FINITE ELEMENT ANALYSIS OF

UNDERFRAME FOR 5500 HP WDG5 LOCOMOTIVE

P.C.S.Yadav R. K. Misra Anurag Mishra Butchi Babu Nalluri

Sse/Mp Directorate
Research Designs & Standards
Organisation
Manak Nagar, Lucknow-226 011
Ade/Mp Directorate
Research Designs & Standards
Organisation
Manak Nagar, Lucknow-226 011
Dy.Dir/Mp Directorate Design Engineer/Emd
Research Designs & Research Designs & Standards
Standards Organisation Organisation
Manak Nagar, Manak Nagar, Lucknow-226 011
Lucknow-226 011

Anil Kumar
Director - Motive Power Directorate/RDSO
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
Simulation Driven Innovation 1
 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

1
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
2
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
3
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
4
 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

5
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.
6
 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

7
 Table 2: Underframe plate thickness

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

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.

8
 Table 3: Locomotive Equipment weight
Locomotive Weight Distribution

Weight
S/No Component Description (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-

9
 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 VonMises Deflection Location of Higher

. Stress Average (mm) stress
(MPa) Max. (Including
(*Local Stress Spring
stress near ignoring Defelction)
loading or local
reaction stress
point Which (MPa)
can be
ignored)
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 456* 310 34.58 Coupler pocket side
loadcase wall
6. 1.0g Ve + (-) 3g longitudinal 501* 310 38.9 Coupler pocket side
loadcase wall

11
7. 1.0g Ve + (+) 1.5g lateral 765* 310 78.46 Lateral stopper
loadcase
8. 1.0g Ve + (-) 1.5g lateral 781.5* 315 60.56 Lateral stopper
loadcase
9. 1.0g Ve + 2000KN buffload at 437* 310 1.64 Buffer location
buffer loadcase
10. 1.0g Ve + 1500KN buffload at 302 280 1.50 Buffer location
50 mm below buffer loadcase
11. 1.0g Ve + lifting at cabend 557* 280 35.39 Jacking pad plate
jack and cabend bogie attach to
underframe other bogie on rail
12. 1.0g Ve + lifting at radend jack 557* 280 35.09 Jacking pad plate
and radend bogie attach to
underframe other bogie on rail
13. 1.0g Ve + lifting at cabend and 589* 345 150.9 Middle of underframe
cabend bogie attach to
underframe other bogie on rail
14. 1.0g Ve + lifting at radend and 676* 340 150 Middle of underframe
radend bogie attach to
underframe other bogie on rail
15. Both end lifting at jack with 766* 300 42.68 Jacking pad plate
lifting load of 1.5x (locomotive
weight).
16. 1g Ve + 3 TE tractive drag 327.5 237.5 Middle of underframe
loadcase
17. Pivot pin load (+) 300 kN/(- 158.6/145.8 158.6/145. 37.6/37.9 Middle of underframe
)270 kN loadcase 8
18. Pivot pin load 3.0g long of 128.6 128.6 37.2 Middle of underframe
bogie weight
19. Anti-climber load of 45300kg 427* 320 85 Anticlimber
verticle loadcase
20. 1.0g vertical load case 400 kN 308 308 84.56 Buffer
at buffer diagonal
21. 1.0g vertical load case 400 kN 325 325 90.6 Buffer
at buffer diagonal
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 + (+) 261.7 261.7 62.51 Lateral stopper
.5g Lateral
24. 1.0g Ve + (+) .25g Ve + (-) .5g 255.9 255.9 61.79 Lateral stopper and
Lateral Fuel Tank mounting
hole
25. 1.0g Ve + (-) .25g Ve + (+) .5g 258.2 258.2 42.59 Lateral stopper
Lateral
12
26. 1.0g Ve + (-) .25g Ve + (-) .5g 261.7 261.7 42.12 Lateral stopper
Lateral
27. 1.0g Ve + (+) .25g Ve + (+) 190 190 45.08 Couple pocket side
.5g Longitudinal wall and Fuel Tank
mounting hole
28. 1.0g Ve + (+) .25g Ve + (-) .5g 194.4 194.4 46.6 Couple pocket side
Longitudinal wall
29. 1.0g Ve + (-) .25g Ve + (+) .5g 60.69 60.69 2.5 Couple pocket side
Longitudinal wall
30. 1.0g Ve + (-) .25g Ve + (-) .5g 143 143 28.08 Couple pocket side
Longitudinal 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 32.75 32.75 .48 Engine mounting
engine torque load of 33896
N-m

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.

