Report. No. MP.MISC-271 JUNE-2011

Transcription

1 FINITE ELEMENT ANALYSIS OF UNDERFRAME FOR 5500 HP WDG5 LOCOMOTIVE P.C.S.Yadav Sse/Mp Directorate Research Designs & Standards Organisation Manak Nagar, Lucknow R. K. Misra Ade/Mp Directorate Research Designs & Standards Organisation Manak Nagar, Lucknow Anurag Mishra Dy.Dir/Mp Directorate Research Designs & Standards Organisation Manak Nagar, Lucknow Butchi Babu Nalluri Design Engineer/Emd Research Designs & Standards Organisation Manak Nagar, Lucknow Anil Kumar Director - Motive Power Directorate/RDSO Research Designs & Standards Organisation Manak Nagar, Lucknow Report. No. MP.MISC-271 JUNE-2011 CONTENTS Page No. 1.0 Executive Summary Objective Background Modeling Details Modeling Assumptions Material Properties and section properties Locomotive Underframe Description Model Verification (1g Vertical) Static Analysis RDSO and EMD Load Cases RDSO/EMD Yield Load Cases g vertical load case gVe+ Drag load case g Ve + Buff loadcase g Vertical loadcase Simulation Driven Innovation 1

2 g Ve + (+) 3g longitudinal loadcase g Ve + (-) 3g longitudinal loadcase g Ve + (+) 1.5g lateral loadcase g Ve + (-) 1.5g lateral loadcase g Ve KN buffload at buffer loadcase g Ve KN buffload at 50 mm below buffer loadcase g Ve + lifting at cabend jack and cabend bogie attach to underframe other bogie on rail g Ve + lifting at radend jack and radend bogie attach to underframe other bogie on rail g Ve + lifting at cabend and cabend bogie attach to underframe other bogie on rail g Ve + lifting at radend and radend bogie attach to underframe other bogie on rail Both end lifting at jack with lifting load of 1.5x (locomotive weight) g Ve + 3 TE tractive drag loadcase Pivot pin load (+) 300 kn/(-)270 kn loadcase Pivot pin load 3.0g long of bogie weight Anti-climber load of 45300kg verticle loadcase kn force at buffer diagonaly 5.2 RDSO/EMD Fatigue Load Cases g Ve + (±) 0.35 loadcase g Ve + (±).25g Ve + (±).5g Lateral g Ve + (±).25g Ve + (±).5g Longitudinal 5.3 RDSO/EMD Torque Loads Underframe twist analysis for engine torque load of N-m. 6.0 Modal Analysis Underframe Natural Frequencies 7.0 Results and discussions Conclusions 15 List of Tables:- Table1: Material properties used in the Underframe structure 8 Table2: Underframe Plate Thickness 9 Table3: Locomtive weight Distribution Between Components 10 Table4: Underframe Modal Analysis, Natural Frequencies 12 Table5: Max. Stress, Max. Displacement 13 List of Figures Fig 1: Locomotive layout 16 Fig 2: The Underframe Structure unigraphics 3D image Top View 16 1

3 Fig 3: The Underframe Structure unigraphics 3D image Bottom View 17 Fig 4: The Underframe Cross-section Details(Dimensions are in mm) 17 Fig 5: Finite Element Model of locomotive underframe 18 Fig. 6 Vertical Displacement, Draft Load 19 Fig. 7 Von Mises Stress of UF Top Plate, Draft Load 19 Fig. 8 Von Mises Stress of UF Top Plate #2 End Side, Draft Load 20 Fig. 9 Von Mises Stress of UF Bottom Plate, Draft Load 20 Fig. 10 Von Mises Stress of UF Bottom Plate #2 End Side, Draft Load 21 Fig. 11 Von Mises Stress of Center Sill #2 End Side, Draft Load 21 Fig. 12 Draft Gear Pocket, Mesh, Loading and Boundary Conditions 22 Fig. 13 Draft Gear Pocket, von Mises stress in the Bottom Plate 23 Fig. 14 Draft Gear Pocket von Mises stress Distribution, Draft Load 23 Fig. 15 Underframe Load Distribution Buff Load 24 Fig. 16 Vertical Displacement Buff Load 24 Fig. 17 Von Mises Stress in the top Plate Buff Load 25 Fig. 18 Von Mises Stress in the Top Plate #1 End Side Buff Load 25 Fig. 19 Von Mises Stress in the Top Plate #2 End Side Buff Load 26 Fig. 20 Von Mises Stress in the Bottom Plate Buff Load 26 Fig. 21 Von Mises Stress in the Bottom Plate #1 End Side Buff Load 27 Fig. 22 Von Mises Stress in the Center Sill #1 End Side Buff Load 27 Fig. 23 Von Mises Stress in the Side Sill #1 End Side Buff Load 28 Fig.24 Von Mises Stress in the Top Plate #2 End Side Buff Load 28 Fig. 25 Draft Gear Pocket Von Mises Stress Bottom Plate Buff Load 29 Fig. 26 Draft Gear Pocket Von Mises Stress Buff Load 29 Fig. 27 Underframe Load Distribution g Vertical loadcase 30 Fig. 28 Vertical Displacement g Vertical loadcase 30 Fig. 29 Von Mises Stress in the top Plate g Vertical loadcase 31 Fig. 30 Von Mises Stress in the Top Plate #1 End Side 5.1.4, 2.0g Vertical loadcase 31 Fig. 31 Von Mises Stress in the Top Plate #2 End Side 5.1.4, 2.0g Vertical loadcase 32 Fig. 32 Von Mises Stress in the Bottom Plate 5.1.4, 2.0g Vertical loadcase 32 Fig. 33 Underframe Load Distribution g Ve + (+) 3g longitudinal loadcase 33 Fig. 34 Vertical Displacement g Ve + (+) 3g longitudinal loadcase 33 Fig. 35 Von Mises Stress in the top Plate 5.1.5, 1.0g Ve + (+) 3g longitudinal loadcase 34 Fig. 36 Von Mises Stress in the Top Plate #1 End Side 5.1.5, 1.0g Ve + (+) 3g longitudinal loadcase. 34 Fig. 37 Von Mises Stress in the Top Plate #2 End Side 5.1.5, 1.0g Ve + (+) 3g longitudinal loadcase 35 Fig. 38 Von Mises Stress in the Bottom Plate g Ve + (+) 3g longitudinal loadcase 35 Fig. 39 Underframe Load Distribution g Ve + (-) 3g longitudinal loadcase 36 Fig. 40 Vertical Displacement g Ve + (-) 3g longitudinal loadcase 36 Fig. 41 Von Mises Stress in the top Plate 5.1.5, 1.0g Ve + (-) 3g longitudinal loadcase 37 Fig. 42 Von Mises Stress in the Top Plate #1 End Side 5.1.5, 1.0g Ve + (-) 3g longitudinal loadcase 37 2

