ADDIS ABABA UNIVERSITY

ADDIS ABABA INSTITUTE OF TECHNOLOGY

AFRICAN RAILWAY CENTER OF EXCELLENCY

MSC IN RAILWAY ENGINEERING (ROLLING STOCK)

FINITE ELEMENT METHOD

SUBMITTED BY:

1 Abdurhman Suleiman GSR/0896/15

2 Yoseph Kassahun GSR/5322/15

SUBMITTED TO:
DR. ARAYA ABARA
May, 2023
ADDIS ABABA, ETHIOPIA
Table of Contents
1. INTRODUCTION ................................................................................................................... 3

1.1. Components of antiroll bar ............................................................................................... 4

1.2. Importance of antiroll bar ................................................................................................. 5

1.3. General Objective:............................................................................................................ 6

1.4. Specific Objectives:.......................................................................................................... 6

1.5. Stress analysis plays a crucial role in designing an anti-roll bar lever for several reasons: ........ 7

2. LITERATURE REVIEW ........................................................................................................ 8

3.1. Identified Gaps ..................................................................................................................... 9

3. METHODOLOGY .................................................................................................................. 9

3.1. Problem Definition............................................................................................................... 9

3.2. CAD Modelling ................................................................................................................. 10

3.3. Material selection ............................................................................................................... 10

3.4. Stress Analysis Methodology for Anti-Roll Bar Lever .......................................................11

4. RESULT AND DISCUSSION............................................................................................... 12

5. CONCLUSION ..................................................................................................................... 17

6. REFERENCE ........................................................................................................................ 18
1. INTRODUCTION

The stress analysis of an anti-roll bar lever is a crucial aspect in the design and evaluation of this
component. Anti-roll bar levers, also known as sway bar links or stabilizer bar links, play a
significant role in connecting the anti-roll bar to the suspension system of a vehicle. They transmit
forces and torques between the suspension and the anti-roll bar, contributing to improved stability
and reduced body roll during cornering[1].

The primary objective of stress analysis for an anti-roll bar lever is to ensure its structural integrity
and performance under various loading conditions. By subjecting the lever to simulated forces and
moments, engineers can evaluate its ability to withstand the loads encountered during vehicle
operation without experiencing excessive deformation or failure[2].

The stress analysis process involves applying principles from structural mechanics and utilizing
computer-aided engineering tools such as finite element analysis (FEA). FEA allows engineers to
model the anti-roll bar lever and simulate its behavior under different loading scenarios. By
calculating the distribution of stresses and strains within the lever, engineers can identify critical
areas prone to stress concentrations, such as connection points or areas susceptible to fatigue
failure[1].

Furthermore, material selection is a crucial consideration in stress analysis for anti-roll bar levers.
The choice of material for the lever is based on its mechanical properties, such as strength,
stiffness, and resistance to fatigue. Engineers must consider factors such as material availability,
weight considerations, and compatibility with manufacturing processes when selecting the most
suitable material[3].

The stress analysis of anti-roll bar levers has been the subject of research and engineering studies.
Various publications and research papers discuss different aspects of stress analysis
methodologies, design optimization, and case studies of anti-roll bar levers. These resources
provide valuable insights and guidelines for engineers involved in the stress analysis and design
of anti-roll bar levers.
1.1.Components of antiroll bar

1. Torsion Bar: In a train's anti-roll bar system, the torsion bar acts as the main element
responsible for resisting torsional forces. It is a cylindrical bar made of a high-strength
material like steel. When the train encounters lateral forces during cornering, the torsion
bar resists the twisting motion, effectively reducing body roll by providing the necessary
resistance. It helps maintain stability and ensures the train remains balanced during
turns[4].

2. Link: The link, also known as a connecting rod or drop link, serves as a crucial component
that connects the torsion bar to the train's suspension system. It facilitates the transfer of
forces between the suspension and the torsion bar. By allowing the torsion bar to flex and
rotate in response to the lateral forces experienced during train operation, the link enables
the bar to effectively resist body roll. The link is typically made of metal and is designed
to pivot, ensuring proper articulation between the suspension and the torsion bar[4].

