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SIMULATION OF COLD PRESS FITTING OF RAILWAY WHEEL-SET BY USING PRO-E AND ANSYS
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NITESH P. YELVE, 2ANIL NAIK, 3SHRADDHA RAMANE, 4PRITHVIRAJ DAGA, 5INDERJIT JOHAL
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Assistant Professor, Fr. C R. Institute of Technology, Vashi, Navi , Mumbai, Students, Department of Mechanical Engineering, Fr. C Rodrigues Institute of Technology, Vashi, Navi Mumbai, Senior Section Engineer2, Central Railway Workshop, Matunga, Mumbai, India
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niteshpy@yahoo.co.in,3 shaddu_s16@yahoo.co.in
ABSTRACT : The press fitting process of a railway vehicle wheel-set is still today a topic for scientific research. Many guidelines and standards have been issued on the topic, but still some important aspects have to be clarified. The entire wheel-set assembly is solely dependent on the press fit joint and if it fails during the running condition the effect would be very disastrous. So the process of press fitting should be controlled and maintained within the limits. The contact stresses between the axle and wheel, especially during the press fitting stage, are very difficult and complicated to be analyzed by calculations but still it is important to know these stresses as they depend upon the uncontrolled variations in some parameters of the press fitting process, such as the friction coefficient and the interference between the wheel bore and axle seat diameters. Hence to facilitate the ease of knowing the contact stresses being developed in the wheel-set during the press fitting process without actually conducting the process on machine; this process is attempted to simulate in ANSYS. The required model of wheel set is imported in ANSYS from Pro-E Wildfire 2.0. Validity of simulation results is checked by comparing them with the actual press fitting results on the machine. KEYWORDS: Wheel-set, Cold Press-Fitting, ANSYS, Pro/E wildfire 2.0.
1. INTRODUCTION Railways are the most efficient and effective means of land based transport system all over the world. Indian railways (IR) is one of the largest and busiest rail networks in the world, transporting 16 million passengers and more than one million tones of freight daily. The railways traverse the length and breadth of the country; the routes cover a total length of 63,140 Km. As of 2002, IR owned a total of 216,717 wagons, 39,263 coaches and 7,739 locomotives and ran a total of 14,444 trains daily, including about 8,702 passenger trains [1]. While running such a large system, lot of problems both technical and non-technical, are encountered. Railway wheel sets are one of the most important components in railway vehicles with regard to safety. Since failure in railway vehicle wheel sets can cause a disaster.The topic under consideration is the control of the process of assembling a wheel set. A wheel set basically consists of two parts; first the solid discs and second the axle. Now these solid discs have to be fitted over the axle by the process of press fitting. As we see that there is no any joint or connection done by means of either a pin or weld, the joint solely depends on the press-fit joint. The wheel-sett is prepared on
the hydraulic press fit machine and it need to be checked properly and taken care that the required amount of pressure for the joint is taken by the machine, and if not the wheel set should be rejected. It is difficult to know analytically the contact stresses developed during the press fitting process of wheel-set for varying factors such as friction coefficient and the interference, without carrying out actual press fitting operation on the machine. Hence, latest software technology is used to know these contact stresses developed before actually going for press fitting. Pro-E Wildfire 2.0 is used to model the wheelset and ANSYS is used to simulate the press fitting process. The simulation results are then compared with the actual process results on the machine to check their validity. In the following section the process of wheel-set assembly is discussed as it is important to understand this process before going for the actual analysis. 2. PROCESS OF WHEEL-SET ASSEMBLY A press fit joint represents a bond between two parts in contact and it is realized by the static friction effect that is caused by mutual pressure acting on their contact surfaces [2]. The strength of a press fit joint represents static friction force.
Fig.4.1 Refined Mesh 4.6 Creating Contact Pair using Contact Wizard This is used to define the contact between the wheel bore and axle seat. This defines the surface to surface contact between two [5]. The parameters governing the press-fitting process are defined in this step and hence complete FE model of the process is developed for load step 1. 4.7 Specifying Solution Criteria Pick the face of wheel hub where it is fixed on the fixture on actual hydraulic press while pressfitting to constrain all dofs [6]. A large displacement static analysis for load step 1 is specified. For load step 2 following things are considered: 4.7.1 Hydraulic Press Operation Pressure gradually increases from 0 to (80-100) ton in 118 sec. of operation of press with total ram movement of 191 mm. Then it is suddenly brought to 0 t at once. The pressure does not increase till first 4-6 sec. Then it suddenly increases till 10-15 t. After interference is achieved pressure starts increasing gradually till the range. The distance versus load curve and time versus load curve is obtained [2]. 4.7.2 Set DOF Displacement for Axle
Fig.5.1 Von Mises Stresses (Load Step 1) The graph of load versus time is obtained from the above analysis as shown in Fig,5.3 which is found to be in close agreement with the load graph obtained from the actual press fitting process.
Fig.5.2 Von Mises Stresses (Load Step 2) The experimental validation of the FE model and the simulation of press fitting presented in this paper have been performed by comparing the results of simulation with the measured data referring to actual experiments made in the workshop of the Central Railway, Matunga, Mumbai for different press-fitting assemblies with different parameters. The graph shown in Fig.5.4 shows the good agreement between the two. The graph has axial load applied for the press-fitting (in ton) on Y-axis and number of experiments taken into consideration on X-axis.
Fig.5.4 Comparison of Results 6. CONCLUSION In this paper the press-fitting process of railway vehicle wheel on its axle has been simulated by using softwares such as Pro-E and ANSYS. Although only an extensive and accurate experimental test campaign may give a reliable contribution to solve the addressed problem, in this paper a preliminary and important contribution has been given to understand the phenomenon of the press fitting (and removal) of a railway wheel on (or from) its axle. There is good agreement between the load graphs of press fitting obtained by ANSYS and on actual machine. Therefore, it is reasonable to state that a FE model can simulate fairly well the press fitting process of railway wheel on its axle. 7. REFERENCES [1] Annexure VIII, R. D. S. O. Ministry Of Railways, Indian Railways [2] IRS R -19/93 (Part 1 &2), Indian Railways [3] Pro/Engineer Wildfire 2.0 Software, PTC, USA Software ANSYS Inc. [4] ANSYS Canonsburg, PA, USA. (www.ansys.com) [5] Sham Tikoo, ANSYS Reference Guide [6] ANSYS Reference Guide, CADD Centre, India [7] ANSYS 8.0 Documentation, Nonlinear Structural Analysis, ANSYS 8.0 [8] Maintenance Manual for BG coaches of ICF design, Indian Railways, Annexure AAxle Report [9] Pro/Engineer Reference Guide, CADD Centre, India