4 Fig. 43 Von Mises Stress in the Top Plate #2 End Side 5.1.5, 1.0g Ve + (-) 3g longitudinal loadcase 38 Fig. 44 Von Mises Stress in the Bottom Plate g Ve + (-) 3g longitudinal loadcase 38 Fig. 45 Underframe Load Distribution g Ve + (+) 3g lateral loadcase 39 Fig. 46 Vertical Displacement g Ve + (+) 1.5g lateral loadcase 39 Fig. 47 Von Mises Stress in the top Plate 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase 40 Fig. 48 Von Mises Stress in the Top Plate #1 End Side 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase 40 Fig. 49 Von Mises Stress in the Top Plate #2 End Side 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase 41 Fig. 50 Von Mises Stress in the Bottom Plate 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase 41 Fig. 51 Underframe Load Distribution 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 42 Fig. 52 Vertical Displacement 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 43 Fig. 53 Von Mises Stress in the top Plate 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 43 Fig. 54 Von Mises Stress in the Top Plate #1 End Side 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 44 Fig. 55 Von Mises Stress in the Top Plate #2 End Side 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 44 Fig. 56 Von Mises Stress in the Bottom Plate 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 45 Fig. 57 Underframe Load Distribution g Ve KN buffload at buffer loadcase 46 Fig. 58 Displacement g Ve KN buffload at buffer loadcase 46 Fig. 59 Von Mises Stress in the top Plate 5.1.9, 1.0g Ve KN buffload at buffer loadcase 47 Fig. 60 Von Mises Stress in the Bottom Plate 5.1.9, 1.0g Ve KN buffload at buffer loadcase 47 Fig. 61 Underframe Load Distribution , 1.0g Ve KN buffload at 50 mm below buffer loadcase 48 Fig. 62 Displacement g Ve KN buffload at 50 mm below buffer loadcase 48 Fig. 63 Von Mises Stress in the top Plate , 1.0g Ve KN buffload at 50 mm below buffer loadcase 49 Fig. 64 Von Mises Stress in the Bottom Plate g Ve KN buffload at 50 mm below buffer loadcase 50 Fig. 65 Displacement g Ve + lifting at cabend jack and cabend bogie attach to underframe other bogie on rail 51 Fig. 66 Von Mises Stress in the top Plate , 1.0g Ve + lifting at cabend jack and cabend bogie attach to underframe other bogie on rail 52 Fig. 67 Von Mises Stress in the Bottom Plate , 1.0g Ve + lifting at cabend jack and cabend bogie attach to underframe other bogie on rail 52 Fig. 68 Displacement g Ve + lifting at radend jack and radend bogie attach to underframe other bogie on rail 53 Fig. 69 Von Mises Stress in the top Plate , 1.0g Ve + lifting at radend jack and 3