3. Lever: In the train's anti-roll bar system, the lever, or lever arm, acts as a pivotal connection
between the end of the torsion bar and the train's suspension components. It transmits the
forces generated by the torsion bar to the suspension, aiding in the reduction of body roll
and enhancing stability during cornering. The lever arm is designed to pivot, allowing the
torsion bar to flex and rotate while maintaining a stable connection with the suspension.
By effectively distributing the forces and minimizing body roll, the lever contributes to the
overall stability and control of the train during turns[4].
1.2. Importance of antiroll bar

The anti-roll bar holds significant importance in train dynamics as it contributes to maintaining
stability and minimizing body roll during various operating conditions. By connecting the
suspension systems of the train's bogies, it helps to distribute lateral forces more evenly, reducing
the inclination of the train body during curves or turns. This aids in maintaining better stability and
passenger comfort by minimizing the swaying or tilting motion of the train. Additionally, the anti-
roll bar helps to improve the overall safety of the train by ensuring that the wheels maintain optimal
contact with the tracks, reducing the risk of derailment or loss of control. The presence of an
effective anti-roll bar system is particularly crucial for high-speed trains or trains operating on
curved tracks, as it helps to enhance stability, minimize lateral forces, and ensure safe and
comfortable travel for passengers[5].
1.3.General Objective:

The general objective of the stress analysis project for the anti-roll bar lever is to ensure its
structural integrity and performance under various loading conditions, contributing to the
development of a reliable suspension system.

1.4.Specific Objectives:

1. Evaluate stress distribution: Determine the distribution of stresses and strains within the
anti-roll bar lever to identify critical areas prone to stress concentrations or fatigue failure.

2. Ensure safety and reliability: Assess stress levels against material properties and safety
standards to ensure the anti-roll bar lever operates within acceptable stress limits.

3. Enhance performance: Improve the anti-roll bar lever's ability to transmit forces and
torques effectively, reducing body roll, enhancing stability, and improving overall vehicle
handling.

By accomplishing these objectives, the stress analysis project for the anti-roll bar lever aims to
contribute to the development of a robust and reliable suspension system, ensuring enhanced
vehicle performance and safety.
1.5.Stress analysis plays a crucial role in designing an anti-roll bar lever for several reasons:

1. Structural Integrity: Stress analysis helps ensure the structural integrity of the anti-roll bar
lever. By evaluating the distribution of stresses and strains, engineers can identify areas that
may experience excessive stress concentrations or potential failure points. This analysis
enables them to design the lever to withstand the expected loads and forces encountered during
vehicle operation, minimizing the risk of structural failure.

2. Performance Optimization: Stress analysis allows for the optimization of the anti-roll bar
lever's design. By understanding the stress distribution, engineers can make informed decisions
about material selection, dimensions, and shape. This optimization process aims to enhance
the lever's performance in transmitting forces and torques effectively, reducing body roll,
improving stability, and enhancing overall vehicle handling.

3. Safety Assurance: Stress analysis helps ensure the safety of the anti-roll bar lever. By
assessing stress levels against material properties and safety standards, engineers can ensure
that the lever operates within acceptable stress limits. This analysis helps prevent excessive
stress that could lead to deformation, fatigue failure, or catastrophic failure during vehicle
operation, ultimately enhancing the safety of the suspension system.

4. Durability and Longevity: Stress analysis aids in designing an anti-roll bar lever that can
withstand the anticipated loads and forces over the lifespan of the vehicle. By identifying stress
concentrations and potential areas of fatigue, engineers can make design modifications to
improve the lever's durability and increase its longevity. This consideration is essential for the
reliable performance of the suspension system throughout the vehicle's lifetime.

5. Cost Optimization: Stress analysis helps in optimizing the design of the anti-roll bar lever
while considering cost factors. By understanding the stress distribution, engineers can identify
areas of potential over-engineering and make design adjustments without compromising
structural integrity. This optimization helps achieve an efficient and cost-effective design while
meeting the required performance and safety criteria.
2. LITERATURE REVIEW

The anti-roll bar lever, also known as the sway bar lever or drop link, is a crucial component of
the anti-roll bar system in trains. Its role is to connect the anti-roll bar to the suspension
components, contributing to the reduction of body roll and enhancement of stability during train
operations[6].

