Mechanical Engineering for Society and Industry

Articles

Verification of urban light rail transit (LRT) bogie frame structure design lifetime under variable fatigue loads

Djoko Wahyu Karmiadji , Budi Haryanto , Anwar Anwar , Budi Prasetyo , Yudi Irawadi , Abdul Rohman Farid , Isach W.Z. Karmiadji , Hijaz Ahmad

Published
April 18, 2022

Vol. 2 No. 1 (2022)
Pages 42-53

DOI

Open Access
Share

Abstract

The bogie frame is the main structure of the train that supports the train's loads during its operation. These structures are subject to fatigue testing to ensure their design life is up to the required standards. The urban light rail transit (LRT) bogie frame used in the Greater Jakarta area is newly designed and manufactured by a commercial railway rolling stock manufacturer. The design lifetime of this newly designed bogie frame structure under various fatigue load conditions is verified experimentally by fatigue testing. Testing and evaluations were conducted following the EN 13749 standard and VDV recommendation. The fatigue test of the urban LRT bogie frame structure was carried out in the test hall of the BPPT Structural Strength Technology Center (B2TKS) using a combination of seven loadings. The bogie frame was subjected to two variable types of fatigue loads, namely driving in curves and passing points (switches), with 2,000,000 cycles, 4,000,000 cycles, and 6,000,000 cycles of fatigue loadings. The parameter measured on the bogie frame structure is the strain value during the test using a dynamic data logger. The stress values analyzed are the average stress and the stress amplitude and then plotted on the maximum and minimum stress curve. The bogie structure is inspected by the non-destructive test method in all areas of its welded joints. This inspection is carried out before and after the test to ensure whether there are cracks caused by fatigue loads. The results of the fatigue test on the bogie structure under the variable fatigue load conditions show that the maximum stress value of 91.71 MPa at 1,500,000 cycles, that occurs during the test, does not exceed the fatigue limit of the material, and there are no cracks in the structure after the test is carried out for up to 6,000,000 cycles.

