Elaboration of design principles of steel joints. Creation of the finite element model in ANSYS program, the study of static behaviour near the bolt hole, deformation of the screw and the stress components of the welded joint. Comparison with the analytical formulas.

Les phénomènes dynamiques observés lors de la circulation des trains provoquent des nuisances, notamment sonores et vibratoires, qui sont amplifiées par la présence de défauts sur la roue et sur le rail. Pour les analyser, il est nécessaire de prédire avec robustesse le comportement dynamique des composants impliqués dans l’interaction véhicule-voie et donc de simuler les efforts de contact générés pour des interfaces non idéalisées.L’objectif de cette thèse est donc de proposer un modèle semi-analytique global compatible avec l’intégration de multiples défauts géométriques sur les surfaces en contact. Afin de simuler l’interaction véhicule-voie dans le domaine temporel et garantir une applicabilité en phase de dimensionnement, une attention particulière est portée sur le compromis entre la précision des résultats et les temps de calcul associés.Le modèle ainsi proposé est composé d’un demi-bogie, dont le comportement vertical est représenté par un ensemble de masses-ressorts-amortisseurs, circulant sur une voie ballastée. Cette dernière est assimilée à une poutre bi-appuyée, supportée périodiquement à l’emplacement des traverses. Ces deux systèmes sont couplés en contact grâce à une procédure Distributed Point Reacting Spring (DPRS) sous forme discrétisée.Une validation du modèle est, d’une part, proposée en considérant des travaux antérieurs dans le cas de géométries parfaites. D’autre part, de multiples combinaisons de défauts, localisés comme le méplat ou répartis comme l’usure ondulatoire, sont introduites dans la simulation. La variabilité spatiale, particulière au cas de l’écaillage, est modélisée par des champs aléatoires. / The appearance of dynamic phenomena during the running of train on track leads to issues such as noise and vibration pollution, which can be further amplified by the presence of defects on the treads. In order to analyze them, it is necessary to predict with reliability the dynamic behavior of the vehicle-track interaction components, in particular the contact forces produced by non perfect treads.The aim of this PhD thesis is to provide a semi-analytical vehicle-track interaction model able to take into account multiple defects on the surfaces in contact. In order to conduct simulations in the time-domain and ensure applicability in the sizing phase, a special attention is given on the compromise between the accuracy of the results and the simulation times.The proposed model is therefore composed of half a bogie running on a ballasted track. This latter is modeled by a pinned-pinned beam with periodic supports located at the sleepers while the vertical behavior of the bogie is given by masses, springs and dampers. These two models are coupled in contact by a discretized Distributed Point Reacting Spring (DPRS) procedure.A validation of the model, based on previous work, is firstly proposed for perfect treads. Then, multiple combinations of defects, either localised as wheelflat or spread as corrugation, are introduced in the simulation. The spatial variability, specific to shelling, is modeled by random fields.

Mobile Miner 40V is a machine used for rock excavation and developed by Epiroc. This machine is equipped with a large cutter wheel to perform the excavation. After a test run, some surfaces associated with bearings within the cutter wheel were found to be damaged due to scuffing - severe sliding wear. There is a static load applied to the surfaces due to gravity. However, the reason for this damaged issue was believed that there is a large dynamic load applied to the surfaces during the excavation. This dynamic load was not found in a previous FE model used to verify safety issues. Therefore, a new FE model that is more in line with reality, and a failure analysis were required. Additionally, a feasibility study for a cutter wheel with a larger dimension was also needed since a larger cutter wheel is desirable. Firstly, wear mechanisms were reviewed, and some theories were chosen to analyze the damaged issue. Since it was unknown whether the surfaces were well-lubricated or not, both cases were investigated. The Archard wear equation was used to analyze the poor-lubricated situation, while the lubrication number and the Reynolds equation were used to analyze the well-lubricated case. Secondly, contact mechanisms between the surfaces were also investigated. The investigation of the contact mechanisms involved several theories, such as the Hertzian contact theory and the impact load factor. Besides these theoretical analyses, a numerical analysis was performed. Lastly, a new FE model was established in Ansys. Both the cutter wheel which was subjected to scuffing(existing cutter wheel), and the cutter wheel with a larger dimension(larger cutter wheel) were analyzed by the use of the new FE model. The maximum and minimum wear rates obtained by the Archard wear equation are approximately 1.9・10-2mm3/m and 4.8・10-3mm3/m, which are considered as a completely unacceptable level in engineering applications. The maximum and minimum critical loads obtained by the Reynold equation are approximately 1.8kN and 24.8kN, which both are larger than the static load applied to the surfaces. The maximum and minimum critical mean contact pressures obtained by the lubrication number are approximately 65MPa and 240MPa, which both are larger than the mean contact pressure generated by the static load. No evidence shows that there is a large dynamic load applied to the surfaces during the excavation. The largest possible contact pressure on the bearings in the existing cutter wheel is very close to the limit of severely damaged. The largest possible contact pressure on the bearings in the larger cutter wheel is believed to exceed the limit of severely damaged. The previous assumption that the surfaces were damaged due to a large dynamic load was wrong. The obtained results support that the surfaces were only subjected to a static load and were damaged due to inadequate lubrication. The existing cutter wheel is operated safely with the current load cases. However, the forward thrust force is suggested to decrease when the cutting angle is large. There is a high risk if the larger cutter wheel is operated with the current load cases.

