U.P.B. Sci. Bull., Series , Vol. , Iss. , 201..

ISSN 1454-2331

STUDY CASE OF A TAMPING TOOL WITH CAD METHOD

Sorin George BADEA1, Ionel POPESCU2, Cristinel BESLEAGA3,
Constantin MINCIU4
Sculele de burare se utilizeaza la operatiile tehnologice de burare, care sunt
incluse in procesele tehnologice de constructie si reparatie a caii ferate. Aceste
scule sunt solicitate la solicitari compuse de incovoiere, compresiune, soc, vibratii,
oboseala, uzura abraziva etc. Studiul si cercetarile privind aceste scule solicita un
mare consum de timp, resurse materiale si financiare. In aceasta lucrare este
propusa o metoda de studiu, privind o scula de burare tip BNRI-85 model 2007
utilizand CAD. Rezultatele teoretice sunt comparate cu cele experimentale, care au
fost obtinute in conditii reale, de santier.
Tamping tools are used at the tamping technological operations, which are
included in the technological process by building and maintenance of the railway.
These tools are stressed at compounds stress by bending, compression, shock,
oscillations, fatigue, abrasive wear and s.o. The study and researches to these tools
request a lot of time, materials and financials resources. In this paper is proposed a
study method regarding to a tamping tool type BNRI- 85 model 2007 using CAD
method. The theoretical results are compared with experimental results, which have
been obtained/ achievement in real conditions, in situ.

Keywords: tamping tool, stress evaluation, lastingness, CAD method, defects.

1. Introduction
Tamping tools are the most stress elements from a tamping machine
compound. These tools are stressed to bending, compression, shock, oscillation,
fatigue, abrasive wear and so another. By the good behavior of these depend: the
quality of the tamping operation, the stability/ the lastingness of the geometry of
the railway, the size of costs of tamping operation and of course, the costs for
building and maintenance of the railway [1].
Tamping tools are made, in generally, by each tamping machine producer,
especially for each type of tamping machine. The technical details of these
11

Engineer, Manager SC IMCF SA Bucharest, Romania, e-mail: soringeorgebadea@yahoo.com

Lector doctor engineer, Process Equipment Department, Faculty of Mechanic and Mechatronic,
University Polytechnic from Bucharest, Romania, e- mail: ic.popescu@yahoo.com
3
Doctor engineer, Chief of SIMC Buzau SC IMCF SA Bucharest, Romania, e-mail:
cristibesleaga@yahoo.com
4
Professor doctor engineer, Machines and Systems of Production Department, Faculty of IMST,
University Polytechnic from Bucharest, Romania
2

Sorin George Badea, Ionel Popescu, Cristinel Besleaga, Constantin Minciu

tamping tools are few or are missing. It is unknown or is known a little, about the
behavior of the tamping tools in using, about technological process by
manufacturing, the weariness and the wear process during using of these, about
the stress system and his effects [2, 3, 4, 5, and 6]. The producers of tamping tools
offer/ give, especially, details regarding to the marketing and commercial
elements.
By a little time, its have been started and presented, researches and studies
concerning to tamping tool, type BNRI- 85 model 94 (1994), using CAD method,
through finite elements [7]. The difficulties in these researches and studies are:
many type of tamping tools, with different dimensions, size, shape, materials,
technological processes for manufacturing; the different stress systems for
tamping tools, depending by using conditions: type of tamping operations, the
hardness of the prism of ballast, the lifting size in leveling operation, the work
regimen of the tamping machine; the finding and definition of hypotheses/
assumptions, for maximum stresses and so another [8].
This paper have as a main objectives, researches and study a new tamping
tool, type BNRI- 85, model 2007, which has been designed in 2007 and now, it is
in experimental study and researches. Tamping tool type BNRI- 85, model 2007,
has a few different important constructive elements, like the shape of axe, which
is right, the position of the tine against/ towards the axe and sizes, which bring
more technological advantages, comparative with the tamping tool type BNRI85, model 94 (1994). We have made the researches and study using CAD method
and we have compared the results with experimental results.
2. Tamping tool type BNRI- 85, model 2007
Tamping machine type BNRI- 85 (Fig.1), for which has been designed this
new tamping tool, type BNRI- 85, model 2007 (Fig.2), has a large spreading/
extent, in big numbers (more than 60) at Romanian Railways.