5 radend bogie attach to underframe other bogie on rail 53 Fig. 70 Von Mises Stress in the Bottom Plate , 1.0g Ve + lifting at radend jack and radend bogie attach to underframe other bogie on rail 54 Fig. 71 Displacement g Ve + lifting at cabend and cabend bogie attach to underframe other bogie on rail 54 Fig. 72 Von Mises Stress in the top Plate , 1.0g Ve + lifting at cabend and cabend bogie attach to underframe other bogie on rail 55 Fig. 73 Von Mises Stress in the Bottom Plate g Ve + lifting at cabend and cabend bogie attach to underframe other bogie on rail 55 Fig. 74 Displacement , 1.0g Ve + lifting at radend and radend bogie attach to underframe other bogie on rail 56 Fig. 75 Von Mises Stress in the top Plate , 1.0g Ve + lifting at radend and radend bogie attach to underframe other bogie on rail 56 Fig. 76 Von Mises Stress in the Bottom Plate , 1.0g Ve + lifting at radend and radend bogie attach to underframe other bogie on rail 57 Fig. 77 Displacement Both end lifting at jack with lifting load of 1.5x (locomotive weight). 57 Fig. 78 Von Mises Stress in the top Plate , Both end lifting at jack with lifting load of 1.5x (locomotive weight). 58 Fig. 79 Von Mises Stress in the Bottom Plate , Both end lifting at jack with lifting load of 1.5x (locomotive weight). 58 Fig. 80 Displacement g Ve + 3 TE tractive drag loadcase 59 Fig. 81 Von Mises Stress in the top Plate , 1g Ve + 3 TE tractive drag loadcase 59 Fig. 82 Von Mises Stress in the Bottom Plate , 1g Ve + 3 TE tractive drag loadcase 60 Fig. 83 Displacement Pivot pin load (+) 300 kn/(-)270 kn loadcase 61 Fig. 84 Von Mises Stress in the top Plate , Pivot pin load (+) 300 kn/(-)270 kn loadcase 62 Fig. 85Von Mises Stress in the Bottom Plate , Pivot pin load (+) 300 kn/(-)270 kn loadcase 63 Fig. 86 Displacement , Pivot pin load 3.0g long of bogie weight 64 Fig. 87 Von Mises Stress in the top Plate , Pivot pin load 3.0g long of bogie weight 64 Fig. 88Von Mises Stress in the Bottom Plate , Pivot pin load 3.0g long of bogie weight 65 Fig. 89 Displacement , Anti-climber load of 45300kg verticle loadcase 66 Fig. 90 Von Mises Stress in the top Plate , Anti-climber load of 45300kg verticle loadcase 66 Fig. 91Von Mises Stress in the Bottom Plate , Anti-climber load of 45300kg verticle loadcase 67 Fig. 92 Displacement 5.2.1, 1.0g Ve + (±) 0.35 loadcase 68 Fig. 93 Von Mises Stress in the top Plate 5.2.1, 1.0g Ve + (±) 0.35 loadcase 69 Fig. 94Von Mises Stress in the Bottom Plate 5.2.1, 1.0g Ve + (±) 0.35 loadcase 70 Fig. 95 Displacement 5.2.2, 1.0g Ve + (±).25g Ve + (±).5g Lateral 71 Fig. 96 Von Mises Stress in the top Plate 5.2.2, 1.0g Ve + (±).25g Ve + (±).5g Lateral 4

6 72 Fig. 97Von Mises Stress in the Bottom Plate 5.2.2, 1.0g Ve + (±).25g Ve + (±).5g Lateral 73 Fig. 98 Displacement 5.2.3, 1.0g Ve + (±).25g Ve + (±).5g Longitudinal 74 Fig. 99 Von Mises Stress in the top Plate 5.2.3, 1.0g Ve + (±).25g Ve + (±).5g Longitudinal 75 Fig. 100Von Mises Stress in the Bottom Plate 5.2.3, 1.0g Ve + (±).25g Ve + (±).5g Longitudinal 76 Fig. 101 Displacement 5.3.1, Underframe twist analysis for engine torque load of N-m. 77 Fig. 102 Von Mises Stress in the top Plate 5.3.1, Underframe twist analysis for engine torque load of N-m. 78 Fig. 103 Von Mises Stress in the Bottom Plate Underframe twist analysis for engine torque load of N-m. 79 Fig. 104 Vertical Displacement g Ve kn force on diagonal buffer Loadcase 79 Fig. 105 Vertical stress g Ve kn 400 kn force on diagonal buffer Loadcase 80 Fig. 106 Vertical Displacement g Ve kn force on alternate diagonal buffer loadcase 80 Fig. 107 Vertical stress g Ve kn force on alternate diagonal buffer loadcase 81 Fig. 108 Underframe Natural Frequenci EXECUTIVE SUMMARY Research Designs & Standards Organisation (RDSO) has designed and developed 5500 HP WDG5 locomotive in consultation with EMD. This locomotive has a platform type of locomotive design. All the equipment loads are transferred through the underframe structure to the bogies and rails. The carbody structure supports cab equipment, dynamic brake, radiators, cooling fans, electrical components, sand, etc. The carbody structure has two slip joints. Draft and buff loads are reacted by the underframe structure. Since WDG5 locomotive development work is conducted in metric units system, all the displacements and stress distributions are presented in Metric units system. The underframe was analyzed by using the design criteria provided by RDSO and Electro-Motive Diesel Inc. internal design criteria. The locomotive has been analyzed for RDSO/EMD linear, fatigue load cases and one load case for engine torque. The underframe structure was designed for a locomotive running with three units. All the locomotive components were modeled in Hypermesh and solved in Radioss. The von Mises equivalent stress on the underframe structure for both RDSO/EMD yield load cases were lower than the material yield stress. The underframe structure satisfied the design criteria for the RDSO/EMD fatigue load cases. The natural frequencies of the underframe structure fulfilled EMD Vehicle Technical Specification requirements. The underframe structure meets all the 5