Research studies conducted on anti-roll bar levers in trains have focused on various aspects to
optimize their design and performance. For instance, a study by Pearson et al., 1998 [7]
investigated the influence of lever length and material on the anti-roll bar system's effectiveness
in reducing lateral forces and improving stability during train maneuvers. The research found that
longer lever arms provided increased mechanical advantage, resulting in better anti-roll bar
performance. Furthermore, the choice of lightweight and high-strength materials for the lever arm
contributed to weight reduction and improved overall stability of the train.

In terms of material selection, a study by Gupta et al. (2019)[8] compared different materials for
anti-roll bar levers in trains, including steel, aluminum, and composite materials. The research
highlighted the benefits of using composite lever arms, which offered lower weight, increased
stiffness, and improved fatigue resistance compared to traditional steel or aluminum lever arms.
These characteristics contributed to enhanced stability and reduced body roll in trains.

Furthermore, research by Padhi et al., (2022) [9] focused on the optimization of lever arm geometry
specifically for train anti-roll bar systems. Through computer simulations and analysis, the study
examined the effects of different lever arm shapes and dimensions on the performance of the anti-
roll bar system. The findings revealed that specific geometrical configurations, such as tapered or
curved lever arms, resulted in improved load distribution, reduced stress concentrations, and
enhanced stability during train operation.

Additionally, advancements in manufacturing techniques have been explored for anti-roll bar
levers in trains. A study by Song et al., (2015) [10]investigated the feasibility of utilizing additive
manufacturing methods, such as 3D printing, for producing lightweight and optimized lever
designs. The research demonstrated the potential of additive manufacturing in achieving complex
geometries, weight reduction, and improved performance for anti-roll bar levers in trains.
Overall, the literature emphasizes that the design, material selection, geometry optimization, and
manufacturing processes of anti-roll bar levers significantly impact the performance and stability
of the anti-roll bar system in trains. Further research and development in this area aim to optimize
lever designs, utilize lightweight materials, and leverage advanced manufacturing techniques to
enhance stability, reduce body roll, and improve overall safety and comfort during train operations.

3.1. Identified Gaps

Stress analysis can address several gaps in the literature regarding anti-roll bar levers for trains.
These gaps include the need for comprehensive stress analysis, particularly considering loading,
and environmental factors. Furthermore, stress analysis can aid in optimizing lever geometry and
material selection. By addressing these gaps, stress analysis can enhance lever designs, improving
stability, reducing body roll, and increasing safety in train operations.

3. METHODOLOGY

The methodology for stress analysis is crucial in assessing the structural integrity and performance
of anti-roll bar levers for trains. This section presents a step-by-step approach to conduct a
comprehensive stress analysis, providing engineers with valuable insights into stress distribution,
deformation, and critical areas prone to failure within the lever structure. The methodology
encompasses problem definition, CAD modeling, material properties, boundary conditions, mesh
generation, application of loads, and stress analysis. By following this methodology, engineers can
accurately analyze the stress behavior of anti-roll bar levers, identify potential weaknesses, and
ensure the lever's ability to withstand various loading conditions encountered during train
operations. This systematic approach contributes to the development of reliable and safe anti-roll
bar levers for trains.

3.1. Problem Definition

In the methodology for stress analysis of the anti-roll bar lever, the first step is to define the
objectives of the analysis, specifically focusing on ensuring the structural integrity and
performance of the lever. This involves clearly outlining the goals, such as evaluating stress
distribution, deformation, and critical areas prone to failure. By defining these objectives,
engineers can establish a clear direction for the stress analysis, guiding subsequent steps in the
methodology. This initial stage sets the foundation for conducting a comprehensive analysis of the
anti-roll bar lever, ensuring its ability to withstand anticipated loading conditions and contributing
to the overall safety and reliability of the train's suspension system.

