3D Digital Reconfiguration of an Automated Welding System for a Railway Manufacturing Application

Caggiano, Alessandra; Nele, Luigi; Sarno, Emanuele; Teti, Roberto

doi:10.1016/j.procir.2014.10.008

Cited by 14 publications

(7 citation statements)

References 12 publications

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“…1 through a mechanism similar to the action of a metal cutting tool, an approach based on 3D digital modeling and simulation was employed [7].…”

Section: D Digital Modeling and Simulation Analysis To Identify The mentioning

confidence: 99%

3D Digital Simulation for Material Damage Mechanism Identification in a Railway Carriage Pressure Vessel

Caggiano¹,

Teti²

2018

Modern Railway Engineering

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Digital simulation approaches applied to railway engineering allow to investigate different railway scenarios via 3D digital twins of real objects, motion simulation, and collision detection to identify the root causes of critical damage and estimate the most likely sources of railway accidents. In this work, a digital simulation approach is applied to a real catastrophic train accident in which a railway carriage carrying a pressure vessel collided with an obstacle that generated a cut in the pressure vessel casing. This cut initiated a liquefied petroleum gas leakage that expanded in the environment and caused the explosion and blaze responsible for human casualties. Traditional railway accident reconstruction procedures identified two potential objects accountable for the cutting of the pressure vessel casing: a wing rail and a track reference stake. Based on digital terrain models and reconstructed models of the railway carriage, 3D digital simulation scenarios were created to detect every possible collision of the pressure vessel with the infrastructure environment and investigate whether the shape of the cut in the pressure vessel wall fits the damage visible on the obstacles and whether the interference between obstacle and pressure vessel wall could generate the chip through an interaction similar to metal cutting.

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“…1 through a mechanism similar to the action of a metal cutting tool, an approach based on 3D digital modeling and simulation was employed [7].…”

Section: D Digital Modeling and Simulation Analysis To Identify The mentioning

confidence: 99%

3D Digital Simulation for Material Damage Mechanism Identification in a Railway Carriage Pressure Vessel

Caggiano¹,

Teti²

2018

Modern Railway Engineering

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“…15 Caggiano et al Designed an automatic controlled welding machine that was watched by video using 3D Motion Simulation and its welding properties were improved. 16 Totala colleagues designed a welding machine that can be welded continuously with a special torch, tested for time and cost. 17 Using Gangadia et al, They have designed special-purpose equipment that reduces setup time and reduces time by up to 70% by synchronizing the source of both sides of the conveyor pulley at once.…”

Section: Introductionmentioning

confidence: 99%

Design and manufacture of automatic plastic valve welding machine

Özdilli

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Plastic welding method is a widely used technology for the welding of pressure and vacuum bags using plastic valves. Conducting this process with traditional methods creates disadvantages in terms of production speed, product quality and economical aspects. Today, assembly costs make up the majority of total production costs, manufacturers pay more attention to assembly automation and work in this direction in order to reduce costs, speed up the production process and increase efficiency. In this study, it is aimed to design and manufacture a single Automatic Valve Welding Machine that can do all of these operations and integrated automation system instead of cutting, punching and plastic welding process that can be performed with multiple machines and workers. In this context, a new automated machine was designed in 3 D, and engineering analyzes were carried out to manufacture a prototype. In design, the machine has been made suitable for developing technology by using PLC (Programming Logic Controller) and pneumatic system. In addition, static analyzes of the machine were made. With the inclusion of a production-specific automatic controlled plastic welding machine, manufacturing can be done faster, with higher quality, lower costs and less wastage compared to the traditional manufacturing process.

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“…Even so, the 25‐year life or more of bogie frames in operation must be ensured . As a classical joining technology, metal active gas (MAG) arc welding can efficiently manufacture the modern railway components . Unfortunately, systematic investigations on the fatigue crack resistance of MAG welded G20Mn5 cast steel are still lacking.…”

Section: Introductionmentioning

confidence: 99%

“…[24][25][26][27] As a classical joining technology, metal active gas (MAG) arc welding can efficiently manufacture the modern railway components. 13,21,[28][29][30][31] Unfortunately, systematic investigations on the fatigue…”

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confidence: 99%

The microstructure, mechanical, and fatigue behaviours of MAG welded G20Mn5 cast steel

Qin

Branco

et al. 2020

Fatigue Fract Eng Mat Struct

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The microstructure, mechanical strength, and fatigue response of metal active gas (MAG) butt‐welded G20Mn5 cast steel was thoroughly investigated for exploring the service safety and reliability of new‐generation railway bogie frames. The fatigue properties of the matrix and welded joints were determined by both low‐ and high‐cycle service regimes. On the basis of nanoindentation testing, the fatigue crack growth (FCG) was derived by correlating with cyclic plastic response of microdomain materials across the MAG joint. The results show that the MAG induces considerable changes in microstructures and hardness of the G20Mn5 matrix and resultantly produces an overmatching welded joint but show comparatively low‐ and high‐cycle fatigue properties to as‐received material. The calculated threshold FCG range based on the Murakami model indicates that the maximum 1.5‐mm defect might be the cracking site subjected to fatigue loading from the structural integrity viewpoint.

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3D Digital Reconfiguration of an Automated Welding System for a Railway Manufacturing Application

Cited by 14 publications

References 12 publications

3D Digital Simulation for Material Damage Mechanism Identification in a Railway Carriage Pressure Vessel

3D Digital Simulation for Material Damage Mechanism Identification in a Railway Carriage Pressure Vessel

Design and manufacture of automatic plastic valve welding machine

The microstructure, mechanical, and fatigue behaviours of MAG welded G20Mn5 cast steel

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