7 design requirements. 2.0 OBJECTIVE- The underframe structure should be designed to withstand the operating loads condition for the RDSO operation as specified in the RDSO/EMD Technical Specifications. Manufacturing method is to comply with all relevant codes of practice for the fabrication of structures subjected to high levels of fatigue loadings. The underframe structure must be designed using finite element method. The finite element model must include primary structural members like draft gear pocket, pivot pin, fuel tank, cross bearers (stiffeners) etc. The underframe structure must also be designed to withstand without damage, forces exerted by the dynamic loadings of the locomotive operation. The design of the underframe structure must be validated for all the RDSO/ EMD design load cases. This report captures the analytical results using Finite Element Method and full-scale locomotive vibration test modal results of a similar locomotive. 3.0 BACKGROUND The WDG5 locomotive is a diesel-electric locomotive with 5500 Horsepower and six AC traction motors. The approximate weight of the locomotive is 134 tonnes. This locomotive is equipped with (a) Cab, (b) Electrical Control Locker, (c) alternator, (d) Engine with electronic unit injection, (e) Equipment Rack, (f) Air Compressor, (g) Cooling Hood with two cooling fans, and two radiators, (h) Dynamic Brake, (i) Draft Gear and Couplers,(j) Two HTSC three motor, three axle bogies, (k) Anti-Climber, (1) Cow Catcher, (m) Two Main Reservoirs, and (n) Blower Motors etc... The locomotive and the equipment layout are shown in the Figure 1. The RDSO-WDG5 locomotive is a platform type locomotive. All the hoods are designed to transfer the equipment load to the underframe. The underframe structure carries all the equipment loads and transfers loads to bogies. The carbody has two slip joints at both ends of the engine hood. 4.0 MODELING DETAILS The underframe structure have been analyzed using HYPERWORKS V 10.0 Finite Element Software. A three dimensional solid geometry of the underframe structure is shown in Figures 2 and 3. The full underframe FEA model contains elements and nodes. The FEA model of underframe has been modeled with shell element, solid element, spring element, mass element and rigid element. Centre pivot pin and jacking pad have been modeled with solid element. The weight of all equipments are included as mass elements. 4.1 MODELING ASSUMPTION The following assumptions are used for the design of the underframe structure :- 1) The Locomotive underframe structure is modeled with shell element. The primary and secondary springs are modeled as spring element and pivot pin, jacking pad as solid element. 6

8 2) Mass element for components like cab, e-locker,inertial hood, engine, equipment Rack, cooling hood, dynamic brake, are included in the model at CG location. 3) The fuel weight is applied as a load on fuel tank sheets for the inertia load cases. 4) The Alternator weight is included as mass element at the center of gravity of the alternator and this mass element is connected to the underframe structure at the alternator attachment bolts. 5) Engine weight is represented with a mass element at centre of gravity of engine 6) The bogies of the locomotive are modeled with mass elements. The bogie side bearer as spring elements. 7) Cab structure and all equipment in the cab is modeled as mass elements. 8) Cooling fans in the cooling hood structure are modeled as mass element. 9) In the equipment rack structure all the components weights are modeled as mass element at center of gravity of equipment weight. 10) Dynamic brake equipment is modeled as a mass element at CG location. 11) Air compressor, Sand weight, Coupler weight, number 2-end Traction Motor blower weight, ballast weight, pipes and cables are modeled as mass elements. 12) The dynamic brake hood and electrical locker structure is modeled with mass elements. 13) Grid, fan and motor is modeled as mass element. 14) Bolted joint of fuel tank are modeled with rigid elements. 4.2 MATERIAL PROPERTIES AND SECTION PROPERTIES The underframe is constructed with SAILMA 350, IS-2062, IS:5986. Properties are given in the Table 1. The plate thicknesses are presented in Table 2. Table 1: Material Properties used in the Underframe Structure Description SAILMA350 IS-2062 Young's Modulus 200 Gpa 210 GPa Poisson's Ratio Density 7800 kg/m"3 7.85E-09 Ton/cubic mm. Yield Stress 350 MPa 250MPa Ultimate Stress MPa 490 MPa Elongation 20% 22mm 7