Fig.1. Tamping machine type BNRI- 85

Study case of a tamping tool with CAD method

Fig.2. Tamping tool type BNRI- 85, model 2007

The material for the body and tine of tamping tool is 42MoC11, STAS
791- 86, r (Rm) =740 1270 [N/mm], 0,2(Rp0,2) = 510 880 [N/mm], -1 = 483
[N/mm], A5 = min.10, KCU 300/5= 39 [J/cm] ([kgfm/ cm]), KCU 300/2= 39
[J/cm] ([kgfm/ cm]), Brinell hardness= max.217 [HB].
The materials for covering the tine, for increasing the resistance at the
wear process, especially at the abrasive wear and shock, are those which are
deposed through manual electrical welding, with covering metallic electrodes,
using two types electrodes: first electrode, utilized like a intermediary/ buffer
material, between main material and final hard material, is BOHLER FOX A 7,

Sorin George Badea, Ionel Popescu, Cristinel Besleaga, Constantin Minciu

DIN 8555: E8-200; DIN 8556: EKb 18.8. Mn 6 20 +, having as main chemical
elements: C=0,15%; Mn=6%; Si=1,1%; Cr=19%; Ni=8,5% ; the second (final)
electrode, utilized like final layer, is FOX LEDURIT 60, DIN 8555: E 10 60,
having as main chemical elements: C=3,4%; Mn=0,2%; Si=1%; Cr=33%.
3. Designing of tamping tool type BNRI- 85, model 2007, with CAD
For to theoretical study case of the tamping tool BNRI- 85, model 2007
(Fig.2), were used two CAD soft (AutoDesk Inventor Professional 2008 and
ANSYS Workbench, rev. 11), in collaboration with the Thermal Research Center,
in the Faculty of Mechanical Engineering and Mechatronics of the Polytechnic
University in Bucharest [9, 10]. There are used 301725 nods and 199727
elements.
The model has been designed with the help of the digital prototyping is
presented in Fig. 3.

Fig.3. The model of tamping tool type BNRI 85, model 2007

4. Establishing the mains owns frequencies for tamping tool type

BNRI- 85, model 2007, with CAD
In Fig.4 is presented the discretization in finite elements.
The mains own vibrations frequencies, for tamping tool BNRI 85 model
2007, have been established and presented below (Fig.5, 6, 7), using CAD
methods, which are based on finite element. In this way, we give an answer
regarding to the question, if the own vibrations frequencies are overlaps on the
work frequency by 35 [Hz].

Study case of a tamping tool with CAD method

Fig.4. The discretization for tamping tool type BNRI- 85 model 2007

Fig.5. The first own frequency by 303.92 [Hz].

Fig.6. The second own frequency by 314.04 [Hz]

The other owns frequencies arent important, because their values are
bigger than the work frequency by 35 [Hz]. We have established that, it isnt the
risk by occurring of the resonance phenomenon.
5. The analysis of the induced stress for 3D model with CAD
Simulation of the induced stresses and deformations, by modeling the
tamping tool/ pick BNRI 85, model 2007, with finite elements, was carried out
by taking into consideration of the following assumptions [11, 12, 13, 14 and 15]:

Sorin George Badea, Ionel Popescu, Cristinel Besleaga, Constantin Minciu

- the body and tine of tamping tool are made from a metallic material,
homogeneous and isotropic;
- modeling of 3D body has been made as close to the model of the designing
tamping tool; some connection rays, which have been selected in a suitable
manner for the discretization of the finite elements, did not lead to notable values
of the stress and deformation conditions;
- there have not been taken into account the options of the computing program
connected to high, as well as elastic- plastic deformations;
- stresses and forces which occur during the tamping operation, both in the
vertical motion, by penetrating of the crushed stone from the component of metal
ballast prism, by the tamping tool and during the simultaneous motions, on the
horizontal direction, by vibration and compression of the crushed stone executed
by the tamping tool, are not applied by shock (with high speed and small shifts
during the application of the stress/ force) and, when reaching the maximum value
of the stress/ force applied, the crushed stone starts cracking and the stones will
move, while the tine will move in the environment considered as uniform and
homogeneous;
- during the stress on the horizontal direction, at the simultaneous vibrating and
compressing motion of the crushed stone by the tamping tool, the reaction value
due to the crushed stone decreases in time, according to its breaking up/
fluidization;
- it wasnt taken in the analysis the situation, in which, force should also be
applied on the other side of the tamping tool (secondary, rear side of the tine) due
to the following reasons: the secondary side is inclined with a large relief angle,
making the forces/ stresses that appear on this surface to break down and to
reduce their value and effect; until now, there havent been identified major/
predominant factors regarding the stresses, deformations, durability and so
another, that affect the secondary side; in case of tamping tools executed through
non-dismountable assembling by welding, between the body and cam follower,
there havent been damages/ faults as a consequence of forcing the welded joint
between the body and cam follower, stresses due to forces acting on the secondary
side;
- the value of the reaction, which arises because of these two extreme situations,
in which can be found the prism of crushed stone, due to the different rate of
wear/ clogging (i-the new or clean ballast prism met at the construction, capital
repair, periodical maintenance with the total riddling of the ballast prism; ii- the
operating ballast prism, with different rates of clogging);
- the stones are free and they can move freely; there is only point or surface
contact;