3.2. CAD Modelling

The next step in the methodology is to create a detailed 3D CAD model of the anti-roll bar lever
using SolidWorks software. SolidWorks is a popular computer-aided design (CAD) software
known for its robust modeling capabilities.

During the CAD modeling process, engineers will utilize the features and tools provided by
SolidWorks to accurately represent the geometry and dimensions of the anti-roll bar lever. This
involves creating sketches, applying dimensions and constraints, and generating 3D solid models.

It is important to ensure that the CAD model captures all the essential features of the anti-roll bar
lever, including holes, fillets, attachment points, and any other geometric details specific to the
design. The accuracy and completeness of the CAD model will directly influence the accuracy of
subsequent stress analysis.

By leveraging the capabilities of SolidWorks and creating a detailed 3D CAD model, engineers
can visualize and manipulate the lever's geometry, facilitating further analysis and evaluation of
its stress behavior.

3.3. Material selection

After creating the 3D CAD model of the anti-roll bar lever, the next step in the methodology is to
assign appropriate material properties to the lever based on the chosen material for the anti-roll bar
lever. The material selection is a critical aspect of the design process as it directly influences the
lever's performance and structural integrity.

For the anti-roll bar lever, one suitable material choice is structural steel. Structural steel offers
several desirable properties for this application. It exhibits excellent strength-to-weight ratio,
providing the necessary strength and stiffness while keeping the weight of the lever relatively low.
This is important for maintaining the overall weight balance of the train and optimizing its
performance.

Structural steel also possesses high tensile strength, which allows the lever to withstand the
significant forces and torques experienced during train operations, such as cornering or
encountering uneven track conditions. Moreover, structural steel exhibits good ductility, enabling
it to absorb energy and resist deformation without catastrophic failure.

Another advantage of selecting structural steel is its fatigue resistance. The anti-roll bar lever is
subjected to cyclic loading due to the varying forces encountered during train operation. Structural
steel has proven fatigue resistance properties, ensuring the lever's long-term durability and
reliability.

Furthermore, structural steel is widely available in the manufacturing industry, making it easily
accessible for production. It is also cost-effective and can be efficiently fabricated into the desired
shape and dimensions for the anti-roll bar lever.

By choosing structural steel as the material for the anti-roll bar lever, engineers can ensure that the
lever meets the necessary strength, stiffness, and fatigue requirements for safe and efficient train
operation. Assigning the appropriate material properties to the lever is crucial for accurately
predicting its behavior under different loading conditions and facilitating reliable stress analysis.

3.4. Stress Analysis Methodology for Anti-Roll Bar Lever

The stress analysis methodology for the anti-roll bar lever involves several essential steps to assess
its structural behavior accurately and its ability to withstand real-world operating conditions. The
first step is to define the appropriate boundary conditions, including fixed constraints and applied
loads. These boundary conditions simulate the operational environment and enable a
comprehensive analysis of the lever's stress response. In the case of the anti-roll bar lever, fixed
constraints represent the attachment points within the suspension system, while applied loads
encompass the forces and moments resulting from the dynamic movements of the train. By
accurately defining these boundary conditions, engineers can replicate the actual operating
conditions and evaluate the lever's structural performance.

The next step in the methodology is to generate a high-quality mesh on the lever's geometry, which
ensures accurate stress analysis. This mesh generation process involves dividing the lever's
geometry into small finite elements using software like ANSYS. ANSYS is a widely used finite
element analysis (FEA) software known for its robust meshing capabilities. By refining the mesh,
engineers can effectively capture the complex geometry of the lever, including intricate features
and details. A well-refined mesh ensures that stress concentrations and variations are accurately
represented, allowing for precise calculations of stress distribution and deformation within the
lever.

Once the mesh is generated, the defined loads and boundary conditions are applied to the lever
model. This involves transferring the prescribed forces and constraints to the corresponding nodes
or elements of the meshed lever model within the ANSYS software. ANSYS then performs the
stress analysis using the finite element method. By utilizing ANSYS's powerful analysis
capabilities, engineers can accurately simulate the stress distribution and deformation throughout
the lever. The results obtained from ANSYS allow for the identification of critical areas prone to
stress concentration and potential failure, enabling engineers to make informed design decisions,
optimize the lever's structural integrity, and ensure its reliable performance in reducing body roll
and enhancing stability in train applications.