No description available.

This bachelor’s degree project aimed to improve the wheel profile of a rail mounted trolley and determine the cause of wheel failure. The proceedings of this project where modelled after an approach for solving wear problems with an emphasis on designing for sustainability. A case study and root cause analysis (RCA) was performed and the flanged wheels were deemed insufficient for the given heavy-haul system. Possible areas of wheel profile improvement were identified and further researched with multiple literature reviews. Throughout the projects duration several limitations were introduced that reduced the concept testing to exclusively theoretical prediction models. Archard’s model was implemented to predict wear and operating time for the proposed material and wheel tread profile concepts. The wheel flange dimensions were chosen based on recommendations from wheel and rail interference handbooks among other sources. The final wheel and rail profile suggestion improved operating time by approximately 300% and wear resistance by 50% compared to its predecessor. This result was achieved by applying the same theoretical prediction model to both current and suggested profiles. The findings of this project are meant to aid SCA among others in similar cases and additionally highlight the value of product improvement from a technological, sociological, and environmental perspective.

The presence of the compressive or tensile thermal residual stresses in layers of a ceramic laminate induced due to different volume change of each layer´s material during the cooling from the sintering temperature can considerably affect resistivity of ceramics against contact damage. Within this work 2D parametric FEM models were created, in order to study the effect of the surface layer thickness, residual stress values and indenting body dimension on the initiation and propagation of the cone crack in the surface layer of the laminate. For the analysis of the critical conditions for the crack initiation, the coupled stress-energy criterion was used and for the determination of the direction of crack propagation we used the maximum tangential stress criterion. The results show that compressive thermal stresses in the surface layer increase the critical force for the crack initiation, shorten the crack distance from the contact area and shorten the occurred crack itself. Moreover, the compressive stresses enlarge the angle of the crack declination during the propagation process which cause an earlier crack arrest. The tensile thermal stresses have exactly the opposite effect. Results of simulations were compared to experimental results but due to lack of available measurements, the verification is partially limited.

