easy certification according to en12663 and dvs using fem ... · final strength report for...
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![Page 1: Easy certification according to EN12663 and DVS using FEM ... · Final strength report for certification by Notified Body. -sim sol.com LIMIT 2017 Page 4 Certification according to](https://reader034.vdocuments.us/reader034/viewer/2022051809/601536038cb6e00a87116072/html5/thumbnails/1.jpg)
Easy certification according to EN12663 and DVS using FEM and LIMIT
LIMIT 2017 Page 1www.cae-sim-sol.com
Railway Applications
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A way to certification of railway vehicles according to DVS
Overview of the strength assessment
Challenges for the assessment of welded structures
Types of railway structures: shells vs. volume
Applying the design codes
Interfaces FEM to LIMIT
Generating Reports as part of the documentation for Notified Body, the completeprocedure with LIMIT
Motivation for LIMIT
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Certification according to EN12663 and DVS
Final strength report forcertification
by Notified Body
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Certification according to EN12663 and DVS
Train design3D geometryMaterialsJoints:▪Many welds▪Many bolts, …
Final report for certification
Finite Element Analysis
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Medium sized structures
▪ Bogies
▪ Sheet thickness starting from 5mm
Typical railway structures
Source: Siemens, Austria
Thin walled large structure
▪ Vehicle body
▪ Sheet thickness down to 2mm!
Source: Bombardier, Vienna
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Shell modelling
▪ Reduction of calculation time
▪ Shell thickness is a parameter of shellcan be modified if necessary
▪ Easier extraction of section forces and moments for weld assessment directly available
▪ Automated weld strengthassessment
▪ Report generation
Modelling strategies
Shell modelSource: Siemens, Austria
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Typical railway structures
Solid modelling
▪ No mid surface modelling(faster)
▪ Large thickness of plates can be captured more accurate
▪ More flexibility with different variants
▪ Less singularities and therefore less conservative
Source: Logomotive, Germany
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Certification according to EN12663 and DVS
Train design3D geometryMaterialsJoints:▪Many welds▪Many bolts, …
Final report for certification
Finite Element Analysis
Strength Requirementsaccording to EN12663
Loads depending on vehicle category
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Finding critical loads and load cycle numbers
▪ According to EN12663: minimum of approximately 25 LCs necessary
Assessing large numbers of welds
▪ 500 to 1000 welds in a typical carbody
Applying the design code
Challenges with certification of railway structures
Complex structure
EN 12663Strength requirements
Static and Fatigueo.k.?
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t1
t2 a
Certification according to EN12663 and DVS
Train design3D geometryMaterialsJoints:▪Many welds▪Many bolts, …
Strength Requirementsaccording to EN12663
Loads depending on vehicle category
Final report for certification
Finite Element Analysis
Static assessmentFatigue assessment▪DVS 1612 (steel)▪DVS 1608 (alu)
Weld quality
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Notch cases, one sided fillet weld:
Typical values t1
t2a
Only nominal stress, root:Longitudinal= E4Transverse = F3 + Excentricity!Shear = H-
Notch cases DVS1612
s⊥
sll
t
t2
sll
s⊥
s⊥
t1
Nominal stress, toe:Longitudinal = E4Transverse = E5Shear = H-
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Assessing the welds
Weld Analysis according to DVS1612E.g.: Single sided fillet weld▪ Fillet throat critical => stresses in throat
needed!A.) Using section forces from shell model
B.) Using section forces from solid model & LIMIT sensors
C.) R1-effective notch
Sensors
A.)
B.)
Cracks
Load
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Typical railway structures
Sensor technology
▪ Are used to calculate section forces and moments in solidstructures
▪ Forces and moments are needed for the weld assessment according to DVS1612
▪ Sensors are generated in LIMIT
Source: Logomotive, Germany
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Comparison for different geometries
Degree of Utilization (DoU)
Results
DoU = 4,88DoU = 0,71DoU = 0,85
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Easy certification with LIMIT
FE modelPatran, Hypermesh,
Abaqus/CAE, ANSYS, NX
Design: 3D-CAD
Finite Element Input.bdf, .out, .dat, .inp
FE Results.fil, .odb, .op2, .rst
LIMIT-SOLVERAnalysis
LIMIT-VIEWERPost processing
FE SolverNastran, Abaqus, ANSYS
Midsurfaces and shell elements
3D-CAD
LIMIT-CAEDefinition of assessments
in the GUI
Global iteration loop, changing
geometry
Local loop, e.g. changing weld quality
Not o.k.!
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Easy certification with LIMIT
FE modelPatran, Hypermesh,
Abaqus/CAE, ANSYS, NX
Design: 3D-CAD
Finite Element Input.bdf, .out, .dat, .inp
FE Results.fil, .odb, .op2, .rst
LIMIT-SOLVERAnalysis
LIMIT-VIEWERPost processing
FE SolverNastran, Abaqus, ANSYS
Automated Report Generation:
LIMIT-CAEDefinition of assessments
in the GUI
All welds o.k.!
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t1
t2 a
Certification according to EN12663 and DVS
Train design3D geometryMaterialsJoints:▪Many welds▪Many bolts, …
Strength Requirementsaccording to EN12663
Loads depending on vehicle category
Final report for certification
Finite Element Analysis
Static assessmentFatigue assessment▪DVS 1612 (steel)▪DVS 1608 (alu)
Weld quality
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LIMIT Interfaces to MSC Products
Interfaces to MSC
▪ MSC-MARC (t16)
▪ MSC-NASTRAN (op2)
▪ HDF5 format will be available in the beginning of 2018 for:
- MSC-Apex
- MSC-Nastran
- Patran
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Further LIMIT Interfaces
The Software
in alphabetic order:
▪ ABAQUS
▪ ANSYS
▪ ANSYS LS DYNA
▪ CATIA FE
▪ NX NASTRAN
▪ RADIOSS/OPTISTRUCT
▪ SOLIDWORKS Simulation
▪ LIMIT Universal Interface
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References
▪ AMST-Systemtechnik GmbH
▪ AUDI, Werkzeugkonstruktion, Germany
▪ Bühler AG, Switzerland
▪ China Energine International Ltd.
▪ FEMCOS-Ingenieurbüro mbH, Germany
▪ Gardner Denver Schopfheim GmbH, Germany
▪ Hydromek, Turkey
▪ IBV-Engineering, Germany
▪ IFF Engineering & Consulting GmbH, Germany
▪ Istanbul Technical University, Turkey
▪ K + V Ingenieurgesellschaft mbH, Germany
▪ Ludwig Engel KG, Austria
▪ Liebherr-Transportation Systems GmbH & Co KG
References
▪ LogoMotive GmbH, Germany
▪ MAV-START, Hungary
▪ NEWAG, Poland
▪ PESA Bydgoszcz SA, Poland
▪ Plasser & Theurer, Austria
▪ Prisma Engineering, Austria
▪ RUAG Schweiz AG, Switzerland
▪ Stadler Valencia, Spain
▪ STREICHER Maschinenbau GmbH & Co. KG, Germany
▪ Taiwan Rolling Stock Company, Taiwan
▪ TUV Rheinland Rail Sciences, Inc., Nebraska, USA
▪ Vossloh Locomotives, Kiel
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Apply for a free test license and experience the benefits for your projects!Please contact:Dr. Nikolaus [email protected] +43 1 974 89 91-12