Stress Analysis of Bogie Frame Structure

69 Pages·2017·1.27 MB·English

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
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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.
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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
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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
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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

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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
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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

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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

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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

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