load case 61 Table 8.1 Comparison of Maximum Von Mises stresses induced 63 in FIAT and New CASNUB bogie frame structures 9 | P a ge 1. Notations (cid:1829) Mass of the driver (cid:2869) (cid:1832) Longitudinal force on bogie (cid:3025) (cid:1832) Vertical force on bogie (cid:3026) (cid:1832) Transverse force on bogie (cid:3027) (cid:1859) Acceleration due to gravity Kg Kilogram (cid:1839) Mass of locomotive in running order (cid:3049) (cid:1865)(cid:1865) Millimetre (cid:1865)(cid:932)(cid:1871)(cid:2870) Meter per second square (cid:1865)(cid:2878) Mass of bogie (cid:1840) Newton (cid:1840)(cid:932)(cid:1865)(cid:1865)(cid:2870) Newton per millimeter square (cid:1866) Number of axles (cid:3028) (cid:1866) Number of bogies (cid:3029) (cid:936) Percentage 10 | P a ge