13
 FIGURE

17135 2370
8655
2884 938
C/L OF LOCO

AIR CONDITIONER FRESH WATER

TANK
EXPANSION TANK

DUST BIN/TCC BLOWER GEN. BLOWER

2208 (CAB)

850
1800

ECC

TCC TOILET
COMPARTMENT C/L OF CRANK SHAFT
280
1723 TOP OF U/F

9310 4559
ENG. START MOTORS
( AIR START)
1092

AIR START
RESERVOIR

45 354
1534 2005 1890
3185 14610 BETWEEN PIVOT CENTRES

Fig. 1 Locomotive Layout

14
 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

15
Fig. 4 Underframe Cross-Section

16
Fig. 5 Finite Element Model of Locomotive Underframe

Fig. 6 Vertical Displacement, Draft Load

17
 Fig.7 Von Mises Stress of UF Top Plate Draft Load

Fig. 8 Von Mises Stress on Top Plate #2 End side, Draft Load

18
 Fig. 9 Von Mises Stress on Bottom Plate, Draft Load

Fig. 10 Von Mises Stress of UF Bottom Plate #2 End Side, Draft Load

19
Fig. 11 Von Mises Stress of UF Center Sill #2 End Side, Draft Load

Fig. 12 Draft Gear Pocket, Mesh, Loading and Boundry Conditions

20
Fig. 13 Draft Gear Pocket, von Mises Stress in the Bottom Plate

Fig. 14 Draft Gear Pocket von Mises Stress Distribution, Draft Load

21
Fig. 15 Underframe Load Distribution Buff Load

Fig. 16 Vertical Displacement Buff load

22
 Fig.17 Von Mises Stress in the Top Plate Buff Load

Fig.18 Von Mises in the Top Plate #1 End Side Buff Load

23
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

24
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

25
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

26
Fig. 25 Draft Gear Pocket Von Mises Stress Bottom Plate Buff Load

Fig. 26 Draft Gear Pocket Von Mises Stress Buff Load

27
Fig. 27 Underframe Load Distribution 5.1.4 2.0g Vertical loadcase

Fig. 28 Vertical Displacement 5.1.4 2.0g Vertical loadcase

28
 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

29
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

30
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

31
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

32
 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

33
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

34
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

35
 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

36
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

37
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

38
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

39
Fig. 51 Underframe Load Distribution 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase

40
 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

41
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

42
Fig. 56 Von Mises Stress in the Bottom Plate 5.1.8, 1.0g Ve + (-) 1.5g lateral
loadcase

43
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

44
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
45
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

46
Fig. 63 Von Mises Stress in the top Plate 5.1.10, 1.0g Ve + 1500KN buffload at 50
mm below buffer loadcase

47
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

48
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. 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

50
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
51
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

52
 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
53
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

54
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).

55
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).

56
 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

57
Fig. 82 Von Mises Stress in the Bottom Plate 5.1.16, 1g Ve + 3 TE tractive drag
loadcase

58
Fig. 83 Displacement 5.1.17 Pivot pin load (+) 300 kN/(-)270 kN loadcase

59
Fig. 84 Von Mises Stress in the top Plate 5.1.17, Pivot pin load (+) 300 kN/(-)270 kN
loadcase

60
Fig. 85Von Mises Stress in the Bottom Plate 5.1.17 , Pivot pin load (+) 300 kN/
(-)270 kN loadcase

61
 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

62
Fig. 88Von Mises Stress in the Bottom Plate 5.1.18, Pivot pin load 3.0g long of bogie
weight

63
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

64
Fig. 91Von Mises Stress in the Bottom Plate 5.1.19, Anti-climber load of 45300kg
verticle loadcase

65
Fig. 92 Displacement 5.2.1, 1.0g Ve + () 0.35 loadcase

66
Fig. 93 Von Mises Stress in the top Plate 5.2.1, 1.0g Ve + () 0.35 loadcase

67
Fig. 94Von Mises Stress in the Bottom Plate 5.2.1, 1.0g Ve + () 0.35 loadcase

68
Fig. 95 Displacement 5.2.2, 1.0g Ve + () .25g Ve + () .5g Lateral

69
Fig. 96 Von Mises Stress in the top Plate 5.2.2, 1.0g Ve + () .25g Ve + () .5g
Lateral

70
Fig. 97Von Mises Stress in the Bottom Plate 5.2.2, 1.0g Ve + () .25g Ve + () .5g
Lateral

71
Fig. 98 Displacement 5.2.3, 1.0g Ve + () .25g Ve + () .5g Longitudinal

72
Fig. 99 Von Mises Stress in the top Plate 5.2.3, 1.0g Ve + () .25g Ve + () .5g
Longitudinal

73
Fig. 100Von Mises Stress in the Bottom Plate 5.2.3, 1.0g Ve + () .25g Ve + () .5g
Longitudinal

74
Fig. 101 Displacement 5.3.1, Underframe twist analysis for engine torque load of
33896 N-m.

75
Fig. 102 Von Mises Stress in the top Plate 5.3.1, Underframe twist analysis for engine
torque load of 33896 N-m.

76
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

77
 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
78
Fig. 107 Vertical stress 5.1.20 1.0g Ve + 400 kN force on alternate diagonal buffer
loadcase

Fig. 108 Underframe Natural Frequency

79
80