Dans le cadre du développement d’un outil semi-analytique de pré-dimensionnement de structures sandwich soumises à des impacts à vitesse intermédiaire (<20m.s-1), nous proposons la détermination d’une solution efficace, basée sur les séries de Fourier avec des conditions aux limites générales. Les équations gouvernantes qui permettent de décrire la réponse transitoire élastique de plaques stratifiées orthotropes avec prise en compte d’une loi non linéaire de contact hertzien sont développées en utilisant un schéma de discrétisation temporelle explicite. Pour les conditions aux limites générales, la solution en séries de Fourier est complétée par une série mixte de polynômes-cosinus, qui permet d’aboutir à la solution, tout en permettant à la série de satisfaire les équations d’équilibres ainsi que les conditions limites, de façon exacte en augmentant le nombre de termes de la série. Afin de tenir compte des phénomènes physiques locaux lors de l’impact de structure sandwich, la plasticité et la rupture locale de la plaque anti-perforation sont introduites dans une formulation modifiée du contact de Hertz et l’écrasement de l’âme du sandwich est ajouté dans l’équation d’équilibre du projectile. Les solutions obtenues par cette méthode sont en accord avec les résultats par modélisation éléments finis de plaques composites multicouches impactées par un projectile. Une campagne expérimentale d’impact de type « box corner » sur des plaques sandwich de 1m², a servi de référence expérimentale et permis la validation de ce modèle complet. Finalement, le couplage de ce modèle à un optimiseur basé sur les techniques de plans d’expériences et de surfaces de réponses (métamodèles), nous a permis de choisir la meilleure structure d’absorption d’énergie (matériaux et géométrie) pour des structures plaques soumises à des impacts de 7kJ. Un test sur un véhicule réel avec la configuration structurelle choisie, nous a permis de valider l’outil final de pré-dimensionnement et de confirmer la qualité des résultats numériques obtenus par ce modèle semi-analytique. / A semi-analytical tool for the design of sandwich structures under intermediate speed loadings impact (<20m.s-1) is proposed by using an efficient solution based on the Fourier series with general boundary conditions. The governing equations, which describe dynamic elastic response of orthotropic laminates and include the non linear Hertzian contact law, are derived by means of explicit time discretization. For the general boundary conditions, the Fourier series solution is supplemented with mixed polynomial-cosine series, which allows derivation of the classical solution by letting the series satisfy exactly the governing differential equation and the boundary conditions with increased values of terms series. To take local physical behavior during sandwich structure impact into account, local plasticity and failure of the protection plate are introduced in a modified form of the Hertzian contact and the compression of the foam is added in the equilibrium equation of the projectile. The solutions obtained with this new method are close to those found by finite element simulations for impact on multilayers composite structures. An experimental campaign with one square meter sandwich structures impacted by corner box projectile is then used to validate the whole model. Finally, the best sandwich structure for energy absorption under a 7kJ impact (material and geometry) is chosen by coupling the model with an optimizer based on the metamodel approach. This solution is applied to a real vehicle and the results confirm the quality of the design of the structure.

In this bachelor thesis we report on our numerical investigations into the optimal design of protective multi-layer coatings subject to an external force of Hertzian form. In view of mechanical reliablity and durability of the substrate and the coating we aim to find the best composition of given materials with the least computational effort. Numerical studies are carried out using the simulation software ELASTICA being the first non-FEM approach for the computation of stress fields within multi-layer coated, elastic materials. We thereby made use of the massive parallel computer CLiC (Chemnitzer Linux Cluster) where we ran our Windows based application in a Wine Environment. The outcome of the optimization is in general very sensitive towards the input parameters(i.e., material properties) which are not always available in the desired accuracy. However, the scheme outlined in this work is shown to produce very good results and could contribute a great deal to find optimal solutions for real applications. / Diese Bachelorarbeit befasst sich mit numerischen Untersuchungen zum optimalen Design von schützenden Mehrschichtbeschichtungen, die einer externen, Hertzschen Last ausgesetzt sind. Hinsichtlich der mechanischen Zuverlässigkeit und Haltbarkeit von Substrat und Beschichtung, versuchen wir die beste Zusammensetzung von gegebenen Materialien mit möglichst geringem Rechenaufwand zu finden. Die numerischen Berechungen wurden mit der Simulationssoftware ELASTICA durchgeführt, welches das erste kommerzielle, nicht-FEM-basierte Programm zur Berechnung von Stressfeldern innerhalb mehrfach beschichteter, elastischer Materialien darstellt. Dafür benutzten wir auf dem massiven Parrallelrechner CLiC (Chemnitzer Linux Cluster) unsere Windows basierte Anwendung unter der Emulationssoftware Wine. Das Ergebnis der Optimierung hängt im allgemeinen sehr stark von der Qualität der Eingangsparameter (z.B. Materialeigenschaften) ab, welche nicht immer in der erwünschten Genauigkeit vorliegen. Es wird gezeigt, dass die in dieser Arbeit vorgestellte Vorgehensweise sehr gute Resultate liefert und für reale Anwendungen einen äusserst ressourcenschonenden Lösungsweg darstellt.