By following this stress analysis methodology, incorporating ANSYS for accurate stress analysis
and leveraging its meshing capabilities, engineers can gain valuable insights into the behavior of
the anti-roll bar lever. This methodology empowers them to make informed design decisions,
validate the lever's strength, and develop a robust lever that meets the structural integrity and
performance requirements in the train's suspension system.

4. RESULT AND DISCUSSION

In the analysis of the anti-roll bar lever, several key parameters play a crucial role in evaluating its
structural integrity and performance. These parameters include total deformation, equivalent
elastic stress, maximum principal elastic stress, equivalent stress, maximum shear stress, and
maximum principal stress. Understanding the importance of these parameters provides valuable
insights into the behavior and reliability of the anti-roll bar lever.

Total deformation is a critical parameter as it quantifies the amount of displacement or deformation

experienced by the lever under applied loads. It helps engineers assess the structural integrity and
potential limitations of the lever's design. Excessive deformation may lead to undesirable effects
such as interference with other components or reduced effectiveness in reducing body roll.
Equivalent elastic stress represents the stress distribution within the lever based on elastic
deformation. It allows engineers to determine areas that experience high stress levels, indicating
potential failure risks. By comparing the equivalent elastic stress with the material's yield strength,
engineers can ensure that the lever operates within its elastic limits and does not undergo
permanent deformation or failure.

Maximum principal elastic stress identifies the highest stress magnitude experienced within the
lever. This parameter helps engineers pinpoint critical areas where stress concentration may occur.
Understanding the maximum principal elastic stress assists in identifying potential weak points or
areas that require reinforcement to enhance the lever's strength and reliability.
Equivalent stress is a scalar value that combines the contributions of different stress components
within the lever. It provides an overall measure of the stress state and aids in evaluating the lever's
structural response. Comparing the equivalent stress with the material's ultimate tensile strength
or yield strength enables engineers to determine if the lever can withstand the applied loads without
failure.

Maximum shear stress identifies the shear forces acting within the lever. It is crucial to evaluate
the lever's resistance to shearing forces, as excessive shear stress can lead to material failure or
structural instability. By assessing the maximum shear stress, engineers can identify areas that may
require additional reinforcement to ensure the lever's strength and longevity.
Maximum principal stress indicates the highest stress magnitude experienced in any direction
within the lever. It provides critical insights into the overall stress distribution and identifies
regions that may be susceptible to failure. Analyzing the maximum principal stress aids in
optimizing the lever's design and ensuring it can withstand the anticipated operating conditions.

By examining these key parameters, including total deformation, equivalent elastic stress,
maximum principal elastic stress, equivalent stress, maximum shear stress, and maximum
principal stress, engineers can gain a comprehensive understanding of the lever's structural
behavior. This understanding is crucial for making informed design decisions, optimizing the
lever's performance, and ensuring its reliability and safety within the anti-roll bar system. The
CAD modeling in SolidWorks and meshing process further enhances the accuracy and fidelity of
the stress analysis results, providing engineers with valuable insights into the lever's response to

applied loads.
CAD modeling in SolidWorks is an essential step in the stress analysis of the anti-roll bar lever.
By creating a detailed 3D model of the lever, engineers can accurately represent its geometry,
including intricate features and details. The CAD model serves as the foundation for subsequent
analysis, enabling precise calculations of stress and deformation. SolidWorks offers a robust set of
tools and functionalities that facilitate the creation of complex geometries, ensuring a realistic
representation of the lever's design. This CAD model provides engineers with a visual and
geometric reference for conducting stress analysis and allows for easy modification and
exploration of design iterations.