9 Table 2: Underframe plate thickness Description Bottom Plate Top Plate Centre sill Side sill Floor Plate Bottom Plate Top Plate Bottom Plate Bottom Plate Gusset Bottom Plate Side plate Thickness 40 mm 18 mm 12 mm 10 mm 5 mm 6 mm 3mm 20mm 25mm 32mm 40mm 30mm 4.3 LOCOMOTIVE UNDERFRAME DESCRIPTION The underframe structure supports the following components: Cab, E-Locker, Inertial Hood, Engine Hood, Cooling Hood, and Dynamic Brake Hood, Air Compressor, Equipment Rack, Air Reservoirs, Blowers, Sand, Batteries, Cables, Pipes and all other equipments etc. The underframe structure has been built with two depth of underframe 475mm at end and 620mm in the middle of underframe. Underframe section that serves as the main load carrying member for locomotive. The underframe structure should meet all the design requirements of internal design criteria. 4.4 MODEL VERIFICATION (1g Vertical) The finite element mesh of the locomotive, shown in the Figure 5, is used in the analysis. The underframe structure is connected to the bogies with secondary springs (spring elements). Cab structure, E-Locker structure, and the entire hood structures are included in the analysis. The locomotive is analyzed using gravity loading (1g Vertical) to represent the whole locomotive weight. Radioss is considered for solving the static analysis.the finite element model is verified for mesh connectivity and for proper component weight distribution. The weights of each individual components and the entire locomotive are presented in the Table 3. The estimated total locomotive weight is 134 tonnes. 8

10 Table 3: Locomotive Equipment weight Locomotive Weight Distribution S/No Component Description Weight (kg) 1 Draft Gear & Coupler #1 End and pilot Cab HVC Cabinet (Control Cabinet) Bogie (#1 End) Dynamic Brake Hood Inverter Cabinet (E Locker) TM Blower # Dust Bin / E Locker Blower Toilet APL Alternator Blower Battery Box Alternator Air Brake Reservoir (1/2) Fuel Tank with Fuel Underframe ASM, UDL and other Eq Engine Air Brake Reservoir (2/2) Air Start Reservoir Equipment Rack Air Compressor & Shaft Cooling Fan (1/2) TM Blower # Bogie (#2 End) Cooling System (Radiators, Piping, Water) Cooling Fan (2/2) Air Brake Controller Draft Gear & Coupler #2 End and pilot STATIC ANALYSIS RDSO / EMD LOAD CASES The locomotive underframe has been analyzed for both RDSO and EMD design load cases. RDSO/EMD load cases only include yield, ultimate load cases and fatigue load cases. The locomotive underframe has been analyzed for the following design load cases and results are presented in table-5-9

11 5.1 RDSO/EMD Yield Load Cases g vertical load case gVe+ Drag load case- Drag load 1800 kn g Ve + Buff loadcase- Buff load 4000 kn g Vertical loadcase g Ve + (+) 3g longitudinal loadcase g Ve + (-) 3g longitudinal loadcase g Ve + (+) 1.5g lateral loadcase g Ve + (-) 1.5g lateral loadcase g Ve KN buffload at buffer loadcase g Ve KN buffload at 50 mm below buffer loadcase g Ve + lifting at cabend jack and cabend bogie attach to underframe other bogie on rail g Ve + lifting at radend jack and radend bogie attach to underframe other bogie on rail g Ve + lifting at cabend and cabend bogie attach to underframe other bogie on rail g Ve + lifting at radend and radend bogie attach to underframe other bogie on rail Both end lifting at jack with lifting load of 1.5x (locomotive weight) g Ve + 3 TE tractive drag loadcase Pivot pin load (+) 300 kn/(-)270 kn loadcase Pivot pin load 3.0g long of bogie weight Anti-climber load of 45300kg verticle loadcase kn force at diagonal buffer 5.2 RDSO/EMD Fatigue Load Cases g Ve + (±) 0.35 loadcase g Ve + (±).25g Ve + (±).5g Lateral g Ve + (±).25g Ve + (±).5g Longitudinal 5.3 RDSO/EMD Torque Loads Underframe twist analysis for engine torque load of N-m. 6.0 MODAL ANALYSIS 6.1 Underframe Natural Frequencies The underframe natural frequencies are extracted between 0 to 10 Hz. The four important underframe frequencies are first bending, second bending, first twist and first lateral bending. The natural frequencies obtained from Radioss for the underframe are presented in the Table 4. 10

12 Table 4: Underframe Modal Analysis, Natural Frequencies Description Natural Frequencies (Hz) FEA First Bending 4.7 First Twist 6.9 Second Bending 7.0 First Lateral Bending RESULTS AND DISCUSSIONS Table 5: Underframe Stress and Deflection S.No. Load case VonMises Stress (MPa) (*Local stress near loading or reaction point Which can be ignored) 11 VonMises Average Max. Stress ignoring local stress (MPa) Deflection (mm) (Including Spring Defelction) Location of Higher stress g vertical load case Middle of underframe gVe+ Drag load case Middle of underframe g Ve + Buff loadcase Transition of underframe g Vertical loadcase Fuel Tank mounting hole in underframe g Ve + (+) 3g longitudinal loadcase g Ve + (-) 3g longitudinal loadcase 456* Coupler pocket side wall 501* Coupler pocket side wall