Keywords

Bogie frame; Fatigue; Mean stress; Amplitude stress; Crack

References

  1. [1] J. W. Seo, H. M. Hur, H. K. Jun, S. J. Kwon, and D. H. Lee, “Fatigue Design Evaluation of Railway Bogie with Full-Scale Fatigue Test,” Advances in Materials Science and Engineering, vol. 2017, pp. 1–11, 2017, doi: 10.1155/2017/5656497.
  2. [2] D. Chen, S. Sun, and Q. Li, “Strength Evaluation of a Bogie Frame by Different Methods,” Mechanical Engineering Science, vol. 1, no. 1, pp. 71–85, 2019, doi: 10.33142/me.v1i1.662.
  3. [3] S. C. Yoon, Y. S. Kim, J. H. Ryu, S. H. Park, and G. S. Park, “A study on the characteristics of Bogie frame materials,” in Applied Mechanics and Materials, 2013, vol. 420, pp. 144–148, doi: 10.4028/www.scientific.net/AMM.420.144.
  4. [4] M. Ozsoy, K. Pehlivan, M. Firat, N. Ozsoy, and V. Ucar, “Structural strength and fatigue life calculation of Y32 bogie frame by finite element method,” Acta Phys. Polon. A, vol. 128, no. 2B, p. B-327, 2015, doi: 10.12693/APhysPolA.128.B-327.
  5. [5] M. Molina Fandos, “Investigation and classification of bogie designs and their potential to adopt lightweight structures by means of a database.” Universitat Politècnica de Catalunya, 2018.
  6. [6] D. W. Karmiadji, B. Haryanto, O. Ivano, M. Perkasa, and A. R. Farid, “Bogie Frame Structure Evaluation for Light-Rail Transit (LRT) Train: A Static Testing,” Automotive Experiences, vol. 4, no. 1, pp. 36–43, 2021, doi: 10.31603/ae.v3i3.4252.
  7. [7] R. Pokkula and T. V. K. Gupta, “Finite Element Method Based Evaluation of Bogie Bolster Design.,” International Journal of Vehicle Structures & Systems (IJVSS), vol. 13, no. 2, pp. 160–163, 2021, doi: 10.4273/ijvss.13.02.05.
  8. [8] G. Mancini and A. Cera, “Design of railway bogies in compliance with new EN 13749 European standard,” 2006.
  9. [9] S. Palli, R. Koona, R. C. Sharma, and V. Muddada, “Dynamic analysis of indian railway integral coach factory bogie,” International Journal of Vehicle Structures and Systems, vol. 7, no. 1, pp. 16–20, 2015, doi: 10.4273/ijvss.7.1.03.
  10. [10] J. Dai, “The Design of Bullet Train Process Bogie and the Finite Element Analysis of Frame Strength,” in 2015 International Conference on Material Science and Applications (icmsa-15), 2014, pp. 926–931, doi: 10.2991/icmsa-15.2015.172.
  11. [11] The European Commission for Standardisation, “Railway applications - Wheelsets and bogies - Method of specifying the structural requirements of bogie frames,” in European Standard Railway Applications, vol. EN 13749:2, 2011, pp. 1–4.
  12. [12] VDV Recommendation, Recommendations on the Design for Strength of Urban Rail Rolling Stock according to BOStrab. Committee on Urban Rail Rolling Stock, 2016.
  13. [13] UIC Code 615-4, Movie power units bogies and running gear bogie frame structure strength tests. 1994.
  14. [14] Q. An, H. Zhao, P. Li, and M. Fu, “Fatigue strength analysis of bogie frames under random loads,” Advances in Mechanical Engineering, vol. 11, no. 9, pp. 1–13, 2019, doi: 10.1177/1687814019878018.
  15. [15] Q. Lan and F. Song, “Fatigue Simulation of Railway Car Bogie Frame Based on Multi-body Dynamics and Finite Element Analysis,” in Journal of Physics: Conference Series, 2021, vol. 1885, no. 4, p. 42057, doi: 10.1088/1742-6596/1885/4/042057.
  16. [16] W. Tang, W. Wang, Y. Wang, and Q. Li, “Fatigue strength and modal analysis of bogie frame for DMUs exported to Tunisia,” Journal of Applied Mathematics and Physics, vol. 2, no. 06, pp. 342–348, 2014, doi: 10.4236/jamp.2014.26041.
  17. [17] W. Wang, J. Bai, S. Wu, J. Zheng, and P. Zhou, “Experimental investigations on the effects of fatigue crack in urban metro welded bogie frame,” Applied Sciences, vol. 10, no. 4, p. 1537, 2020, doi: 10.3390/app10041537.
  18. [18] M. Willcox and G. Downes, A brief description of NDT techniques, Insight NDT. Toronto: NDT Equipment Limited, 2003.
  19. [19] M. Gupta, M. A. Khan, R. Butola, and R. M. Singari, “Advances in applications of Non-Destructive Testing (NDT): A review,” Advances in Materials and Processing Technologies, pp. 1–22, 2021, doi: 10.1080/2374068X.2021.1909332.
  20. [20] J. Vaughan, Application of B & K Equipment to Strain Measurement. Brüel & Kjær.
  21. [21] TML Pam E-1007E, Precise & Flexible Strain Gauges. Tokyo Measuring Instruments Lab, 2017.
  22. [22] J. Tittel, M. Kepka, and P. Heller, “Static and dynamic testing of a bogie,” IOP Conference Series: Materials Science and Engineering, vol. 723, no. 1, pp. 1–6, 2020, doi: 10.1088/1757-899X/723/1/012031.
  23. [23] B. Wang, S. Sun, S. Ma, and X. Wang, “Fatigue damage and reliability assessment of subway train bogie frames under operating conditions,” Advances in Mechanical Engineering, vol. 12, no. 1, pp. 1–9, 2020, doi: 10.1177/1687814020903590.
  24. [24] R. C. A. Liliana, B. Florin, I. Nicolae, and A. Costica, “Stresses in a bogie frame of a rail carriage,” Procedia Engineering, vol. 100, no. January, pp. 482–487, 2015, doi: 10.1016/j.proeng.2015.01.394.
Article Metrics
28
Views
39
Downloads

SCITE

DIMENSIONS

Publication Information
Published April 18, 2022
Section Articles
Copyright Copyright (c) 2022 Djoko Wahyu Karmiadji, Budi Haryanto, Anwar Anwar, Budi Prasetyo, Yudi Irawadi, Abdul Rohman Farid, Isach W.Z. Karmiadji, Hijaz Ahmad
Keywords
  • Bogie frame
  • Fatigue
  • Mean stress
  • Amplitude stress
  • Crack