Study case of a tamping tool with CAD method

- the stones are linked together with material (resulted from wear, break, grind of
crushed stone, from bad weather, drained material, fallen from the rolling stock
and so another) which after strengthening, it could get various consistencies;
- for the calculation at weariness, Gerber correction of the medium tension was
used.
The discretization model of tamping tool BNRI- 85, model 2007 is
presented in Fig.8.

Fig.8. The discretization model of tamping tool type BNRI- 85-2007

For modeling of the solicitations system, we have taken into account the
most disadvantages situations. The material which will be worked, the crushed
stone- the ballast, which contain many stones, can take contact with the surface of
the active part of tamping tool- tine, in one point or simultaneously, in many
point. This is an aleatory situation. The most disadvantage situation of solicitation
is, if the contact, between surface of tine and crushed stone is made in one point.
We have analyzed three cases, on which we have considered the most
disadvantages solicitations. These three cases are presented below.
5.1. The analysis of the induced stress for 3D model with CAD- case 1
The directions and the applications points of the horizontal and vertical
forces, for case 1, are presented in Fig.9.

Sorin George Badea, Ionel Popescu, Cristinel Besleaga, Constantin Minciu

The equivalent stresses (tensions) are presented in Fig.10.

Fig.9. Case 1- The system of solicitations for tamping tool BNRI-85, model 2007

Fig.10. The equivalent stresses (tensions), for case 1 by system of solicitations

Study case of a tamping tool with CAD method

5.2. The analysis of the induced stress for 3D model with CAD- case 2
The directions and the applications points of the horizontal and vertical
forces, for case 1, are presented in Fig.11.
The equivalent stresses (tensions) are presented in Fig.12.

Fig.11. Case 2- The system of solicitations for tamping tool BNRI-85, model 2007

Fig.12. The equivalent stresses (tensions), for case 2 by system of solicitations

Sorin George Badea, Ionel Popescu, Cristinel Besleaga, Constantin Minciu

5.3. The analysis of the induced stress for 3D model with CAD- case 3
The directions and the applications points of the horizontal and vertical
forces, for case 1, are presented in Fig.13.
The equivalent stresses (tensions) are presented in Fig.14 and Fig.15.

Fig.13. Case 3- The system of solicitations,

for tamping tool BNRI-85, model 2007

Fig.14. The equivalent stresses (tensions),

for case 3 by system of solicitations

Fig.15. The equivalent stresses (tensions), for case 3 by system of solicitations

Study case of a tamping tool with CAD method

6. The experimental results

During the experimental researches of the tamping tool BNRI- 85, we
have achieved some defects (damages), at the bodies and the tines (the active
part). A few defects are present in Fig.16. In this way, we can make a comparison,
between those three cases analyzed through CAD method and the experimental
results.

Fig.16. Defects (damages) at the BNRI- 85 tamping tool, at the body and the tine (active part)

7. Conclusions
- Designing a tamping tool and checking of this, to the different stress, with
especially CAD soft, can offer many advantages, possibilities and reduce a lot of
time and more accurate results;
- Another novelty is represented by the determination of owns vibrations
frequencies of a tamping tool (BNRI 85, model 2007), using computer- aided
modern methods- CAD, methods which are based on finite element. From the
analysis performed, after establishing the 2 own frequencies ( ) of the tamping
tool BNRI 85 type, model 2007, it can be concluded that the operating
frequency f = 35 Hz is not found in any of the ranges 0.8 1.2 from the values of
those six own frequencies and, therefore, there is no danger of occurrence of the
resonance phenomenon.
- Modeling of the stress state from tamping tool using finite elements method has
leaded to following conclusions:
- The stresses from the body of tamping tool are at the acceptable level; thus,
dont appear the possibility a damages at a little numbers by cycles; for some of
them can appear the breakage (Fig.10, 12 and 16)
- In the zone where is applied the force (the contact between a stone and the
plane surface of tine) the stresses are bigger than break limit and in that zone
will appear the defects (damages) of material. Because the material of the
crushed stones is very hard, and it has many points/ vertexes, this fact can lead
to the cutting of the surfaces and to the wear of the surfaces (Fig. 10, 12, 15
and 16).

Sorin George Badea, Ionel Popescu, Cristinel Besleaga, Constantin Minciu

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