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Easy certification according to EN12663 and DVS using FEM and LIMIT
LIMIT 2017 Page 1www.cae-sim-sol.com
Railway Applications
LIMIT 2017 Page 2www.cae-sim-sol.com
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
LIMIT 2017 Page 3www.cae-sim-sol.com
Certification according to EN12663 and DVS
Final strength report forcertification
by Notified Body
LIMIT 2017 Page 4www.cae-sim-sol.com
Certification according to EN12663 and DVS
Train design3D geometryMaterialsJoints:▪Many welds▪Many bolts, …
Final report for certification
Finite Element Analysis
LIMIT 2017 Page 5www.cae-sim-sol.com
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
LIMIT 2017 Page 6www.cae-sim-sol.com
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
LIMIT 2017 Page 7www.cae-sim-sol.com
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
LIMIT 2017 Page 8www.cae-sim-sol.com
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
LIMIT 2017 Page 9www.cae-sim-sol.com
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.?
LIMIT 2017 Page 10www.cae-sim-sol.com
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
page 11www.cae-sim-sol.com LIMIT 2017
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-
page 12www.cae-sim-sol.com LIMIT 2017
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
LIMIT 2017 Page 13www.cae-sim-sol.com
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
LIMIT 2017 Page 14www.cae-sim-sol.com
Comparison for different geometries
Degree of Utilization (DoU)
Results
DoU = 4,88DoU = 0,71DoU = 0,85
LIMIT 2017 Page 15www.cae-sim-sol.com
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.!
LIMIT 2017 Page 16www.cae-sim-sol.com
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.!
LIMIT 2017 Page 17www.cae-sim-sol.com
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
LIMIT 2017 Page 18www.cae-sim-sol.com
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
LIMIT 2017 Page 19www.cae-sim-sol.com
Further LIMIT Interfaces
The Software
in alphabetic order:
▪ ABAQUS
▪ ANSYS
▪ ANSYS LS DYNA
▪ CATIA FE
▪ NX NASTRAN
▪ RADIOSS/OPTISTRUCT
▪ SOLIDWORKS Simulation
▪ LIMIT Universal Interface
LIMIT 2017 Page 20www.cae-sim-sol.com
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
LIMIT 2017 Page 21www.cae-sim-sol.com
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