Study of Failure in Center Pivot Assembly of of Casnub Bogie Using FEA Techniques and nd Correlating the Results with

Actual. Further Extending Study to Recommend the t Design Changes.

S.K. Khare
AGM-Rolling Stock Larsen & Toubro Limited 12/4, Mathura Road Faridabad-121003 (HR, IN)

Amardeep Singh
Asst. Manager Larsen & Toubro Limited 12/4, Mathura Road Faridabad-121003 (HR, IN)

Rajan Raheja
Asst. Manager Larsen & Toubro Limited 12/4, Mathura Road Faridabad-121003 121003 (HR, IN)

Keywords: Failure, Optimization, Non-linear, Non Center pivot top.

Abstract It has been observed that there are frequent failures in center pivot of casnub bogie. This results in an early removal of wagon from service. Normal service life of a wagon is 2years between two consecutive ROH (Routine Overhauling) but due to failure in center cen pivot these wagons are removed causing low productivity and high maintenance mainten cost. Study was done to find possible areas of failure of pivot assembly and it was concluded that the maximum no of failures were due to failure of center pivot top. Existing design of center pivot top was analyzed by using FEA techniques and a correlation correlation was found with the actual. Study was further extended to find new and better design for the center pivot. Same boundary conditions were used and by varying vary material properties & geometry, optimal design was found.

Introduction Study was done to find possible areas of failure of pivot assembly and it was concluded that the maximum no of failures were due to failure of center pivot top.

Simulation Driven Innovation

Process Methodology (details with figures) Data collection: Data was collected from various rehabilitation units and different research institutes. institutes It was found that majority of failures (about 95%) was due to cracking of center pivot top. The location and direction of crack was studied.

Simulation Driven Innovation

3D model of center pivot was made.

Step file was created for transferring the geometry to Hypermesh.

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FE model creation Import of STEP solid from CAD. Geometric cleanup (using Auto cleanup) Defining Rigids igids for defining constraints.

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Iterations with varying loading condition to simulate the actual breakage.

Iterations were done by varying the Geometry of pivot top to get the Optimization profile.

Simulation Driven Innovation

Results & Discussions A basic correlation was found between the actual fracture and the simulation results. These results were then used to further optimize the existing design of center pivot top.

Benefits Summary The results found can be extended to design new and improved improved designs of pivot top.

Challenges Finding the actual loading and boundary conditions, because in actual working scenario there are numerous forces which are acting due to motion of the system. Finding the correlation between the actual crack formation and the FEA simulation.

Future Plans We will try to use the Multibody techniques to accrue the more accurate forces from the system and further use these forces to do a reliability study in the pivot assembly.

Conclusions By using the simple concepts of FEA we were able to find an equivalent load which can be used for simulating the actual field failure.

Simulation Driven Innovation