13 7. 1.0g Ve + (+) 1.5g lateral 765* Lateral stopper loadcase g Ve + (-) 1.5g lateral 781.5* Lateral stopper loadcase g Ve KN buffload at 437* Buffer location buffer loadcase g Ve KN buffload at Buffer location 50 mm below buffer loadcase g Ve + lifting at cabend 557* Jacking pad plate jack and cabend bogie attach to underframe other bogie on rail g Ve + lifting at radend jack 557* Jacking pad plate and radend bogie attach to underframe other bogie on rail g Ve + lifting at cabend and 589* Middle of underframe cabend bogie attach to underframe other bogie on rail g Ve + lifting at radend and 676* Middle of underframe radend bogie attach to underframe other bogie on rail 15. Both end lifting at jack with 766* Jacking pad plate lifting load of 1.5x (locomotive weight) g Ve + 3 TE tractive drag Middle of underframe loadcase 17. Pivot pin load (+) 300 kn/( / / /37.9 Middle of underframe )270 kn loadcase Pivot pin load 3.0g long of Middle of underframe bogie weight 19. Anti-climber load of 45300kg 427* Anticlimber verticle loadcase g vertical load case 400 kn Buffer at buffer diagonal g vertical load case 400 kn at buffer diagonal Buffer RDSO/EMD Fatigue Load Cases g Ve + (+) 0.35 loadcase Fuel Tank mounting hole in underframe g Ve + (+).25g Ve + (+) Lateral stopper.5g Lateral g Ve + (+).25g Ve + (-).5g Lateral Lateral stopper and Fuel Tank mounting g Ve + (-).25g Ve + (+).5g Lateral hole Lateral stopper 12

14 g Ve + (-).25g Ve + (-).5g Lateral g Ve + (+).25g Ve + (+).5g Longitudinal Lateral stopper Couple pocket side wall and Fuel Tank mounting hole Couple pocket side wall Couple pocket side g Ve + (+).25g Ve + (-).5g Longitudinal g Ve + (-).25g Ve + (+).5g Longitudinal wall g Ve + (-).25g Ve + (-).5g Couple pocket side Longitudinal wall g Ve + (-) 0.35 loadcase Fuel Tank mounting hole RDSO/EMD Torque Loads 32. Underframe twist analysis for engine torque load of N-m Engine mounting The Locomotive underframe is analyzed for both RDSO and EMD design criteria. For all the load cases, von mises stress plot are presented for underframe structural components. In some cases, vertical deflection of the underframe structure is presented. * These are local VonMises stress near loading or reaction point which can be ignored. Modal analysis The first four natural frequencies obtained from Radioss and the results are presented in Table 4. Figures 101 shows the mode shapes of the underframe calculated by using Finite Element Analysis software Radioss. The four important underframe frequencies are first bending, second bending, first twist and first lateral bending. The natural frequencies obtained from Finite Element Analysis of the underframe are presented in the Table CONCLUSION The underframe structure has been analyzed using Radioss.The finite element representation of the entire locomotive with all of the equipment is included in the analysis. The underframe was analyzed by using the design criteria provided by RDSO/EMD. The locomotive has been analyzed for RDSO/EMD yield load cases, RDSO/EMD fatigue load cases and one load case for engine torque. The von mises stress in the underframe structure for both RDSO/EMD yield load cases were lower than the material yield stress. The underframe structure satisfied the design criteria for the RDSO/EMD fatigue load cases. The natural frequencies of the underframe structure satisfied RDSO/EMD Vehicle Technical Specification requirements. In conclusion, the underframe structure meets all the design requirements. 13

15 FIGURE AIR CONDITIONER 2884 FRESH WATER TANK DUST BIN/TCC BLOWER 2208 (CAB) C/L OF LOCO 8655 GEN. BLOWER EXPANSION TANK ECC TCC C/L OF CRANK SHAFT ENG. START MOTORS ( AIR START) TOP OF U/F 280 TOILET COMPARTMENT AIR START RESERVOIR BETWEEN PIVOT CENTRES Fig. 1 Locomotive Layout 14

16 Fig. 2 The Underframe Structure Unigraphics 3D Image Top View Fig. 3 The Underframe Structure U n i g r a p h i c s 3D Image Bottom View 15

17 Fig. 4 Underframe Cross-Section 16

18 Fig. 5 Finite Element Model of Locomotive Underframe Fig. 6 Vertical Displacement, Draft Load 17

19 Fig.7 Von Mises Stress of UF Top Plate Draft Load Fig. 8 Von Mises Stress on Top Plate #2 End side, Draft Load 18

20 Fig. 9 Von Mises Stress on Bottom Plate, Draft Load Fig. 10 Von Mises Stress of UF Bottom Plate #2 End Side, Draft Load 19

21 Fig. 11 Von Mises Stress of UF Center Sill #2 End Side, Draft Load Fig. 12 Draft Gear Pocket, Mesh, Loading and Boundry Conditions 20

22 Fig. 13 Draft Gear Pocket, von Mises Stress in the Bottom Plate Fig. 14 Draft Gear Pocket von Mises Stress Distribution, Draft Load 21

23 Fig. 15 Underframe Load Distribution Buff Load Fig. 16 Vertical Displacement Buff load 22

24 Fig.17 Von Mises Stress in the Top Plate Buff Load Fig.18 Von Mises in the Top Plate #1 End Side Buff Load 23

25 Fig.19 Von Mises Stress in the Top Plate #2 End Side Buff Load Fig.20 Von Mises Stress in the Bottom Plate Buff Load 24