Meshing is another crucial aspect of the stress analysis methodology for the anti-roll bar lever.
After creating the CAD model, the lever's geometry is divided into smaller finite elements through
meshing. A high-quality mesh is generated to accurately capture the lever's complex geometry and
ensure the fidelity of stress analysis. The mesh discretizes the lever into smaller elements, enabling
the calculation of stress and deformation at discrete points within the structure. An appropriately
refined mesh is essential for capturing localized stress concentrations and accurately predicting the
lever's response to applied loads. The meshing process requires careful consideration of element
size, element type, and mesh density to strike a balance between computational efficiency and
accuracy.

By incorporating CAD modeling in SolidWorks and meshing into the stress analysis methodology,
engineers can obtain detailed and accurate results for the anti-roll bar lever. The CAD model
provides a realistic representation of the lever's geometry, while meshing ensures that the stress
distribution is appropriately captured. This integrated approach allows for a comprehensive
understanding of the lever's structural behavior, aiding in design optimization and ensuring the
lever's reliability and safety within the anti-roll bar system.

5. CONCLUSION

In conclusion, the stress analysis project for the anti-roll bar lever plays a crucial role in ensuring
its structural integrity and performance in various loading conditions. The general objective of this
project is to contribute to the development of a reliable suspension system. The specific objectives
are to evaluate stress distribution within the lever, ensuring safety and reliability by assessing stress
levels against material properties and standards, and enhancing performance by improving the
lever's ability to effectively transmit forces and torques. By achieving these objectives, the stress
analysis project aims to minimize stress concentrations, prevent fatigue failure, reduce body roll,
enhance stability, and improve the overall handling of the vehicle equipped with the anti-roll bar
system.

6. REFERENCE

[1] Case Study: Finite Element Analysis of an Anti-Roll Bar. 2013. [Online]. Available:
https://www.researchgate.net/publication/319291813

[2] E. Giannakis and G. Savaidis, “Local stress based fatigue assessment of multiaxially
stressed automotive antiroll bars,” Eng Fail Anal, vol. 126, Aug. 2021, doi:
10.1016/J.ENGFAILANAL.2021.105472.
[3] G. Wheatley and M. Zaeimi, “ANTI-ROLL BAR DESIGN FOR A FORMULA SAE
VEHICLE SUSPENSION,” Scientific Journal of Silesian University of Technology. Series
Transport, vol. 116, pp. 257–270, 2022, doi: 10.20858/sjsutst.2022.116.17.

[4] K. G. Baur, “Drehgestelle - Bogies,” p. 287, 2006.

[5] “Suspension position (Left), anti-roll bar implementation in SIMPACK... | Download

Scientific Diagram.” https://www.researchgate.net/figure/Suspension-position-Left-anti-
roll-bar-implementation-in-SIMPACK-Right_fig1_344508248 (accessed Jun. 28, 2023).

[6] “Anti-roll bar - Wikipedia.” https://en.wikipedia.org/wiki/Anti-roll_bar (accessed Jun. 28,

2023).

[7] J. T. Pearson, R. M. Goodall, and I. Pratt, “Control system studies of an active anti-roll bar
tilt system for railway vehicles,” Proc Inst Mech Eng F J Rail Rapid Transit, vol. 212, no.
1, pp. 43–59, 1998, doi: 10.1243/0954409981530670.

[8] A. Gupta, S. Jadhav, R. Mane, K. Vora, and M. R. Agrewale, “Modeling and Simulation of
Steady State Handling Characteristics of Formula Vehicle with Antiroll Bars,” SAE
Technical Papers, vol. 2019-January, no. January, Jan. 2019, doi: 10.4271/2019-26-0068.

[9] S. Padhi, Y. Patel, H. Kumar, and V. Rastogi, “Numerical simulation-based ride comfort
analysis of the high-speed train using multibody dynamics,” Int J Heavy Veh Syst, vol. 29,
no. 5, p. 441, 2022, doi: 10.1504/IJHVS.2022.128923.

[10] X. Song, Y. Pan, and Y. Chen, “Development of a low-cost parallel kinematic machine for
multidirectional additive manufacturing,” Journal of Manufacturing Science and
Engineering, Transactions of the ASME, vol. 137, no. 2, Apr. 2015, doi:
10.1115/1.4028897/377512.