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Load Collective Development for Fatigue Assessment of Rail Vehicles
KTH, School of Engineering Sciences (SCI), Engineering Mechanics, Vehicle engineering and technical acoustics.
2024 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesisAlternative title
Last Kollektiv utveckling för utmattningsbedömning av järnvägsfordon (Swedish)
Abstract [en]

This thesis investigates fatigue life assessment of rail vehicle components under random vibration loads, focusing on developing a frequency-domain load collective using power spectral density (PSD) functions. Random vibration fatigue, a critical cause of structural failure, is evaluated through two methods: the time-domain rainflow and the frequency-domain spectral approaches. The frequency-domain method, enhanced by the pseudo excitation method (PEM), is shown to maintain high accuracy while significantly reducing computational complexity.PEM, which provides an algorithm for obtaining dynamic response of the multi-degree-offreedom (multi-DOFs) systems, reduces the computational workload compared to traditional methods like Complete Quadratic Combination (CQC) equation. The method is validated using a cantilever beam example from literature, the modal shapes and eigenfrequencies are analysed first for the modal superposition method. Then the stress response PSD and corresponding spectral characteristics such as spectral moment of area and irregularity factors are calculated based on PEM method. The stress range distribution histograms from PEM obtained by the spectral method in NCODE can closely match those of traditional time-domain methods based on rainflow counting and damage accumulative method.In the case study of a 70% low-floor train carbody, multi-body dynamic simulations in SIMPACK reveal that different excitation cases affect the dynamic response of the vehicle, where the “Measured” track irregularity and higher speed can cause larger excitation and acceleration response from the vehicle. Theses sumulation results are then used as load collective and applied by spectral fatigue assessment method based on PEM in ABAQUS. The narrowband model yields the most conservative fatigue life estimates, while the Dirlik and Lalanne models offer similar, but less conservative results. Multi-axial loading causes more critical damage than single-axis loading, and higher operating speeds result in increased damage. The comparison of different track irregularities shows that ”Measured” excitations cause greater damage than ”ERRI-high” irregularities.This study concludes that the frequency-domain load collective based on the spectral method particularly with PEM method, is an efficient and usable approach for fatigue life assessment, offering substantial reductions in computational effort while providing precise predictions, making it usable for practical engineering applications.

Abstract [sv]

Denna avhandling undersöker utmattningslivsbedömning av järnvägsfordonskomponenter under slumpmässiga vibrationsbelastningar, med fokus på att utveckla en lastkollektiv i frekvensdomänen med PSD-funktioner. Slumpmässig vibrationsutmattning, en kritisk orsak till strukturellt fel, utvärderas genom två metoder: tidsdomänens regnflödesmetod och frekvensdomänens spektrala metoder. Frekvensdomänsmetoden, förbättrad med den så kallade pseudoexciteringsmetoden (PEM), visade sig bibehålla hög noggrannhet samtidigt som den avsevärt minskade den beräkningsmässiga komplexiteten.PEM minskar beräkningsbelastningen jämfört med traditionella metoder som den kompletta kvadratiska kombinationen (CQC). Metoden valideras med ett konsolbalkexempel där stressresponsens PSD och spektrala egenskaper, såsom moment av area och oregelbundna faktorer, beräknas med PEM. Stressomfångets fördelningshistogram, som erhålls genom den spektrala metoden i NCODE, stämmer väl överens med traditionella tidsdomänsmetoder baserade på regnflödesräkning och skademodeller.I fallstudien på en 70% låggolvstågskorg visar simuleringar i SIMPACK att olika spåroregelbundenheter och hastigheter påverkar fordonets dynamiska respons. ”Uppmätta” oregelbundenheter och högre hastigheter orsakar större excitation och accelerationsrespons, vilket leder till större skador. Dessa simuleringar används sedan i ABAQUS för att tillämpa spektral utmattningsbedömning baserad på PEM. Smalbandsmodellen ger de mest konservativa bedömningarna av utmattningslivslängd, medan Dirlik- och Lalanne-modellerna ger liknande, men mindre konservativa resultat. Multiaxiell belastning orsakar mer kritiska skador än enkelaxlig belastning, och högre hastigheter ökar skadorna ytterligare.Studien bekräftar att frekvensdomänens lastkollektiv, särskilt i kombination med PEMmetoden, är ett effektivt och användbart verktyg för utmattningslivsbedömning i praktiska ingenjörstillämpningar, och erbjuder betydande minskningar i beräkningsinsats utan att kompromissa med precisionen.

Place, publisher, year, edition, pages
2024.
Series
TRITA-SCI-GRU ; 2024:395
Keywords [en]
Load collective, Spectral method, Pseudo excitation method, Fatigue life assessment
Keywords [sv]
Lastkollektiv, spektral metod, pseudo-exciteringsmetod, utvärdering av livslängd under trötthet
National Category
Vehicle and Aerospace Engineering
Identifiers
URN: urn:nbn:se:kth:diva-360081OAI: oai:DiVA.org:kth-360081DiVA, id: diva2:1938094
Subject / course
Rail Vehicle Engineering
Educational program
Master of Science - Vehicle Engineering
Supervisors
Examiners
Available from: 2025-02-17 Created: 2025-02-17 Last updated: 2025-02-17Bibliographically approved

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