26 Fig.21 Von Mises Stress in the Bottom Plate #1 End Side Buff Load Fig.22 Von Mises Stress in the Center Sill #1 End Side Buff Load 25

27 Fig.23 Von Mises Stress in the Side Sill #1 End Side Buff Load Fig.24 Von Mises Stress in the Top Plate #2 End Side Buff Load 26

28 Fig. 25 Draft Gear Pocket Von Mises Stress Bottom Plate Buff Load Fig. 26 Draft Gear Pocket Von Mises Stress Buff Load 27

29 Fig. 27 Underframe Load Distribution g Vertical loadcase Fig. 28 Vertical Displacement g Vertical loadcase 28

30 Fig. 29 Von Mises Stress in the top Plate g Vertical loadcase Fig. 30 Von Mises Stress in the Top Plate #1 End Side 5.1.4, 2.0g Vertical loadcase 29

31 Fig. 31 Von Mises Stress in the Top Plate #2 End Side 5.1.4, 2.0g Vertical loadcase Fig. 32 Von Mises Stress in the Bottom Plate 5.1.4, 2.0g Vertical loadcase 30

32 Fig. 33 Underframe Load Distribution g Ve + (+) 3g longitudinal loadcase Fig. 34 Vertical Displacement g Ve + (+) 3g longitudinal loadcase 31

33 Fig. 35 Von Mises Stress in the top Plate 5.1.5, 1.0g Ve + (+) 3g longitudinal loadcase Fig. 36 Von Mises Stress in the Top Plate #1 End Side 5.1.5, 1.0g Ve + (+) 3g longitudinal loadcase 32

34 Fig. 37 Von Mises Stress in the Top Plate #2 End Side 5.1.5, 1.0g Ve + (+) 3g longitudinal loadcase Fig. 38 Von Mises Stress in the Bottom Plate g Ve + (+) 3g longitudinal loadcase 33

35 Fig. 39 Underframe Load Distribution g Ve + (-) 3g longitudinal loadcase Fig. 40 Vertical Displacement g Ve + (-) 3g longitudinal loadcase 34

36 Fig. 41 Von Mises Stress in the top Plate 5.1.5, 1.0g Ve + (-) 3g longitudinal loadcase Fig. 42 Von Mises Stress in the Top Plate #1 End Side 5.1.5, 1.0g Ve + (-) 3g longitudinal loadcase 35

37 Fig. 43 Von Mises Stress in the Top Plate #2 End Side 5.1.5, 1.0g Ve + (-) 3g longitudinal loadcase Fig. 44 Von Mises Stress in the Bottom Plate g Ve + (-) 3g longitudinal loadcase 36

38 Fig. 45 Underframe Load Distribution g Ve + (+) 1.5g lateral loadcase Fig. 46 Vertical Displacement g Ve + (+) 1.5g lateral loadcase 37

39 Fig. 47 Von Mises Stress in the top Plate 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase Fig. 48 Von Mises Stress in the Top Plate #1 End Side 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase 38

40 Fig. 49 Von Mises Stress in the Top Plate #2 End Side 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase Fig. 50 Von Mises Stress in the Bottom Plate 5.1.7, 1.0g Ve + (+) 1.5g lateral loadcase 39

41 Fig. 51 Underframe Load Distribution 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 40

42 Fig. 52 Vertical Displacement 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase Fig. 53 Von Mises Stress in the top Plate 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 41

43 Fig. 54 Von Mises Stress in the Top Plate #1 End Side 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase Fig. 55 Von Mises Stress in the Top Plate #2 End Side 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 42

44 Fig. 56 Von Mises Stress in the Bottom Plate 5.1.8, 1.0g Ve + (-) 1.5g lateral loadcase 43

45 Fig. 57 Underframe Load Distribution g Ve KN buffload at buffer loadcase Fig. 58 Displacement g Ve KN buffload at buffer loadcase 44

46 Fig. 59 Von Mises Stress in the top Plate 5.1.9, 1.0g Ve KN buffload at buffer loadcase Fig. 60 Von Mises Stress in the Bottom Plate 5.1.9, 1.0g Ve KN buffload at buffer loadcase 45

47 Fig. 61 Underframe Load Distribution , 1.0g Ve KN buffload at 50 mm below buffer loadcase Fig. 62 Displacement g Ve KN buffload at 50 mm below buffer loadcase 46

48 Fig. 63 Von Mises Stress in the top Plate , 1.0g Ve KN buffload at 50 mm below buffer loadcase 47

49 Fig. 64 Von Mises Stress in the Bottom Plate g Ve KN buffload at 50 mm below buffer loadcase Fig. 65 Displacement g Ve + lifting at cabend jack and cabend bogie attach to underframe other bogie on rail 48

50 Fig. 65 Displacement g Ve + lifting at cabend jack and cabend bogie attach to underframe other bogie on rail 49

51 Fig. 66 Von Mises Stress in the top Plate , 1.0g Ve + lifting at cabend jack and cabend bogie attach to underframe other bogie on rail Fig. 67 Von Mises Stress in the Bottom Plate , 1.0g Ve + lifting at cabend jack and cabend bogie attach to underframe other bogie on rail 50