Compression fracture specimens are ideally suited for miniaturization down to tens of microns. Fracture testing of thermal barrier coatings, ceramics and glasses are also best accomplished under compression or indentation. Compression fracture specimen of finite size with constant form factor was not available in the literature. The finite-sized specimen of edge cracked semicircular disk (ECSD) is designed which has the property of constant form factor. The novel ECSD specimen is explored further using weight function concept. This thesis, therefore, is mainly concerned with the design, development and geometric optimization of compression fracture specimen vis a vis their characterization of form factors, weight functions and isotropic points in the uncracked geometry. Inspired by the Brazilian disk geometry, a novel compression fracture specimen is designed in the form of a semicircular disk with an edge crack which opens up due to the bending moment caused by the compressive load applied along its straight edge. This new design evolved from a set of photoelastic experiments conducted on the Brazilian disk and its two extreme cases. Surprisingly, normalized mode-I stress intensity factor of the semicircular specimen loaded under a particular Hertzian way, is found constant for a wide range of relative crack lengths. This property of constant form factor leads to the development of weight function for ECSD for deeper analysis of the specimen. The weight function of a cracked geometry does not depend on loading configuration and it relates stress intensity factor to the stress distribution in the corresponding uncracked geometry through a weighted integral. The weight function for the disk specimen is synthesized in two different ways: using the conventional approach which requires crack opening displacement and the dual form factor method which is newly developed. Since stress distribution in the uncracked specimen is required in order to use weight function concept, analytical solution is attempted using linear elasticity theory. Since closed form solution for stresses in the uncracked semicircular disk is seldom possible with the available techniques, a new semi-analytical method called partial boundary collocation (PBC), is developed which may be used for solving any 2-D elasticity problem involving a semi-geometry. In the new method, part of the boundary conditions are identically satisfied and remaining conditions are satisfied at discrete boundary points. The classical stress concentration factor for a semi-in finite plate with a semicircular edge notch re-derived using PBC is found to be accurate to the eighth decimal. To enhance the form factor in order to test high-toughness materials, edge cracked semicircular ring (ECSR) specimen is designed in which bending moment at the crack-tip is increased significantly due to the ring geometry. ECSR is analyzed using nite element method and the corresponding uncracked problem is analyzed by PBC. Constant form factor is found possible for the ring specimen with tiny notch. In order to avoid varying semi-Hertzian angle during practice and thereby ensure consistent loading conditions, the designs are further modified by chopping at the loading zones and analyzed. Photoelastic isotropic points (IPs) which are a special case of zeroth order fringe (ZOF) are often found in uncracked and cracked specimens. An analytical technique based on Flamant solution is developed for solving any problem involving circular domain loaded at its boundary. Formation of IPs in a circular disk is studied. The coefficients of static friction between the surfaces of disk and loading fixtures, in photoelastic experiments of three-point and four-point loadings, are explored analytically to confirm with experimental results. The disk under multiple radial loads uniformly spaced on its periphery is found to give rise to one isolated IP at the center. Splitting of this IP into a number of IPs can be observed when the symmetry of normal loading is perturbed. Tangential loading is introduced along with normal loading to capture the effect of the composition on formation of IPs. Bernoulli's lemniscate is found to fit fringe order topology local to multiple IPs. Isotropic points along with other low fringe order zones including ZOF are ideal locations for material removal for weight reduction. Making a small hole in the prospective crack path at the IP location in the uncracked geometry might provide dual benefits: 1. Form factor enhancement; 2. Crack arrestor. Thus, this thesis describes experimental, theoretical and computational investigations for the design, development and calibration of novel compact compression fracture specimens.

Der Vortrag stellt das neue, unendlich reibungsbehaftete Kontaktmodell der FEM-Berechnungssoftware Pro/ENGINEER Mechanica in der Version Wildfire 4.0 von PTC vor. Dabei werden sowohl die Grundlagen des reibungsfreien Kontaktes als auch die Theorie des unendlich reibungsbehafteten Kontaktmodells behandelt sowie die Grundlagen der zur numerischen Lösung in der Software verwendeten Penalty- und Newton-Raphson-Methode erläutert. Als Anwendungsbeispiel für das reibungsfreie Kontaktmodell wird ein Zylinderrollenlager vollständig mit sämtlichen Wälzkontakten für verschiedene Lager- und Einbauspiele berechnet, die Ergebnisse umfassend dargestellt sowie eine analytische Gegenrechnung nach der Hertzschen Theorie ausgeführt, die sehr gute Übereinstimmung mit der numerischen Simulation zeigt. Für das reibungsbehaftete Kontaktmodell wird exemplarisch eine geschrumpfte Welle-Nabe-Verbindung unter Torsion berechnet. Diese wird einer analytischen Lösung sowie verschiedenen 2D-Idealisierungen (ebener Spannungszustand, ebener Dehnungszustand, 2D-Axialsymmetrie) gegenübergestellt.