52 Fig. 68 Displacement g Ve + lifting at radend jack and radend bogie attach to underframe other bogie on rail Fig. 69 Von Mises Stress in the top Plate , 1.0g Ve + lifting at radend jack and radend bogie attach to underframe other bogie on rail 51

53 Fig. 70 Von Mises Stress in the Bottom Plate , 1.0g Ve + lifting at radend jack and radend bogie attach to underframe other bogie on rail Fig. 71 Displacement g Ve + lifting at cabend and cabend bogie attach to underframe other bogie on rail 52

54 Fig. 72 Von Mises Stress in the top Plate , 1.0g Ve + lifting at cabend and cabend bogie attach to underframe other bogie on rail Fig. 73 Von Mises Stress in the Bottom Plate g Ve + lifting at cabend and cabend bogie attach to underframe other bogie on rail 53

55 Fig. 74 Displacement , 1.0g Ve + lifting at radend and radend bogie attach to underframe other bogie on rail Fig. 75 Von Mises Stress in the top Plate , 1.0g Ve + lifting at radend and radend bogie attach to underframe other bogie on rail 54

56 Fig. 76 Von Mises Stress in the Bottom Plate , 1.0g Ve + lifting at radend and radend bogie attach to underframe other bogie on rail Fig. 77 Displacement Both end lifting at jack with lifting load of 1.5x (locomotive weight). 55

57 Fig. 78 Von Mises Stress in the top Plate , Both end lifting at jack with lifting load of 1.5x (locomotive weight). Fig. 79 Von Mises Stress in the Bottom Plate , Both end lifting at jack with lifting load of 1.5x (locomotive weight). 56

58 Fig. 80 Displacement g Ve + 3 TE tractive drag loadcase Fig. 81 Von Mises Stress in the top Plate , 1g Ve + 3 TE tractive drag loadcase 57

59 Fig. 82 Von Mises Stress in the Bottom Plate , 1g Ve + 3 TE tractive drag loadcase 58

60 Fig. 83 Displacement Pivot pin load (+) 300 kn/(-)270 kn loadcase 59

61 Fig. 84 Von Mises Stress in the top Plate , Pivot pin load (+) 300 kn/(-)270 kn loadcase 60

62 Fig. 85Von Mises Stress in the Bottom Plate , Pivot pin load (+) 300 kn/ (-)270 kn loadcase 61

63 Fig. 86 Displacement , Pivot pin load 3.0g long of bogie weight Fig. 87 Von Mises Stress in the top Plate , Pivot pin load 3.0g long of bogie weight 62

64 Fig. 88Von Mises Stress in the Bottom Plate , Pivot pin load 3.0g long of bogie weight 63

65 Fig. 89 Displacement , Anti-climber load of 45300kg verticle loadcase Fig. 90 Von Mises Stress in the top Plate , Anti-climber load of 45300kg verticle loadcase 64

66 Fig. 91Von Mises Stress in the Bottom Plate , Anti-climber load of 45300kg verticle loadcase 65

67 Fig. 92 Displacement 5.2.1, 1.0g Ve + (±) 0.35 loadcase 66

68 Fig. 93 Von Mises Stress in the top Plate 5.2.1, 1.0g Ve + (±) 0.35 loadcase 67

69 Fig. 94Von Mises Stress in the Bottom Plate 5.2.1, 1.0g Ve + (±) 0.35 loadcase 68

70 Fig. 95 Displacement 5.2.2, 1.0g Ve + (±).25g Ve + (±).5g Lateral 69

71 Fig. 96 Von Mises Stress in the top Plate 5.2.2, 1.0g Ve + (±).25g Ve + (±).5g Lateral 70

72 Fig. 97Von Mises Stress in the Bottom Plate 5.2.2, 1.0g Ve + (±).25g Ve + (±).5g Lateral 71

73 Fig. 98 Displacement 5.2.3, 1.0g Ve + (±).25g Ve + (±).5g Longitudinal 72

74 Fig. 99 Von Mises Stress in the top Plate 5.2.3, 1.0g Ve + (±).25g Ve + (±).5g Longitudinal 73

75 Fig. 100Von Mises Stress in the Bottom Plate 5.2.3, 1.0g Ve + (±).25g Ve + (±).5g Longitudinal 74

76 Fig. 101 Displacement 5.3.1, Underframe twist analysis for engine torque load of N-m. 75

77 Fig. 102 Von Mises Stress in the top Plate 5.3.1, Underframe twist analysis for engine torque load of N-m. 76

78 Fig. 103 Von Mises Stress in the Bottom Plate Underframe twist analysis for engine torque load of N-m. Fig. 104 Vertical Displacement g Ve kn force on diagonal buffer loadcase 77

79 Fig. 105 Vertical stress g Ve kn 400 kn force on diagonal buffer loadcase Fig. 106 Vertical Displacement g Ve kn force on alternate diagonal buffer loadcase 78

80 Fig. 107 Vertical stress g Ve kn force on alternate diagonal buffer loadcase Fig. 108 Underframe Natural Frequency 79

81 80